Enclosed additive manufacturing system

Patent metadata

Field	Value
Publication number	US-10843265-B2
Application number	US-201615336465-A
Country	US
Kind code	B2
Filing date	Oct 27, 2016
Priority date	Oct 30, 2015
Publication date	Nov 24, 2020
Grant date	Nov 24, 2020

Abstract

A method of additive manufacture is disclosed. The method may include restricting, by an enclosure, an exchange of gaseous matter between an interior of the enclosure and an exterior of the enclosure. The method may further include running multiple machines within the enclosure. Each of the machines may execute its own process of additive manufacture. While the machines are running, a gas management system may maintain gaseous oxygen within the enclosure at or below a limiting oxygen concentration for the interior.

First claim

The invention claimed is:

1. A method of additive manufacture, the method comprising:
restricting, by an enclosure, an exchange of gaseous matter between an interior of the enclosure and an exterior of the enclosure;
operating a plurality of machines located within the enclosure, each machine of the plurality of machines having a separate powder bed;
executing, by each machine of the plurality of machines during the operating, an independent process of additive manufacture comprising directing an energy beam at powder resting in the powder bed corresponding thereto; and
maintaining, by a gas management system during the executing, gaseous oxygen within the enclosure below atmospheric level.

2. The method of claim 1 , wherein the enclosure comprises an airlock interfacing between the interior and the exterior.

3. The method of claim 2 , wherein the airlock comprises a first door, a second door, and a space located between the first door and the second door, the first door, second door, and space being sized to enable one or more humans to pass through the airlock.

4. The method of claim 2 , further comprising removing from the enclosure through the airlock a first part manufactured by a first machine of the plurality of machines in a first process of additive manufacture.

5. The method of claim 4 , further comprising removing from the enclosure through the airlock a second part manufactured by a second machine of the plurality of machines in a second process of additive manufacture, the second processing being independent of the first process.

6. The method of claim 5 , further comprising assisting, by a human, in removing unamalgamated powder from around the first part.

7. The method of claim 6 , wherein the assisting occurs within the enclosure.

8. The method of claim 7 , further comprising wearing, by the human during the assisting, a self contained breathing apparatus.

9. The method of claim 8 , wherein each independent process of additive manufacture comprises powder bed fusion.

10. The method of claim 9 , wherein each independent process of additive manufacture further comprises directing radiant energy at selected granules of the powder.

11. The method of claim 10 , wherein each independent process of additive manufacture further comprises heating, by the radiant energy, the selected granules to at least a melting point thereof.

12. The method of claim 10 , wherein each independent process of additive manufacture further comprises:
distributing a first layer of granules of the powder;
directing the radiant energy at all granules within the first layer that form part of the selected granules;
distributing a second layer of granules of the powder over the top of the first layer; and
directing the radiant energy at all granules within the second layer that form part of the selected granules.

13. The method of claim 1 , further comprising:
assisting, by a human within the enclosure, in removing unamalgamated powder from around a first part manufactured by a first machine of the plurality of machines in a first process of additive manufacture; and
wearing, by the human during the assisting, a self contained breathing apparatus.

14. The method of claim 1 , wherein each independent process of additive manufacture comprises:
distributing a first layer of the powder;
directing radiant energy at a first subset of granules within the first layer;
distributing a second layer of the powder over the top of the first layer; and
directing radiant energy at a second subset of granules within the second layer.

15. The method of claim 14 , wherein each independent process of additive manufacture further comprises:
melting or sintering the first subset of granules; and
melting or sintering the second subset of granules.

16. The method of claim 15 , further comprising:
assisting, by a human within the enclosure, in removing unamalgamated granules of the powder from around a first part manufactured by a first machine of the plurality of machines in a first process of additive manufacture; and
wearing, by the human during the assisting, a self contained breathing apparatus.

17. A method of additive manufacture, the method comprising:
restricting, by an enclosure, an exchange of gaseous matter between an interior of the enclosure and an exterior of the enclosure;
operating a plurality of machines located within the enclosure, each machine of the plurality of machines having a separate powder bed;
executing, by each machine of the plurality of machines during the operating, an independent process of additive manufacture comprising repeatedly (1) distributing a layer of a powder within the enclosure and (2) amalgamating a subset of granules within the layer by directing radiant energy at the subset of granules; and
maintaining, by a gas management system during the executing, gaseous oxygen within the enclosure below atmospheric levels.

18. The method of claim 17 , further comprising:
assisting, by a human within the enclosure, in removing an unamalgamated portion of the powder from around a first part manufactured by a first machine of the plurality of machines in a first process of additive manufacture; and
wearing, by the human during the assisting, a self contained breathing apparatus.

19. The method of claim 18 , further comprising:
removing the first part from the enclosure through an airlock; and
removing from the enclosure through the airlock a second part manufactured by a second machine of the plurality of machines in a second process of additive manufacture, the second process being independent of the first process.

Assignees

• Seurat Tech Inc

Inventors

• Demuth James A
• Toomre Erik
• Leard Francis L
• Kamshad Kourosh
• Fees Heiner
• Berdichevsky Eugene

Classifications

• B22F10/39

  Traceability, e.g. incorporating identifier into a workpiece or article · CPC title

• Y02P10/25

  Process efficiency · CPC title

• Y02P80/40

  Minimising material used in manufacturing processes · CPC title

• G02B27/108

  for sampling a portion of a beam or combining a small beam in a larger one, e.g. wherein the area ratio or power ratio of the divided beams significantly differs from unity, without spectral selectivity · CPC title

• B29C64/286

  Optical filters, e.g. masks · CPC title