Additive manufacturing system for joining and surface overlay
AssigneeIllinois Tool Works Inc.
InventorsBruce Patrick Albrecht, Christopher Hsu
Life of this patent
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Abstract
An additive manufacturing system includes an additive manufacturing tool configured to receive a plurality of metallic anchoring materials and to supply a plurality of droplets to a part, and a controller configured to independently control the composition, formation, and application of each droplet to the plurality of droplets to the part. The plurality of droplets is configured to build up the part. Each droplet of the plurality of droplets includes at least one metallic anchoring material of the plurality of metallic anchoring materials.
Claims20
An additive manufacturing system, comprising:
- an additive manufacturing tool configured to receive one or more metallic anchoring materials;
- a position sensor configured to measure a position of the additive manufacturing tool relative to a first base material, a second base material, or a part;
- a robotic system configured to move the additive manufacturing tool;
- a power source configured to provide DC or AC power to the one or more metallic anchoring materials to melt the one or more metallic anchoring materials into a plurality of droplets, the additive manufacturing tool being configured to deposit the plurality of droplets;
- and
- a controller configured to control the additive manufacturing tool or the power source to fasten the first base material to the second base material via the plurality of droplets, the controller comprising executable instructions which, when executed,
- cause the position sensor to detect where a recess formed in the second base material is aligned with the first base material,
- cause the robotic system to move the additive manufacturing tool to a deposition position where the additive manufacturing tool can apply the plurality of droplets within the recess,
- cause the additive manufacturing tool or the power source to apply the plurality of droplets within the recess to build up the part on the first base material without melting the second base material, and
- cause the additive manufacturing tool or the power source to complete the part by forming a cap on the part that resists separation of the second base material from the first base material, thereby securing the second base material from movement in one or more directions relative to the first base material without melting the second base material.
A method of additively forming a part that fastens a first base material to a second base material, the method comprising:
- receiving one or more metallic anchoring materials at an additive manufacturing tool;
- measuring a position of the additive manufacturing tool relative to a first base material, a second base material, or a part;
- providing, by a power source, AC or DC power to the one or more metallic anchoring materials to melt the one or more metallic anchoring materials into a plurality of droplets;
- and
- controlling, via a controller, the additive manufacturing tool or the power source to fasten the first base material to the second base material via the plurality of droplets by
- detecting, via a position sensor, where a recess formed in the second base material is aligned with the first base material,
- moving the additive manufacturing tool, via a robotic system, to a deposition position where the additive manufacturing tool can apply the plurality of droplets within the recess,
- applying, via the additive manufacturing tool or the power source, the plurality of droplets within the recess to build up the part on the first base material without melting the second base material, and
- completing the part by forming a cap on the part, via the additive manufacturing tool or the power source, the cap resisting separation of the second base material from the first base material, thereby securing the second base material from movement in one or more directions relative to the first base material without melting the second base material.
Dependencies are inferred from the claim text.