Powder bed fusion apparatus and methods

A powder bed fusion apparatus for building an object in a layer-by-layer manner, the powder bed fusion apparatus comprising a build platform movable within a build sleeve to define a build volume, the build platform for supporting a powder bed within the build volume, an irradiation device arranged to generate an energy beam and a scanner arranged to steer the energy beam to irradiate powder of the powder bed to selectively fuse the powder bed and a mechanical manipulator arranged to engage with the object and/or a build substrate, to which the object is attached, wherein the mechanical manipulator comprises an end effector positionable to receive the object and/or the build substrate when conveyed from the build sleeve such that the object and/or the build substrate attach to the end effector, and coupling members for retaining a replacement build substrate, the end effector and the coupling members movable to move the object and/or the build substrate from a location adjacent to the build platform and to locate the replacement build substrate to the location adjacent the build platform, the coupling members further arranged to release the replacement build substrate on to the build platform.

A break-out device for the break-out of an object from unsolidified powder, the object built in a layer-by-layer manner in a powder bed fusion apparatus comprising a build platform movable within a build sleeve to define a build volume, the build platform for supporting a powder bed within the build volume, an irradiation device arranged to generate an energy beam and a scanner arranged to steer the energy beam to irradiate powder of the powder bed to selectively fuse the powder bed, the build sleeve movable from a build position in which the powder is fused, the break-out device comprising a space for receiving the build sleeve moved from the build position and a mechanical manipulator comprising a frame having coupling members thereon for engaging with the object and/or a build substrate on which the object is built, the frame rotatable to tilt the object such that powder is freed from the object, the coupling members positioned or positionable to receive the object and/or the build substrate when conveyed from the build sleeve received in the space within the break-out device to cause the coupling members to engage the object and/or the build substrate.