Method of fabrication for the repair and augmentation of part functionality of metallic components

Patent metadata

Field	Value
Publication number	US-2017095882-A1
Application number	US-201615282048-A
Country	US
Kind code	A1
Filing date	Sep 30, 2016
Priority date	Oct 2, 2015
Publication date	Apr 6, 2017
Grant date	—

Abstract

Methods and systems for manufacturing a three-dimensional product. Fabrication of a three-dimensional part from a powder spread over a work table as a powder bed can be initiated. The fabrication process can be paused to cool down the work table to room temperature to obtain access to the three-dimensional part for post-processing operations such as, for example, embedding external artifacts. Fabrication can continue by preheating the powder rather than the work table until fabrication of the three-dimensional part is complete. A damaged part may be placed within the powder bed, wherein the fabrication process can be directly initiated to achieve part repair. Additionally, a material of the same part's composition can be used or a different material utilized to render the part better than new. Access to the three-dimensional part allows embedding of a foreign object in the three-dimensional part within the powder bed while the three-dimensional part remains non-finished.

First claim

What is claimed is:

1 . A method of manufacturing a three-dimensional product, comprising:
initiating a fabrication of a three-dimensional part from powder spread over a work table as a powder bed; pausing said fabrication and cooling said work table to room temperature to obtain access to said three-dimensional part; and continuing fabrication by preheating said powder rather than said work table until fabrication of said three-dimensional part is complete.

2 . The method of claim 1 wherein said access to said three-dimensional part allows embedding of a foreign object in said three-dimensional part within said powder bed while said three-dimensional part remains in a non-finished state.

3 . The method of claim 1 wherein said access to said three-dimensional part allows for repair of said three-dimensional part during a post-processing operation.

4 . The method of claim 1 further comprising utilizing varying material options including materials matching a composition of a foreign object or a material of a different composition to assist in rendering a damaged component better than new.

5 . The method of claim 1 further comprising:
varying of an intensity of an energy beam from a low intensity; and
applying said energy beam with said varying of said intensity to said powder bed to avoid smoking of said powder.

6 . The method of claim 5 further comprising gradually increasing said intensity of said energy beam to avoid powder repelling of said powder during said preheating.

7 . The method of claim 1 automatically recording with a controlling computer, a last registration of a position of said energy beam during an initial portion of said fabrication of said three-dimensional part.

8 . The method of claim 7 further comprising utilizing a visual feedback system in case said three-dimensional part is removed from said powder bed to resolve any registration issues thereof.

9 . The method of claim 8 further comprising storing a prior build position using said visual feedback system and determining a following build position utilizing a reference recorded by said controlling computing during a prior processing step of said fabrication.

10 . A system for manufacturing a three-dimensional product, comprising:
a work table, wherein a fabrication of a three-dimensional part from powder spread over said work table as a powder bed is initiated; wherein said fabrication is paused and said work table is cooled to room temperature to obtain access to said three-dimensional part; and wherein said fabrication is continued by preheating said powder rather than said work table until fabrication of said three-dimensional part is complete.

11 . The system of claim 10 wherein said access to said three-dimensional part allows embedding of a foreign object in said three-dimensional part within said powder bed while said three-dimensional part remains in a non-finished state.

12 . The system of claim 10 wherein said access to said three-dimensional part allows for repair of said three-dimensional part during a post-processing operation.

13 . The system of claim 10 further comprising an energy beam source that provides an energy beam, wherein an intensity of said energy beam is varied from a low intensity, and wherein said energy beam is applied with variable intensity to said powder bed to avoid smoking of said powder.

14 . The system of claim 13 wherein said intensity of said energy beam is gradually increased to avoid powder repelling of said powder during said preheating.

15 . The system of claim 10 further comprising a controlling computer, wherein a last registration of a position of said energy beam is automatically recorded by said controlling computer during an initial portion of said fabrication of said three-dimensional part.

16 . The system of claim 15 further comprising a visual feedback system that resolves any registration issues in case said three-dimensional part is removed from said powder bed.

17 . The system of claim 16 wherein:
a prior build position is storable via said visual feedback system; and
a following build position is determinable utilizing a reference recorded by said controlling computing during a prior processing operation of said fabrication.

18 . A three-dimensional apparatus, comprising:
a three-dimensional part configured via a fabrication from powder spread over a work table as a powder bed; wherein said fabrication is paused and said work table is cooled to room temperature to obtain access to said three-dimensional part; and wherein said fabrication is continued by preheating said powder rather than said work table until fabrication of said three-dimensional part is complete.

19 . The apparatus of claim 18 wherein:
said access to said three-dimensional part allows embedding of a foreign object in said three-dimensional part within said powder bed while said three-dimensional part remains in a non-finished, state; and
said access to said three-dimensional part allows for repair of said three-dimensional part during a post-processing operation.

20 . The apparatus of claim 18 wherein an energy beam utilized in said fabrication is varied from a lower intensity and wherein said energy beam is applied by varying of said intensity to said powder bed to avoid smoking of said powder.

Assignees

• Univ Texas

Inventors

• Mireles Jorge
• Hossain Mohammad
• Wicker Ryan

Classifications

• B22F10/64

  by thermal means (control of energy beam parameters for post heating B22F10/364) · CPC title

• B22F10/28

  Powder bed fusion, e.g. selective laser melting [SLM] or electron beam melting [EBM] · CPC title

• B22F10/362

  for preheating · CPC title

• B22F7/08

  with one or more parts not made from powder {(B22F7/062 takes precedence)} · CPC title

• B33Y30/00

  Apparatus for additive manufacturing; Details thereof or accessories therefor · CPC title