System and method for additively manufacturing an object
AssigneeThe Boeing Company
InventorsElaine MacDonald, Russell W. Cochran, Daniel J. Braley
Life of this patent
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Abstract
A method of additively manufacturing an object includes successively forming a plurality of powder layers by depositing powder over a build platform using a powder-deposition apparatus. The method also includes successively forming a binder shell by bonding select regions of each one of the plurality of powder layers before forming each successive one of the plurality of powder layers using a binder-delivery apparatus. The binder shell encloses a portion of the powder. The method further includes densifying the portion of the powder bound by the binder shell using a consolidation apparatus.
Claims20
An additive manufacturing system comprising:
- a build platform;
- a recoater configured to deposit powder;
- a base positioned over the build platform;
- a printhead actuator coupled to the base;
- a printhead coupled to and movable relative to the base by the printhead actuator, the printhead is configured to selectively deposit binder to the powder;
- a tamper actuator coupled to the base;
- a tamper coupled to and movable relative to the base by the tamper actuator, the tamper is configured to densify the powder;
- and
- a controller programmed to cause:
- the recoater to successively form a plurality of powder layers over the build platform;
- the printhead to successively form a binder shell by applying the binder to bond select regions of each one of the plurality of powder layers before the recoater forms each successive one of the plurality of powder layers such that the binder shell is formed of bonded powder and the binder shell encloses an entirety of a powder core formed of unbonded powder;
- and
- the tamper to selectively pack a portion of the unbonded powder bound within the binder shell during layer-by-layer formation.
An additive manufacturing system comprising:
- a power chamber;
- a build platform;
- a recoater configured to transfer powder from the powder chamber to the build platform;
- a base positioned over the build platform;
- a printhead actuator coupled to the base;
- a printhead coupled to and movable relative to the base by the printhead actuator, the printhead is configured to deliver binder to the powder;
- a tamper actuator coupled to the base;
- a vibrator tamper coupled to and movable relative to the base by the tamper actuator, the tamper is configured to densify the powder;
- and
- a controller programmed to cause:
- the recoater to successively form a plurality of powder layers over the build platform;
- the printhead to successively form a binder shell by bonding select regions of each one of the plurality of powder layers before the recoater forms each successive one of the plurality of powder layers such that the binder shell is formed of bonded powder and the binder shell encloses an entirety of a powder core formed of unbonded powder;
- and
- the tamper to compact a portion of the unbound powder bound within the binder shell during layer-by-layer formation.
Dependencies are inferred from the claim text.