Systems and methods for finishing additive manufacturing faces with different orientations

Patent metadata

Field	Value
Publication number	US-2019381605-A1
Application number	US-201816007336-A
Country	US
Kind code	A1
Filing date	Jun 13, 2018
Priority date	Jun 13, 2018
Publication date	Dec 19, 2019
Grant date	—

Abstract

An additive manufacturing system includes a build platform, at least one first consolidation device, and at least one second consolidation device. The at least one first consolidation device is configured to direct at least one first energy beam to a first face of a component. The first face has a first orientation. The at least one second consolidation device is configured to simultaneously direct at least one second energy beam toward a second face of the component as the first consolidation device directs the at least one first energy beam toward the first face. The second face has a second orientation different from the first orientation.

First claim

What is claimed is:

1 . An additive manufacturing system comprising:
a build platform; at least one first consolidation device configured to direct at least one first energy beam to a first face of a component, wherein the first face has a first orientation; and at least one second consolidation device configured to simultaneously direct at least one second energy beam toward a second face of the component as said first consolidation device directs the at least one first energy beam toward the first face, wherein the second face has a second orientation different from the first orientation.

2 . The additive manufacturing system of claim 1 , wherein said second consolidation device is configured to finish the second face of the component.

3 . The additive manufacturing system of claim 1 , wherein said second consolidation device is configured to consolidate the second face of the component.

4 . The additive manufacturing system of claim 1 , wherein the second face is oriented substantially orthogonal to the first face.

5 . The additive manufacturing system of claim 1 , wherein the second face of the component is a down facing face of the component.

6 . The additive manufacturing system of claim 1 , wherein said at least one second consolidation device comprises a plurality of second consolidation devices positioned circumferentially around the component.

7 . The additive manufacturing system of claim 1 further comprising an actuator system coupled to said at least one second consolidation device and configured to move said at least one second consolidation device.

8 . The additive manufacturing system of claim 7 , wherein said actuator system is configured to move said at least one second consolidation circumferentially about the component.

9 . The additive manufacturing system of claim 1 , wherein the first face is offset from said build platform and is oriented substantially parallel to said build platform.

10 . The additive manufacturing system of claim 1 , wherein the second face is oriented substantially orthogonal to said build platform.

11 . The additive manufacturing system of claim 1 , wherein said at least one first consolidation device and said at least one second consolidation device are the same.

12 . A controller for use in an additive manufacturing system including at least one first consolidation device and at least one second consolidation device, the at least one first consolidation device configured to direct at least one first energy beam to a first face of a component, the first face has a first orientation, the at least one second consolidation device configured to simultaneously direct at least one second energy beam to at least one second face of the component as the first consolidation device directs the at least one first energy beam toward the first face, the second face has a second orientation different from the first orientation, said controller configured to:
receive a build file, the build file defining a plurality of first scan paths for the first consolidation device and a plurality of second scan paths for the second consolidation device; control the first consolidation device, based on the build file, to consolidate a plurality of first particles along the plurality of first scan paths to form at least a portion of the first face; and control the second consolidation device, based on the build file, to direct the at least one second energy beam to the second face along the plurality of second scan paths.

13 . The controller in accordance with claim 12 , wherein said controller is configured to control the second consolidation device, based on the build file, to finish the second face.

14 . The controller in accordance with claim 12 , wherein said controller is configured to control the second consolidation device, based on the build file, to consolidate the second face.

15 . The controller in accordance with claim 12 , wherein said controller is configured to move the second consolidation device, based on the build file, circumferentially around the component.

16 . A method of fabricating a component, said method comprising:
depositing particles onto a build platform; distributing the particles to form a first face of a component; operating at least one first consolidation device to consolidate a first plurality of particles along a first scan path along the first face, wherein the first face has a first orientation; and simultaneously operating at least one second consolidation device to consolidate a second plurality of particles along a second scan path along a second face of the component as the at least one first consolidation device consolidates the first plurality of particles along the first scan path, wherein the second face has a second orientation different from the first orientation.

17 . The method in accordance with claim 16 , wherein the second face is oriented substantially orthogonal to the first face.

18 . The method in accordance with claim 16 , wherein operating at least one second consolidation device comprises operating a plurality of second consolidation devices.

19 . The method in accordance with claim 16 , wherein operating at least one second consolidation device comprises moving the at least one second consolidation device circumferentially around the component.

20 . The method in accordance with claim 16 further comprising operating the at least one second consolidation device to finish the second face.

Assignees

• Gen Electric

Inventors

• Madelone Jr John Joseph
• Adcock Thomas Charles
• Deaton Jr John Broddus
• Graham Michael Evans

Classifications

• B33Y30/00 Primary

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

• B33Y50/02

  for controlling or regulating additive manufacturing processes · CPC title

• B23K26/34

  Laser welding for purposes other than joining · CPC title

• B23K26/354 Primary

  by melting · CPC title

• B33Y10/00

  Processes of additive manufacturing · CPC title