Compliant recoater assemblies, systems, and related methods

Patent metadata

Field	Value
Publication number	US-12521940-B2
Application number	US-202318331112-A
Country	US
Kind code	B2
Filing date	Jun 7, 2023
Priority date	Jun 7, 2023
Publication date	Jan 13, 2026
Grant date	Jan 13, 2026

Abstract

Disclosed embodiments are generally related to recoater assemblies for additive manufacturing systems. In some embodiments, a recoater blade may include a plurality of flexible portions that are configured to deflect relative to one another when moved over and past a defect on a build surface. In other embodiments, a recoater assembly may include compliant attachments that exhibit compliances that increase in an outward direction relative to a central portion of a body of the recoater assembly. In still other embodiments, a pair of scoops may be disposed on opposing end portions of a recoater blade and/or recoater assembly to help guide and collect excess powder dispensed onto a build surface.

First claim

The invention claimed is:

1 . A recoater assembly, comprising:
a recoater blade comprising a plurality of plates, wherein at least one plate of the plurality of plates comprises a plurality of grooves forming a plurality of separate flexible portions extending from a first portion including a first edge of the at least one plate towards a second edge of the at least one plate opposite the first edge; and a body comprising a rounded surface, wherein the plurality of separate flexible portions is configured to be deformed against the rounded surface when a force is applied to the plurality of separate flexible portions, wherein the plurality of plates of the recoater blade is attached to the body with the plurality of grooves of the at least one plate extending away from the body.

2 . The recoater assembly of claim 1 , wherein the plurality of plates comprises a first plate and a second plate, wherein the first plate comprises a first set of the grooves and the second plate comprises a second set of the grooves and wherein the first set of grooves and the second set of grooves are staggered relative to one another.

3 . The recoater assembly of claim 1 , wherein the plurality of separate flexible portions are disposed between the plurality of grooves and arranged along a length of the at least one plate.

4 . The recoater assembly of claim 1 , wherein the plurality of separate flexible portions have a spring force of greater than or equal to 0.25 N and less than or equal to 2 N.

5 . The recoater assembly of claim 1 , wherein a dimension of the plurality of grooves extending from the first edge towards the second edge is greater than or equal to 1 mm and less than or equal to 50 mm.

6 . The recoater assembly of claim 1 , wherein a groove-to-groove spacing of the plurality of grooves is greater than or equal to 0.1 mm and less than or equal to 2 mm.

7 . The recoater assembly of claim 1 , wherein the recoater assembly is configured to dispense a powder precursor material onto a build surface.

8 . The recoater assembly of claim 1 , wherein the plurality of plates comprise greater than or equal to 2 plates and less than or equal to 10 plates.

9 . The recoater assembly of claim 1 , further comprising a clamp connecting the recoater blade to the body.

10 . The recoater assembly of claim 1 , wherein the body comprises a central compliant attachment configured to connect the recoater assembly to a motion stage.

11 . The recoater assembly of claim 1 , wherein the body comprises a plurality of compliant attachments configured to attach the recoater assembly to a motion stage.

12 . The recoater assembly of claim 11 , wherein a compliance of the plurality of compliant attachments increases from a central portion of the body towards opposing end portions of the body.

13 . The recoater assembly of claim 1 , wherein each plate of the plurality of plates includes a separate plurality of the grooves offset from the plurality of grooves formed in adjacent plates of the plurality of plates.

14 . The recoater assembly of claim 13 , wherein the separate plurality of the grooves offset from the plurality of grooves of the plurality of plates does not include a straight path extending through the grooves from a front surface of the recoater blade to a back surface of the recoater blade.

15 . The recoater assembly of claim 1 , wherein the recoater blade is angled relative to a vertical direction of the recoater assembly when installed on an additive manufacturing system.

16 . The recoater assembly of claim 1 , wherein the at least one plate is configured to elastically deform during a recoating and scraping operation.

17 . The recoater assembly of claim 1 , wherein the at least one plate is configured to operate continuously at a temperature between or equal to 60° C. and 100° C.

18 . The recoater assembly of claim 1 , further comprising a pair of scoops attached to opposing end portions of the body with the recoater blade extending between the pair of scoops, wherein the recoater blade and the pair of scoops extend away from the body, and wherein the pair of scopes extend beyond the recoater blade.

19 . An additive manufacturing system, comprising:
a build plate; the recoater assembly of claim 1 ; and a motion stage, wherein the recoater assembly is attached to the motion stage, and wherein the motion stage is configured to move the recoater assembly relative to the build plate.

20 . The additive manufacturing system of claim 19 , further comprising one or more laser energy sources.

21 . The additive manufacturing system of claim 20 , further comprising an optics assembly movable relative to the build plate and configured to direct laser energy from the one or more laser energy sources toward a build surface on the build plate to melt at least a portion of a layer of material disposed on the build surface.

22 . The additive manufacturing system of claim 19 , wherein the recoater blade is angled relative to the build plate.

23 . The additive manufacturing system of claim 19 , wherein an angle between the recoater blade and a plane parallel to the build plate is greater than or equal to 15° and less than or equal to 25°.

24 . The additive manufacturing system of claim 19 , further comprising a leveling mount configured to adjust a vertical position of the recoater blade relative to the build plate.

25 . The additive manufacturing system of claim 24 , wherein the leveling mount is configured to adjust an orientation of the recoater blade relative to the build plate.

Assignees

• Vulcanforms Inc

Inventors

• Buermeyer Lucas
• Stone William Curtis
• Aggarwal Raghav

Classifications

• B22F12/67

  Blades · CPC title

• B33Y10/00 Primary

  Processes of additive manufacturing · CPC title

• B33Y40/00

  Auxiliary operations or equipment, e.g. for material handling · CPC title

• B29C64/153

  using layers of powder being selectively joined, e.g. by selective laser sintering or melting · CPC title

• B29C64/268

  using laser beams; using electron beams [EB] · CPC title