Large area recoating for additive manufacturing
AssigneeApplied Materials, Inc.
InventorsHou T. Ng, Daihua Zhang, Nag B. Patibandla
Life of this patent
Estimating the term…
Abstract
Methods and systems for additive manufacturing can include a modular spreader unit including multiple spreaders that collectively span the width of a large build area. The spreaders can be arranged in offset rows so that spreaders in a second row cover gaps between spreaders in a first row. The spreaders can be secured with quick release mechanisms for rapid replacement and adjustment during service intervals.
Claims20
An additive manufacturing apparatus comprising:
- a platform for receiving successive layers of feed material;
- a dispenser assembly to deliver the feed material onto the platform;
- and
- a modular spreader unit to spread feed material delivered by the dispenser assembly and onto the platform into a layer, the modular spreader unit spanning a width of the platform in a first direction and configured to translate across the platform in a second direction, the modular spreader unit including a frame and a plurality of spreaders, each spreader independently detachable from the frame, the plurality of spreaders including
- a plurality of first spreaders arranged in a first row parallel to the first direction, and
- one or more second spreaders arranged in a second row parallel to the first direction so as to cover gaps between adjacent spreaders in the first row of first spreaders.
An additive manufacturing system comprising:
- a ganged assembly of spreaders for iteratively recoating a build area with feed material iteratively delivered by a feed dispenser,
- wherein the ganged assembly includes a first row of spreaders and a second row of spreaders offset from the first row of spreaders so that gaps between adjacent spreaders in the first row of spreaders do not coincide with gaps between adjacent spreaders in the second row of spreaders.
A method of operating an additive manufacturing system, comprising:
- depositing a layer of feed material on a platform;
- first spreading the layer with a first set of rollers or blades on a spreader assembly spanning the platform, where the first spreading leaves a set of ridges corresponding to gaps between adjacent rollers or blades in the first set of rollers or blades;
- and
- second spreading the layer with a second set of rollers or blades on the spreader assembly spanning the platform, wherein the second spreading removes the ridges corresponding to the gaps between adjacent spreaders in the first set of rollers or blades.
The method of claim 19, further comprising:
- cyclically repeating an ordered sequence of the depositing, the first spreading, and the second spreading.
The method of claim 20, wherein the system includes a build chamber and a service chamber separated by a seal, and the method further comprises:
- moving the spreader assembly through the seal from the build chamber to the service chamber;
- removing a worn roller or blade and replacing it with a new roller or blade via a quick release mechanism;
- and
- adjusting height and skew of the new roller or blade relative to the platform via an alignment mechanism.
Dependencies are inferred from the claim text.