Continuous Linear Production in a Selective Laser Sintering System

Patent metadata

Field	Value
Publication number	US-2017136544-A1
Application number	US-201615368665-A
Country	US
Kind code	A1
Filing date	Dec 4, 2016
Priority date	Sep 21, 2010
Publication date	May 18, 2017
Grant date	—

Abstract

A method and apparatus for forming objects. Layers of precursor material may be placed on top of each other. The layers of precursor material may be selectively cured as the layers of precursor material are placed on top of each other to form an object and a frame associated with the object.

First claim

1 - 15 . (canceled)

16 . An apparatus comprising:
a chamber; a curing system configured to cure portions of layers of precursor material deposited in the chamber to form an object and a frame connected to the object; and a movement system configured to engage the frame and move the frame and the object connected to the frame as a new layer of precursor material is placed on a prior layer of precursor material.

17 . The apparatus of claim 16 , wherein the frame comprises a plurality of base structures.

18 . The apparatus of claim 17 , wherein the frame comprises a plurality of connectors.

19 . The apparatus of claim 16 further comprising:
a separation system configured to separate the object from a base structure.

20 . The apparatus of claim 19 , wherein the separation system is configured to separate the object from the base structure as the base structure and the object are moved by the movement system.

21 . The apparatus of claim 16 , wherein the movement system comprises a plurality of gears having first teeth configured to engage second teeth formed on sides of a base structure.

22 . The apparatus of claim 16 further comprising:
a precursor deposition system configured to deposit the new layer of precursor material on the prior layer of precursor material.

23 . The apparatus of claim 16 further comprising:
a temperature control system configured to control a temperature of at least one of the object and the frame.

24 . The apparatus of claim 23 , wherein the temperature control system comprises:
a plurality of heating and cooling elements configured to heat and cool walls of the chamber to control the temperature of the at least one of the object and the frame.

25 . The apparatus of claim 23 , wherein the temperature control systems is configured to cool uncured precursor material that has been deposited to change a density of the uncured precursor material such that a flow of gas through the precursor material is reduced.

26 . The apparatus of claim 16 further comprising:
a recycling system configured to recycle the portions of layers of precursor material that remain uncured.

27 . The apparatus of claim 17 , wherein the plurality of base structures are for the frame configured to support the object during formation of the object in the chamber.

28 . The apparatus of claim 16 , wherein the curing system is selected from at least one of a heating system, a laser, and an electron beam.

29 . The apparatus of claim 16 , wherein the precursor material is selected from one of a powder, a liquid, a metal powder, and a ceramic powder.

30 . A sintering apparatus comprising:
a chamber; a curing system, configured to cure portions of layers of precursor material, deposited in the chamber to form an aircraft part and a frame, connected to the aircraft part, wherein the frame comprises a plurality of base structures and a plurality of connectors and is configured to support the aircraft part during formation of the aircraft part in the chamber and wherein the curing system is selected from at least one of a heating system, a laser, and an electron beam, and wherein the curing system is further configured to selectively cure a new layer of the precursor material to form a portion of the aircraft part, being formed in the chamber, and to form a portion of a new base structure to be added to the plurality of base structures; a movement system, configured to engage the frame and move the frame, connected to the aircraft part, as a new layer of precursor material is placed on a prior layer of precursor material, wherein the movement system comprises a plurality of gears, having first teeth configured to engage second teeth, formed on sides of the plurality of base structures; a precursor deposition system, configured to deposit the new layer of precursor material on the prior layer of precursor material; a temperature control system, configured to control a temperature of at least one of the aircraft part and the frame, wherein the temperature control system comprises a plurality of heating and cooling elements, configured to heat and cool walls of the chamber to control the temperature of the at least one of the aircraft part and the frame and wherein the temperature control system is configured to cool uncured precursor material that has been deposited to change a density of the uncured precursor material such that a flow of gas through the precursor material is reduced; a separation system, configured to separate the aircraft part from the plurality of base structures as the plurality of base structures and the aircraft part are moved by the movement system; and a recycling system, configured to recycle the portions of layers of precursor material that remain uncured, wherein the layers of precursor material are selected from one of a powder, a liquid, a metal powder, and a ceramic powder.

31 . The apparatus of claim 19 , wherein the separation system comprises cutters.

32 . The sintering apparatus of claim 30 , wherein the separation system comprises cutters.

33 . The apparatus of claim 16 , wherein the curing system includes a laser disposed over the chamber.

34 . The sintering apparatus of claim 30 , wherein the curing system is the laser, and wherein the laser disposed over and directed into the chamber.

35 . The sintering apparatus of claim 34 , wherein an opening is disposed in the chamber opposite the laser, and wherein the recycling system further comprises:
a conveyor belt, located under the opening, opposite the laser; and a powder clean-up station, configured to receive powder carried by the conveyor belt after the powder falls through the opening and onto the conveyor belt.

Assignees

• Boeing Co

Inventors

• Lyons Brett Ian

Classifications

• B33Y10/00

  Processes of additive manufacturing · CPC title

• B29C64/357

  Recycling · CPC title

• B33Y30/00

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

• B28B1/001

  Rapid manufacturing of 3D objects by additive depositing, agglomerating or laminating of material (selective deposition modelling of metallic powder B22F10/00; rapid manufacturing of 3D objects in general and in particular of plastics B29C64/00) · CPC title

• B29C64/393

  for controlling or regulating additive manufacturing processes · CPC title