Long and High Resolution Structures Formed by Additive Manufacturing Techniques

Patent metadata

Field	Value
Publication number	US-2024342988-A1
Application number	US-202418753760-A
Country	US
Kind code	A1
Filing date	Jun 25, 2024
Priority date	Oct 30, 2015
Publication date	Oct 17, 2024
Grant date	—

Abstract

A method of additive manufacture suitable for large and high resolution structures is disclosed. The method may include sequentially advancing each portion of a continuous part in the longitudinal direction from a first zone to a second zone. In the first zone, selected granules of a granular material may be amalgamated. In the second zone, unamalgamated granules of the granular material may be removed. The method may further include advancing a first portion of the continuous part from the second zone to a third zone while (1) a last portion of the continuous part is formed within the first zone and (2) the first portion is maintained in the same position in the lateral and transverse directions that the first portion occupied within the first zone and the second zone.

First claim

1 . A method comprising:
providing a powder material; providing an energy source comprising multiple energy beams; directing a combined beam from the energy source toward an energy patterning unit to form a two-dimensional patterned energy beam; and directing the two-dimensional patterned energy beam upon the powder material to form a structure having a length greater than or equal to 10 meters and a size calculated by applying a scaling factor to the length, the scaling factor being greater than or equal to 1 and less than or equal to five and in units of meters.

2 . The method of claim 1 , wherein the structure is one of a blade, an airfoil, and a propeller.

3 . The method of claim 1 , wherein the structure comprises a frame.

4 . The method of claim 1 , wherein the structure comprises a truss.

5 . The method of claim 1 , wherein the structure comprises a lattice structure.

6 . The method of claim 1 , wherein the powder material is powdered metal material.

7 . The method of claim 1 , wherein the energy source comprises electron beams.

8 . The method of claim 1 , wherein the energy source comprises solid state lasers.

9 . The method of claim 1 , wherein the energy source comprises semiconductor lasers.

10 . The method of claim 1 , wherein the powder material comprises one or more of metal, ceramic, and plastic.

11 . A method comprising:
providing a powder material; providing an energy source comprising multiple energy beams; directing a combined beam from the energy source toward an energy patterning unit to form a two-dimensional patterned energy beam; and directing the two-dimensional patterned energy beam upon the powder material to form an object having a length greater than or equal to 10 meters.

12 . The method of claim 11 , wherein the powder material is powdered metal material.

13 . The method of claim 11 , wherein the object comprises at least one of a frame, a truss, and a lattice structure.

14 . The method of claim 11 , wherein the energy source comprises electron beams, solid state lasers, or semiconductor lasers.

15 . The method of claim 11 , wherein the size of the object is greater than a value determined by applying a scaling factor to the length that is greater than or equal to 1 and less than or equal to five and in units of meters.

16 . The method of claim 11 , wherein a printed resolution of the object is greater than a value calculated by a function of a longest dimension of the object.

17 . The method of claim 11 , wherein a printed resolution of the object is greater than a value calculated by a function of average mass deposition rate achieved in creating the object.

18 . The method of claim 17 , wherein the average mass deposition rate is greater than a value calculated by a function of a longest dimension of the object.

Assignees

• Seurat Tech Inc

Inventors

• Demuth James A
• Toomre Erik
• Leard Francis L
• Kamshad Kourosh
• Fees Heiner
• Berdichevsky Eugene

Classifications

• B22F10/39

  Traceability, e.g. incorporating identifier into a workpiece or article · CPC title

• Y02P80/40

  Minimising material used in manufacturing processes · CPC title

• G02B27/108

  for sampling a portion of a beam or combining a small beam in a larger one, e.g. wherein the area ratio or power ratio of the divided beams significantly differs from unity, without spectral selectivity · CPC title

• B29C64/286

  Optical filters, e.g. masks · CPC title

• Y02P10/25

  Process efficiency · CPC title