Process for manufacturing metal parts using deployable manufacturing center (DMC) system

A process for manufacturing metal parts comprising:

• providing a deployable manufacturing center (DMC) system comprising:
• a foundry module configured to store a feedstock, to remove contaminants from the feedstock, to melt the feedstock to form a molten metal, and to atomize the molten metal into an alloy powder, the foundry module comprising a metallurgical system and a first container configured to contain the metallurgical system, the metallurgical system comprising a plasma torch configured to heat the feedstock into the molten metal, a mixing cold hearth configured to mix the molten metal into a uniform composition and an atomization system configured to atomize the molten metal into the alloy powder;
• and
• an additive manufacturing (AM) module configured to form the alloy powder from the foundry module into rough metal parts, the additive manufacturing (AM) module comprising an additive manufacturing system and a second container configured to contain the additive manufacturing system, the additive manufacturing (AM) system comprising a system selected from the group consisting of 3-D printer systems, direct energy deposition systems, powder bed fusion systems and cold spray systems, the first container and the second container configured for deployment to a desired location for manufacturing the metal parts at the desired location;
• deploying the deployable manufacturing center (DMC) system to the desired location;
• storing the feedstock, analyzing the chemical composition of the feedstock and removing the contaminants from the feedstock using the foundry module;
• forming the alloy powder from the feedstock using the mixing cold hearth to melt the feedstock into the molten metal and the atomization system to atomize the molten metal into the alloy powder;
• and
• forming the rough metal parts from the alloy powder using the additive manufacturing (AM) module.

A process for manufacturing metal parts comprising:

• providing a deployable manufacturing center (DMC) system comprising:
• an array of transportable modules containing equipment configured to convert a feedstock into an alloy powder, and then to build the metal parts from the alloy powder using an additive manufacturing (AM) process,
• the modules including a foundry module configured to store a feedstock, to remove contaminants from the feedstock, to melt the feedstock to form a molten metal, and to atomize the molten metal into an alloy powder, the foundry module comprising a metallurgical system and a first container configured to contain the metallurgical system, the metallurgical system comprising a plasma torch configured to heat the feedstock into the molten metal, a mixing cold hearth configured to mix the molten metal into a uniform composition and an atomization system configured to atomize the molten metal into the alloy powder, the mixing cold hearth including a composition correction system for adding additives to the molten metal;
• an additive manufacturing (AM) module configured to form the alloy powder from the foundry module into rough metal parts, the additive manufacturing (AM) module comprising a 3-D printer and a second container configured to contain the 3-D printer, the 3-D printer configured to form the alloy powder into the rough metal parts;
• and
• a machining module configured to machine the rough metal parts formed by the additive manufacturing (AM) module into the metal parts, the machining module comprising a machining system and a third container configured to contain the machining system;
• the first container, the second container, and the third container configured for deployment to a desired location for manufacturing the metal parts at the desired location;
• deploying the deployable manufacturing center (DMC) system to the desired location;
• storing the feedstock, and removing the contaminants from the feedstock using the foundry module;
• forming the alloy powder from the feedstock using the mixing cold hearth to melt the feedstock into the molten metal and the atomization system to atomize the molten metal into the alloy powder;
• forming the rough metal parts from the alloy powder using the additive manufacturing (AM) module;
• and
• machining the rough metal parts into the metal parts using the machining module.