Method for real-time simultaneous additive and subtractive manufacturing with a dynamically grown build wall

Patent metadata

Field	Value
Publication number	US-2018345600-A1
Application number	US-201715610113-A
Country	US
Kind code	A1
Filing date	May 31, 2017
Priority date	May 31, 2017
Publication date	Dec 6, 2018
Grant date	—

Abstract

A method for large-scale, real-time simultaneous additive and subtractive manufacturing is described. The apparatus used in the method includes one or more build units and a machining mechanism that are attached to a positioning mechanism, and a rotating build platform. The method involves at least rotating the build platform; repetitive cycles of moving the build unit(s) to deposit powder and irradiating at least a selected portion of the powder to form at least one fused layer to form at least one object and a build wall that retains unfused powder about the object; and removing the build wall by rotational machining.

First claim

1 . A method of manufacturing at least one object, comprising:
(a) rotating a build platform; (b) moving at least one build unit to deposit powder, wherein the at least one build unit comprises a powder delivery mechanism, a powder recoating mechanism and an irradiation beam directing mechanism; (c) irradiating at least one selected portion of the powder to form at least one fused layer; (d) repeating at least steps (b) and (c) to form the at least one object and a build wall, wherein the build wall retains unfused powder about the at least one object; and (e) removing the build wall by rotational machining.

2 . The method according to claim 1 , further comprising machining the at least one object.

3 . The method according to claim 1 , further comprising leveling the at least one selected portion of the powder.

4 . The method according to claim 1 , wherein at step (b), the build unit is moved over and substantially parallel to at least one build area within the build platform.

5 . The method according to claim 1 , wherein the machining is one or more material removal processes selected from the group consisting of cutting, tapping, tooling, drilling, chamfering, abrading, forming, grinding, shaping and knurling.

6 . The method according to claim 1 , wherein the machining is one or more material removal processes automated by computer numerical control.

7 . The method according to claim 1 , wherein the at least one selected portion of the powder is irradiated with a laser beam and the method further comprises providing a substantially laminar gas flow to the first build area within the build platform.

8 . The method according to claim 1 , wherein the at least a portion of the at least one layer of powder is irradiated with an electron beam.

9 . The method according to claim 1 , wherein the at least one object is an aircraft component.

10 . The method according to claim 9 , wherein the aircraft component is selected from the group consisting of a turbine or vane shrouding, a central engine shaft, a casing, a compressor liner, a combustor liner, and a duct.

11 . A method of manufacturing at least one annular object, comprising:
(a) rotating a build platform; (b) moving at least one build unit to deposit powder, wherein the at least one build unit comprises a powder delivery mechanism, a powder recoating mechanism and an irradiation beam directing mechanism; (c) irradiating at least a selected portion of the powder to form at least one fused layer; (d) repeating at least steps (b) and (c) to form the at least one annular object and a build wall, wherein the build wall retains unfused powder about the at least one annular object; and (e) removing the build wall by rotational machining.

12 . The method according to claim 11 , further comprising machining the at least one annular object.

13 . The method according to claim 11 , further comprising leveling the at least one selected portion of the powder.

14 . The method according to claim 11 , wherein at step (b), the build unit is moved over and substantially parallel to at least one build area within the build platform.

15 . The method according to claim 11 , wherein the machining is one or more material removal processes selected from the group consisting of cutting, tapping, tooling, drilling, chamfering, abrading, forming, grinding, shaping and knurling.

16 . The method according to claim 11 , wherein the machining is one or more material removal processes automated by computer numerical control.

17 . The method according to claim 11 , wherein the at least one portion of the powder is irradiated with a laser beam and the method further comprises providing a substantially laminar gas flow to the first build area within the build platform.

18 . The method according to claim 11 , wherein the at least a portion of the at least one layer of powder is irradiated with an electron beam.

19 . The method according to claim 11 , wherein the at least one annular object is an aircraft component.

20 . The method according to claim 19 , wherein the aircraft component is selected from the group consisting of a turbine or vane shrouding, a central engine shaft, a casing, a compressor liner, a combustor liner, and a duct.

Assignees

• Gen Electric

Inventors

• Holford Brandon
• VAUGHT Jeffrey
• Redding Mackenzie Ryan
• Mamrak Justin

Classifications

• B22F10/50

  Treatment of workpieces or articles during build-up, e.g. treatments applied to fused layers during build-up · CPC title

• G05B19/4099 Primary

  Surface or curve machining, making three-dimensional [3D] objects, e.g. desktop manufacturing · CPC title

• B22F12/37

  Rotatable · CPC title

• B22F10/47

  characterised by structural features · CPC title

• B22F12/22

  Driving means · CPC title