# US 11,440,255 B2 · Additive manufacturing under generated force

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- Number: US 11,440,255 B2
- Document ID: US11440255B2
- Status: Granted
- Kind: B2
- Application number: 16/571,473
- Filed: 2019-09-16
- Published: 2020-03-19
- Granted: 2022-09-13
- Earliest claimed: 2018-09-14
- Assignees: MRI. Materials Resources LLC
- Applicants: Mrl Materials Resources LLC
- Inventors: Ayman A. Salem; Daniel P. Satko
- Web page: https://patentgrep.com/patent/US11440255B2

## CPC

- B29C 64/241: for rotary motion
- B22F 10/14: by jetting of binder onto a bed of metal powder
- B22F 10/25: Direct deposition of metal particles, e.g. direct metal deposition [DMD] or laser engineered net shaping [LENS]
- B22F 10/28: Powder bed fusion, e.g. selective laser melting [SLM] or electron beam melting [EBM]
- B22F 12/226: {for rotary motion}
- B22F 12/37: Rotatable
- B22F 12/49: Scanners
- B22F 12/50: Means for feeding of material, e.g. heads
- B29C 64/153: using layers of powder being selectively joined, e.g. by selective laser sintering or melting
- B29C 64/205: Means for applying layers
- B29C 64/245: Platforms or substrates (support structures intended to be sacrificed after manufacture B29C64/40)
- B29C 64/393: for controlling or regulating additive manufacturing processes
- B33Y 10/00: Processes of additive manufacturing
- B22F 10/18: by mixing binder with metal in filament form, e.g. fused filament fabrication [FFF]
- B22F 10/31: Calibration of process steps or apparatus settings, e.g. before or during manufacturing
- B22F 10/32: of the atmosphere, e.g. composition or pressure in a building chamber
- B22F 2999/00: Aspects linked to processes or compositions used in powder metallurgy
- B29C 64/118: using filamentary material being melted, e.g. fused deposition modelling [FDM]
- B29C 64/268: using laser beams; using electron beams [EB]
- B29C 64/295: Heating elements
- B33Y 30/00: Apparatus for additive manufacturing; Details thereof or accessories therefor
- B33Y 40/00: Auxiliary operations or equipment, e.g. for material handling
- B33Y 50/02: for controlling or regulating additive manufacturing processes
- 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

## Abstract

A system for additive manufacturing under generated force includes a mechanical arm, a build platform, a build platform controller, a material delivery system controller, a laser scan system, a laser scan system controller, a motor controller and a master controller. The master controller determines a location of the material delivered to the build platform. The master controller further calculates a rate of rotation of the build platform as a function of the location of the material delivered and a desired centrifugal acceleration. The master controller further calculates an adjustment factor to correlate a rotation of the laser scan system to a rotation of the mechanical arm as a function of the location of the material delivered and a calculated rate of rotation of the build platform.

## Claims

### Claim 1

A system comprising:
a rotational center;
a mechanical arm extending from the rotational center, the mechanical arm comprising a central section, the mechanical arm further comprising a peripheral section;
a build platform located at the peripheral section of the mechanical arm, the build platform being movable incrementally and in parallel to the mechanical arm;
a build platform controller configured for controlling incremental movement of the build platform;
a material delivery system for delivering material to the build platform;
a material delivery system controller configured for controlling amounts of the material delivered to the build platform;
a laser scan system for scanning the material delivered to the build platform;
a laser scan system controller configured for controlling the laser scan system;
a motor operatively coupled to the central section of the mechanical arm, the motor for rotating the mechanical arm about the rotational center, a desired centrifugal acceleration being applied to the build platform during rotation of the mechanical arm about the rotational center, the motor further operatively coupled to the laser scan system, the motor for further rotating the laser scan system about the rotational center, rotation of the laser scan system correlating to the rotation of the mechanical arm;
a motor controller configured for controlling the rotation of the mechanical arm, the motor controller further for controlling the rotation of the laser scan system; and
a master controller communicatively coupled to the build platform controller, the material delivery system controller, the laser scan system controller, and the motor controller, wherein the master controller is configured to:
determine a location of the material delivered to the build platform;
calculate a rate of rotation of the build platform, the rate of rotation being a function of:
the location of the material delivered; and
the desired centrifugal acceleration; and
calculate an adjustment factor to correlate the rotation of the laser scan system to the rotation of the mechanical arm, the adjustment factor being calculated as a function of:
the location of the material delivered; and
the calculated rate of rotation of the build platform; and
convey the calculated rate of rotation to the motor controller.

### Claim 2 (depends on 1)

The system of claim 1, further comprising a build chamber housing the build platform.

### Claim 3 (depends on 1)

The system of claim 1, wherein the master controller is configured to determine the incremental movement of the build platform as a function of the amounts of material delivered to the build platform.

### Claim 4 (depends on 1)

The system of claim 1, wherein the mechanical arm comprises a means for rotationally securing the build platform to the rotational center.

### Claim 5 (depends on 4)

The system of claim 4, wherein the means for rotationally securing the build platform to the rotational center is a rigid rod.

### Claim 6

A system comprising:
a rotational center;
a mechanical arm extending from the rotational center;
a build platform movable incrementally and in parallel to the mechanical arm;
a build platform controller configured for controlling incremental movement of the build platform;
a material delivery system for delivering material to the build platform;
a material delivery system controller configured for controlling amounts of the material delivered to the build platform;
a laser scan system for scanning the material delivered to the build platform;
a laser scan system controller configured for controlling the laser scan system;
a motor for rotating the mechanical arm about the rotational center, a centrifugal force being applied to the build platform during rotation of the mechanical arm about the rotational center, the motor for further rotating the laser scan system about the rotational center, rotation of the laser scan system correlating to the rotation of the mechanical arm;
a motor controller configured for controlling the rotation of the mechanical arm, the motor controller further for controlling the rotation of the laser scan system; and
a master controller communicatively coupled to the build platform controller, the material delivery system controller, the laser scan system controller, and the motor controller, wherein the master controller is configured to:
determine a location of the material delivered to the build platform;
calculate a rate of rotation of the build platform;
calculate an adjustment factor to correlate the rotation of the laser scan system to the rotation of the mechanical arm, the adjustment factor being calculated as a function of:
the location of the material delivered: and
the calculated rate of rotation of the build platform; and convey the calculated rate of rotation to the motor controller.

### Claim 7 (depends on 6)

The system of claim 6, wherein the material delivery system and laser scan system are connected, such that material delivery and processing by melting or sintering occur simultaneously.

### Claim 8 (depends on 6)

The system of claim 6, wherein the material delivery system delivers a powder material to the build platform.