# US 10,479,021 B2 · Curved plate production by additive layer manufacture

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- Number: US 10,479,021 B2
- Document ID: US10479021B2
- Status: Granted
- Kind: B2
- Application number: 16/044,859
- Filed: 2018-07-25
- Published: 2019-01-31
- Granted: 2019-11-19
- Earliest claimed: 2017-07-26
- Assignees: ROLLS-ROYCE plc
- Applicants: ROLLS-ROYCE plc
- Inventors: Matthew Tan
- Web page: https://patentgrep.com/patent/US10479021B2

## CPC

- B29C 64/40: Structures for supporting 3D objects during manufacture and intended to be sacrificed after completion thereof
- B22F 10/20: Direct sintering or melting
- B22F 10/40: Structures for supporting workpieces or articles during manufacture and removed afterwards
- B29C 64/153: using layers of powder being selectively joined, e.g. by selective laser sintering or melting
- B33Y 10/00: Processes of additive manufacturing
- B29L 2007/002: {Panels; Plates; Sheets}
- B29L 2031/7739: {Curved shaped}
- B33Y 80/00: Products made by additive manufacturing
- Y02P 10/25: Process efficiency
- B29C: SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING (making preforms B29B11/00; making laminated products by combining previously unconnected layers which become one product whose layers will remain together B32B37/00 - B32B41/00)
- B22F: WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER (making alloys by powder metallurgy C22C); APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
- B33Y: ADDITIVE MANUFACTURING, i.e. MANUFACTURING OF THREE-DIMENSIONAL [3D] OBJECTS BY ADDITIVE DEPOSITION, ADDITIVE AGGLOMERATION OR ADDITIVE LAYERING, e.g. BY 3D PRINTING, STEREOLITHOGRAPHY OR SELECTIVE LASER SINTERING
- B29L: INDEXING SCHEME ASSOCIATED WITH SUBCLASS B29C, RELATING TO PARTICULAR ARTICLES
- Y02P: CLIMATE CHANGE MITIGATION TECHNOLOGIES IN THE PRODUCTION OR PROCESSING OF GOODS

## Abstract

A method of producing a curved plate by additive layer manufacture is provided. The method includes building up the plate layer-by-layer such that a first layer forms a bottom edge of the plate and the plate is additively extended upwards therefrom by subsequent layers such that a last layer forms an opposing top edge of the plate. In this way, spaced, first and second lateral edges of the plate each grow layer-by-layer to extend between respective ends of the bottom and top edges. The plate thus built up arches over from the bottom edge to adopt a curved shape on cross-sections through the plate normal to the bottom edge.

## Claims

### Claim 1

A method of producing a curved plate by additive layer manufacture, the method including:
building up the plate layer-by-layer such that a first layer forms a bottom edge of the plate and the plate is additively extended upwards therefrom by subsequent layers such that a last layer forms an opposing top edge of the plate, wherein spaced, first and second lateral edges of the plate each grow layer-by-layer to extend between respective ends of the bottom and top edges, and the plate thus built up arches over from the bottom edge to adopt a curved shape on cross-sections through the plate normal to the bottom edge;
simultaneously building up layer-by-layer with the plate first and second sacrificial plate additions along respectively the first and second lateral edges, each sacrificial plate addition continuing the geometry of the plate beyond its lateral edge such that the additions also arch over from the bottom edge to adopt a curved shape on cross-sections through the additions normal to the bottom edge; and
removing the sacrificial plate additions.

### Claim 2 (depends on 1)

A method of producing a curved plate according to claim 1, wherein the sacrificial plate additions are thinned where they join to the plate along the first and second lateral edges.

### Claim 3 (depends on 1)

A method of producing a curved plate according to claim 1, wherein the length of each sacrificial plate addition in the direction of the bottom edge is at least 5% of the length of the bottom edge.

### Claim 4 (depends on 1)

A method of producing a curved plate according to claim 1, wherein the length of each sacrificial plate addition in the direction of the bottom edge is at most 30% of the length of the bottom edge.

### Claim 5 (depends on 1)

A method of producing a curved plate according to claim 1, wherein the spacing between the first and second lateral edges and/or the spacing between the bottom and top edges is at least ten times greater than the thickness of the plate.

### Claim 6 (depends on 1)

A method of producing a curved plate according to claim 1, wherein one or each of the sacrificial plate additions is anchored during plate build up by further additive layer material to a respective support structure.

### Claim 7 (depends on 1)

A method of producing a curved plate according to claim 1, wherein the plate thus built up also has a curved shape on cross-sections normal to the direction of additive layer growth.