Back to results
US 11,766,832 B2Granted
System and method for additively manufacturing an object
AssigneeThe Boeing Company
InventorsElaine MacDonald, Daniel J. Braley
Life of this patent
Estimating the term…
Abstract
A method of additively manufacturing an object includes steps of: (1) selectively depositing build powder inside of a build contour of the object to form a build-powder section of a powder layer; and (2) selectively depositing support powder outside of the build contour to form a support-powder section of the powder layer. According to the method, the build powder includes a build-powder composition, the support powder includes a support-powder composition, and the build-powder composition and the support-powder composition are different.
Claims20
A method of additively manufacturing an object, the method comprising:
- selectively depositing build powder only inside of a first build contour of the object to form a first build-powder section of a first powder layer;
- selectively depositing support powder only outside of the first build contour to form a first support-powder section of the first powder layer;
- joining the build powder of the first powder layer to form a first object layer;
- joining the support powder of a portion of the first powder layer that is outside of the first build contour and that is inside of a second build contour of the object to form a support layer;
- selectively depositing the support powder inside of the second build contour to form an intermediate support-powder layer on the support layer;
- selectively depositing the build powder only inside of the second build contour of the object to form a second build-powder section of a second powder layer;
- selectively depositing the support powder only outside of the second build contour to form a second support-powder section of the second powder layer;
- and
- joining the build powder of the second powder layer to form a second object layer such that a portion of the second object layer is joined to the first object layer and another portion of the second object layer is supported on but not joined to the intermediate support-powder layer;
- wherein:
- the build powder comprises a build-powder composition;
- the support powder comprises a support-powder composition;
- and
- the build-powder composition and the support-powder composition are different.
11 more elements
A method of additively manufacturing an object, the method comprising:
- selectively depositing build powder only inside of a first build contour of the object to form a first build-powder section of a first powder layer;
- selectively depositing support powder only outside of the first build contour to form a first support-powder section of the first powder layer,
- joining the build powder of the first powder layer to form a first object layer;
- joining the support powder of a portion of the first powder layer that is outside of the first build contour and that is inside of a second build contour of the object to form a support layer;
- selectively depositing the support powder inside of the second build contour to form an intermediate support-powder layer on the support layer;
- selectively depositing the build powder only inside of the second build contour of the object to form a second build-powder section of a second powder layer;
- selectively depositing the support powder only outside of the second build contour to form a second support-powder section of the second powder layer;
- and
- joining the build powder of the second powder layer to form a second object layer such that a portion of the second object layer is joined to the first object layer and another portion of the second object layer is supported on but not joined to the intermediate support-powder layer.
6 more elements
An additive-manufacturing system comprising:
- a powder-deposition apparatus;
- a powder-joining apparatus;
- and
- a controller programmed to command the powder-deposition apparatus and the powder-joining apparatus to:
- selectively deposit build powder only inside of a first build contour to form a first build-powder section of a first powder layer;
- selectively deposit support powder only outside of the first build contour to form a first support-powder section of the first powder layer;
- join the build powder of the first powder layer to form a first object layer;
- join the support powder of a portion of the first powder layer that is outside of the first build contour and that is inside of a second build contour of the object to form a support layer;
- selectively deposit the support powder inside of the second build contour to form an intermediate support-powder layer on the support layer;
- selectively deposit the build powder only inside of the second build contour of the object to form a second build-powder section of a second powder layer;
- selectively deposit the support powder only outside of the second build contour to form a second support-powder section of the second powder layer;
- and
- join the build powder of the second powder layer to form a second object layer such that a portion of the second object layer is joined to the first object layer and another portion of the second object layer is supported on but not joined to the intermediate support-powder layer.
10 more elements
Dependencies are inferred from the claim text.