Back to results
US 11,890,807 B1Granted
Systems and methods for controlling additive manufacturing processes
AssigneeBlue Origin, LLC
InventorsLandon Luick, Steven James Craigen
Life of this patent
Estimating the term…
Abstract
Systems and methods for controlling additive manufacturing processes are disclosed. The systems can include multiple laser directors, soot-removal devices, magnetic chucks, replenishable powder distribution blades, automated powder level detectors, and/or overall process automation techniques.
Claims25
An additive manufacture system, comprising:
- a build chamber;
- a gantry positioned in the build chamber;
- a first head,
- at least one first energy beam director carried by the first head and positioned to direct a first energy beam toward a support element positioned to support an additive build platform;
- a second head;
- and
- at least one second energy beam director carried by the second head and positioned to direct a second energy beam toward the support element at an angle of less than 70° from horizontal, wherein at least one of the first and second heads is carried by the gantry and movable in lateral direction in the build chamber.
4 more elements
An additive manufacture system, comprising:
- a build chamber;
- an energy beam director positioned to direct an energy beam toward a support element positioned to support an additive build platform, wherein the energy beam director is movable relative to the build chamber;
- and
- a chamber purification system coupled to the build chamber and including:
- a chamber exit passage;
- a chamber entrance passage;
- a separator coupled between the chamber exit passage and the chamber entrance passage to remove oxygen from a flow of gas from the chamber;
- and
- a gas supply coupled to the chamber entrance passage to direct a non-air gas into the chamber.
6 more elements
An additive manufacture system, comprising:
- a build chamber;
- at least one energy beam director positioned to direct an energy beam toward a support element positioned to support an additive build platform, wherein at least one of the support element and the at least one energy beam director is movable relative to the other;
- and
- a powder control system comprising:
- a powder source;
- and
- a recoater arm positioned proximate to the powder source to distribute additive material powder in a build region beneath the at least one energy beam director, wherein the recoater arm comprises:
- a first transverse arm portion coupled to a replenishable blade supply to provide a first blade to the first transverse arm portion, wherein the replenishable blade supply includes a first supply reel positioned to carry an un-used portion of the first blade;
- and
- a second transverse arm portion coupled to the replenishable blade supply to provide a second blade to the second transverse arm portion, wherein the replenishable blade supply includes a second supply reel positioned to carry an un-used portion of the second blade.
7 more elements
An additive manufacture system, comprising:
- a build chamber;
- at least one energy beam director positioned in the build chamber to direct an energy beam toward a support element positioned to support an additive build platform;
- and
- a powder control system comprising:
- a powder source;
- a recoater arm having a powder application chamber and being positioned in the build chamber and movable relative to the powder source to receive additive material powder from the powder source and distribute the additive material powder onto a new layer in a build region of the additive build platform;
- and
- a plurality of powder level sensors positioned along a length of the recoater arm, with individual powder level sensors configured to issue corresponding sensor signals corresponding to a quantity of powder in the build region of the additive build platform.
5 more elements
An additive manufacture system, comprising:
- multiple processing chambers positioned to removably receive a movable build container, wherein the movable build container is configured to carry an additive build platform, and wherein individual processing chambers include:
- at least one energy beam director positioned in the processing chamber to direct an energy beam toward the additive build platform;
- and
- a powder control system comprising:
- a powder source;
- and
- a coater arm having a powder application chamber and being positioned in the movable build container and movable relative to the powder source to receive additive powder material from the powder source and distribute the additive powder material in a build region beneath the at least one energy beam director;
- at least one post-processing station positioned apart from the processing chambers and also positioned to removably receive the movable build container;
- first and second tracks mounted perpendicular to one another to move multiple movable build containers between the processing chambers and the at least one post-processing station;
- and
- a transporter movable along the first track and having a fixed third track oriented perpendicular to the first track and parallel with the second track, the third track being positional to carry the movable build container.
8 more elements
Dependencies are inferred from the claim text.