Systems and methods for finishing additive manufacturing faces with different orientations

An additive manufacturing system includes a build platform, at least one first consolidation device, and at least one second consolidation device. The at least one first consolidation device is configured to direct at least one first energy beam to a first face of a component. The first face has a first orientation. The at least one second consolidation device is configured to simultaneously direct at least one second energy beam toward a second face of the component as the first consolidation device directs the at least one first energy beam toward the first face. The second face has a second orientation different from the first orientation.

BACKGROUND

The subject matter described herein relates generally to additive manufacturing systems and, more particularly, to finishing multiple faces of components manufactured using additive manufacturing systems, where each face has a different orientation.

At least some known additive manufacturing systems involve the consolidation of a particulate material to make a component. Such techniques facilitate producing complex components from expensive materials at a reduced cost and with improved manufacturing efficiency. At least some known additive manufacturing systems, such as Direct Metal Laser Melting (DMLM), Selective Laser Melting (SLM), Direct Metal Laser Sintering (DMLS), and LaserCusing® systems, fabricate components using a focused energy source, such as a laser device or an electron beam generator, a build platform, and a particulate, such as, without limitation, a powdered metal. (LaserCusing is a registered trademark of Concept Laser GmbH of Lichtenfels, Germany.) In at least some DMLM systems, the focused energy source is positioned relative to the component such that the focused energy source is directed toward only one face of the component. This allows the focused energy source to consolidate the powdered metal and finish the component on that face of the component. However, at least some known components may require consolidation of powdered metal and finishing on other faces of the component.

BRIEF DESCRIPTION

In one aspect, an additive manufacturing system is provided. The additive manufacturing system includes a build platform, at least one first consolidation device, and at least one second consolidation device. The at least one first consolidation device is configured to direct at least one first energy beam to a first face of a component. The first face has a first orientation. The at least one second consolidation device is configured to simultaneously direct at least one second energy beam toward a second face of the component as the first consolidation device directs the at least one first energy beam toward the first face. The second face has a second orientation different from the first orientation.

In another aspect, a controller for use in an additive manufacturing system is provided. The additive manufacturing system includes at least one first consolidation device and at least one second consolidation device. The at least one first consolidation device is configured to direct at least one first energy beam to a first face of a component. The first face has a first orientation. The at least one second consolidation device is configured to simultaneously direct at least one second energy beam to at least one second face of the component as the first consolidation device directs the at least one first energy beam to the first face. The second face has a second orientation different from the first orientation. The controller is configured to receive a build file defining a plurality of first scan paths for the first consolidation device and a plurality of second scan paths for the second consolidation device. The controller is also configured to control the first consolidation device, based on the build file, to consolidate a plurality of first particles along the plurality of first scan paths to form at least a portion of the first face. The controller is further configured to control the second consolidation device, based on the build file, to direct the at least one second energy beam to the second face along the plurality of second scan paths.

In yet another aspect, a method of fabricating a particle containment system is provided. The method includes depositing particles onto a build platform. The method also includes distributing the particles to form a first face of a component. The method further includes operating at least one first consolidation device to consolidate a first plurality of particles along a first scan path along the first face. The first face has a first orientation. The method also includes simultaneously operating at least one second consolidation device to consolidate a second plurality of particles along a second scan path along a second face of the component as the at least one first consolidation device consolidates the first plurality of particles along the first scan path. The second face has a second orientation different from the first orientation.

DETAILED DESCRIPTION

Further, as used herein, the terms “software” and “firmware” are interchangeable, and include any computer program storage in memory for execution by personal computers, workstations, clients, and servers.

As used herein, the terms “consolidate” and “consolidation” refer to the process of melting a powdered material with a consolidation device such that the powdered material consolidates into a solid, integrally formed component once the melted powdered material has cooled. Furthermore, as used herein, the term “finish” refers to the process of smoothing or polishing a face of the component after consolidation of the powdered material into the solid component. The face of the component may be rough and dull after completion of the consolidation process. The face is finished by directing an energy beam to the face and melting only a top layer of the face such that the finished top layer is smooth and polished after the melted top layer cools to form a solid top layer.

The systems and methods described herein include an additive manufacturing system including a first consolidation device and a second consolidation device. The first consolidation device directs a first energy beam toward a first face of the component. The first face has a first orientation relative to a build plate. The second consolidation device directs a second energy beam toward a second face. The second face has a second orientation relative to the build plate different from the first orientation. In the embodiments described herein, the first face is a top build layer of the component and the second face is a face other than the top build layer of the component. The top build layer is offset from the build plate in the Z-axis and oriented substantially parallel to the build plate. The second face is oriented obliquely to both the first face and the build plate. Some examples of the second face include a side of the component or a down face of the component. Accordingly, the first consolidation device is offset from the build plate in the Z-axis and the second consolidation device is offset from the build plate in the X-axis, Y-axis, and Z-axis such that the second consolidation device is positioned circumferentially about the component. The arrangement of the first and second consolidation devices allows the additive manufacturing system to manufacture the component without a surrounding powder bed or support structures. The arrangement of the first and second consolidation devices also allows the second face to be manufactured by the second consolidation device as the first face is manufactured by the first consolidation device. The second consolidation device also finishes or smooths the second face while the first consolidation device manufactures and finishes the first face. As such, the arrangement of the first and second consolidation devices reduces the time, costs, and raw materials required to manufacture the component.

