Apparatus and methods for optimization of powder removal features in additively manufactured components

Patent metadata

Field	Value
Publication number	US-2022176450-A1
Application number	US-202217681142-A
Country	US
Kind code	A1
Filing date	Feb 25, 2022
Priority date	Sep 12, 2017
Publication date	Jun 9, 2022
Grant date	—

Abstract

Techniques for optimizing powder hole removal are disclosed. In one aspect, an apparatus for inserting powder removal features may identify what powder removal features are optimal for a given AM component, as well as the optimal location and physical characteristics of these features. The features are automatedly added to the component, and an FEA test is run. In the event of failure, the offending feature is removed and the process is repeated. If successful then the loose powder may be removed in a post-processing step following AM.

First claim

What is claimed is:

1 . A method for automatedly inserting powder removal features in an additively manufactured component, the method comprising:
receiving a model of a component to be additively manufactured; automatedly determining optimal size and location of one or more apertures in the component for powder removal; and updating the model to include the one or more determined powder removal apertures.

2 . The method of claim 1 , further comprising additively manufacturing the component based on the updated model.

3 . The method of claim 2 , further comprising removing trapped powder from the additively manufactured component using the one or more powder removal apertures.

4 . The method of claim 1 , wherein the automatedly determining optimal size and location of the one or more apertures comprises evaluating potential gravitational advantages for facilitating powder removal.

5 . The method of claim 1 , wherein the automatedly determining optimal size and location of the one or more apertures comprises selecting an aperture size based at least in part on a type of material to be used as powder particles in the additive manufacturing of the component.

6 . The method of claim 1 , wherein the automatedly determining optimal size and location of the one or more apertures comprises evaluating loading and boundary conditions for the component.

7 . The method of claim 1 , further comprising automatedly determining geometry and location of one or more powder channels for removing powder after additively manufacturing the component.

8 . The method of claim 7 , wherein the automatedly determining geometry and location of the one or more powder channels comprises identifying a shortest removal path.

9 . The method of claim 7 , wherein the automatedly determining geometry and location of the one or more powder channels comprises identifying a path of least material resistance.

10 . The method of claim 7 , wherein the automatedly determining geometry and location of the one or more powder channels comprises evaluating potential gravitational advantages for facilitating powder removal.

11 . The method of claim 1 , wherein the automatedly determining optimal size and location of the one or more apertures comprises specifying an aerodynamic contour for the aperture to facilitate subsequent powder removal through air flow.

12 . The method of claim 7 , wherein the automatedly determining geometry and location of the one or more powder channels comprises specifying an aerodynamic contour for the one or more powder channels to facilitate subsequent powder removal through air flow.

13 . The method of claim 1 , wherein the automatedly determining optimal size and location of the one or more apertures comprises evaluating at least one of powder material, powder particle size distribution, average powder flow rate, and powder type.

14 . The method of claim 7 , wherein the automatedly determining size and placement of the one or more powder channels comprises evaluating at least one of powder material, powder particle size distribution, average powder flow rate, and powder type.

15 . A method for removing powder from an additively manufactured component having at least one aperture, comprising:
receiving a data model of the component; additively manufacturing the component based on the data model; removing trapped powder from the additively manufactured component using the at least one aperture; and performing a layup process using at least one material to seal the aperture.

Assignees

• Divergent Tech Inc

Inventors

• Lakshman Narender Shankar
• Bowden Jr Thomas Samuel
• Bucknell John Russell
• Byers Ross Harrison
• Tenhouten Broc William
• Martinez Antonio Bernerd
• Zafar Muhammad Faizan
• HOYLE Richard Winston
• Okoli Chukwubuikem Marcel

Classifications

• B23K26/342 Primary

  Build-up welding · CPC title

• B22F3/24

  After-treatment of workpieces or articles {(B22F3/1146 takes precedence)} · CPC title

• B22F12/52

  Hoppers · CPC title

• B22F10/80

  Data acquisition or data processing · CPC title

• B22F10/68

  Cleaning or washing · CPC title