Automated system for forming objects by incremental buildup of layers

An automated system for manufacturing an article that is formed by the incremental buildup of layers onto a work surface comprising:

• a moveable work surface onto which layers are deposited to form the article;
• a material deposition station sized and positioned to receive the moveable work surface, where each layer of the article is deposited onto at least one of the work surface, a substrate placed on the work surface and a preceding layer;
• at least one processing station sized and positioned to receive the moveable work surface, each processing station capable of performing a desired operation on selected deposited layers of the article;
• a complementary material deposition means for applying complementary material to at least one of the work surface and selected layers of deposition material, the complementary deposition means positioned in one of the material deposition station and a separate processing station;
• and
• an article transfer apparatus sized and positioned for repetitively placing, removing and returning the work surface and any layers formed thereon at the deposition station and at the at least one processing station until each layer is processed and a completely manufactured article is produced.

An automated system for manufacturing an article that is formed by the incremental buildup of layers onto a work surface comprising:

• (a) a moveable work surface onto which layers are deposited to form the article;
• (b) a material deposition station sized and positioned to receive the moveable work surface, where each layer of the article is deposited onto at least one of the work surface, a substrate placed on the work surface and a preceding layer, wherein the deposition station comprises:
• (i) a work table for receiving the moveable work surface;
• (ii) a series of material delivery devices for depositing material onto at least one of the moveable work surface and a preceding layer of deposited material, the devices including at least one of thermal spray heads and welders;
• and
• (iii) a robotic device which can acquire at least one material delivery device and move the acquired material delivery device relative to the work surface to apply a layer onto the work surface;
• (c) at least one processing station sized and positioned to receive the moveable work surface, each processing station capable of performing a desired operation on selected deposited layers of the article;
• and
• (d) an article transfer apparatus sized and positioned for repetitively placing, removing and returning the work surface and any layers formed thereon at the deposition station and at the at least one processing station until each layer is processed and a completely manufactured article is produced.

A method of manufacturing an article that is formed by the incremental buildup of layers on a work surface, comprising the steps of:

• a) providing a moveable work surface on which layers are deposited, the moveable work surface being moveable by an article transfer apparatus;
• b) placing the moveable work surface in a material deposition station where at least one layer of deposition material is deposited onto at least one of the work surface and a preceding layer, wherein each layer deposited on a preceding layer is simultaneously deposited and bonded to the preceding layer to form a portion of the article;
• c) removing the moveable work surface from the material deposition station;
• d) placing the moveable work surface and any layers deposited thereon in at least one processing station, where each processing station performs a desired function on selected layers;
• e) removing the moveable work surface having at least one processed layer thereon from the processing station;
• and
• f) repeating at least some of steps b through e until all layers have been deposited and all selected layers have been processed.

A method of manufacturing an article that is formed by the incremental buildup of layers on a work surface, comprising the steps of:

• (a) providing a moveable work surface on which layers are deposited, the moveable work surface being moveable by an article transfer apparatus;
• (b) placing the moveable work surface in a material deposition station where at least one layer of deposition material is deposited onto at least one of the work surface and a preceding layer;
• (c) removing the moveable work surface from the material deposition station;
• (d) placing the moveable work surface and any layers deposited thereon in at least one processing station, where each processing station performs a desired function on selected deposited layers;
• (e) applying a layer of a complementary material before one of steps b and d;
• and
• (f) removing the moveable work surface having at least one processed layer thereon from the processing station;
• (g) repeating at least some of steps b through f until all layers have been deposited and all selected layers have been processed.