Resilient build plates for powder bed fusion - laser additive manufacturing
OwnerLawrence A. Binek, Matthew Siopis +1inventors
InventorsLawrence A. Binek, Matthew Siopis, Jesse R. Boyer
Life of this patent
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Abstract
A build plate for a powder bed fusion-laser (PBF-L) additive manufacturing system has a support region and a top region. The top region is formed on the support region by a cold spray process, such that the top region is under a compressive stress. The build plate can be prepared by preparing the build plate support region to receive the top region and depositing, using a cold spray process, a layer of metal on the support region. The layer of metal is formed with a compressive stress to form the top region. The top region is then machined to provide a desired surface roughness.
Claims19
A build plate for a powder bed fusion-laser (PBF-L) additive manufacturing system, comprising:
- a build plate having a support region and a top region, wherein the top region is formed on the support region by a cold spray process such that the top region is under a compressive stress.
A method of preparing a build plate for use in a powder bed fusion-laser (PBF-L) additive manufacturing system, comprising:
- preparing a support region of the build plate to receive a top region;
- depositing, using a cold spray process, a layer of metal on the support region, wherein the layer of metal forms the top region and the layer of metal is formed with a compressive stress;
- and
- machining to top region to provide a desired surface roughness.
A method of preparing a build plate for use in a powder bed fusion-laser (PBF-L) additive manufacturing system, comprising:
- removing from the build plate one or more builds formed on the build plate during a first PBF-L additive manufacturing campaign to expose a support region;
- repairing any defects formed in the build plate as a result of removing the one or more builds from the build plate;
- preparing the support region of the build plate to receive a top region;
- depositing, using a cold spray process, a layer of metal on the support region, wherein the layer of metal forms the top region such that the top region is between 0.020 inches and 0.030 inches thick and the top region is formed with a compressive stress;
- machining to top region to provide a desired surface roughness;
- installing the build plate the PBF-L additive manufacturing system;
- and
- polishing the top region by a laser in the PBF-L additive manufacturing system before build powder is deposited on top of the top region to start a second PBF-L additive manufacturing campaign.
Dependencies are inferred from the claim text.