Additive manufacturing processes and systems employ materials including, for example, and without limitation, polymers, plastics, metals, ceramics, sand, glass, waxes, fibers, biological matter, composites, and hybrids of these materials. These materials may be used in these processes and systems in a variety of forms as appropriate for a given material and the process or system, including, for example, and without limitation, as liquids, solids, powders, sheets, foils, tapes, filaments, pellets, liquids, slurries, wires, atomized, pastes, and combinations of these forms.

FIG. 1is a schematic view of an exemplary additive manufacturing system10. A coordinate system12includes an X-axis, a Y-axis, and a Z-axis. In the exemplary embodiment, additive manufacturing system10includes a first consolidation device14including a first laser device16, a first scanning motor18, a first scanning mirror20, and a first scanning lens22for fabricating a component24using a layer-by-layer manufacturing process. Alternatively, first consolidation device14may include any component that facilitates consolidation of a material using any of the processes and systems described herein. First laser device16provides a high-intensity heat source configured to generate a melt pool26(not shown to scale) in a powdered material using a first energy beam28. First laser device16is contained within a first housing30that is coupled to a first mounting system32. Additive manufacturing system10also includes a computer control system, or controller34.

First mounting system32is moved by an actuator or an actuator system36that is configured to move first mounting system32in the X-direction, the Y-direction, and the Z-direction to cooperate with first scanning mirror20to facilitate fabricating a layer of component24within additive manufacturing system10. For example, and without limitation, first mounting system32is pivoted about a central point, moved in a linear path, a curved path, and/or rotated to cover a portion of the powder on a build platform38to facilitate directing first energy beam28along the face of a plurality of particles45of a first face44to form a layer of component24. Alternatively, first housing30and first energy beam28are moved in any orientation and manner that enables additive manufacturing system10to function as described herein.

First scanning motor18is controlled by controller34and is configured to move first scanning mirror20such that first energy beam28is reflected to be incident along a predetermined path along build platform38, such as, for example, and without limitation, a linear and/or rotational scan path40. In the exemplary embodiment, the combination of first scanning motor18and first scanning mirror20forms a two-dimension scan galvanometer. Alternatively, first scanning motor18and first scanning mirror20may include a three-dimension (3D) scan galvanometer, dynamic focusing galvanometer, and/or any other method that may be used to deflect first energy beam28of first laser device16.

In the exemplary embodiment, build platform38is mounted to a support structure42, which is moved by actuator system36. As described above with respect to first mounting system32, actuator system36is also configured to move support structure42in a Z-direction (i.e., normal to a top face of build platform38). In some embodiments, actuator system36is also configured to move support structure42in the XY plane. For example, and without limitation, in an alternative embodiment where first housing30is stationary, actuator system36moves support structure42in the XY plane to cooperate with first scanning motor18and first scanning mirror20to direct first energy beam28of first laser device16along scan path40about build platform38. In the exemplary embodiment, actuator system36includes, for example, and without limitation, a linear motor(s), a hydraulic and/or pneumatic piston(s), a screw drive mechanism(s), and/or a conveyor system.

In the exemplary embodiment, additive manufacturing system10is operated to fabricate component24from a computer modeled representation of the 3D geometry of component24. The computer modeled representation may be produced in a computer aided design (CAD) or similar file. The CAD file of component24is converted into a layer-by-layer format that includes a plurality of build parameters for each layer of component24, for example, first face44of component24including particles45to be consolidated by additive manufacturing system10. In the exemplary embodiment, component24is modeled in a desired orientation relative to the origin of the coordinate system used in additive manufacturing system10. The geometry of component24is sliced into a stack of layers of a desired thickness, such that the geometry of each layer is an outline of the cross-section through component24at that particular layer location. Scan paths40are generated across the geometry of a respective layer. The build parameters are applied along scan path40to fabricate that layer of component24from particles45used to construct component24. The steps are repeated for each respective layer of component24geometry. Once the process is completed, an electronic computer build file (or files) is generated, including all of the layers. The build file is loaded into controller34of additive manufacturing system10to control the system during fabrication of each layer.

After the build file is loaded into controller34, additive manufacturing system10is operated to generate component24by implementing the layer-by-layer manufacturing process, such as a direct metal laser melting method. The exemplary layer-by-layer additive manufacturing process does not use a pre-existing article as the precursor to the final component, rather the process produces component24from a raw material in a configurable form, such as particles45. For example, and without limitation, a steel component can be additively manufactured using a steel powder. Additive manufacturing system10enables fabrication of components, such as component24, using a broad range of materials, for example, and without limitation, metals, ceramics, glass, and polymers.

In the exemplary embodiment, additive manufacturing system10also includes at least one second consolidation device60including at least one second laser device62, at least one second scanning motor64, at least one second scanning mirror66, and at least one second scanning lens68for fabricating component24. Second consolidation device60is configured to finish or consolidate a second face25. In the exemplary embodiment, additive manufacturing system10includes a single second consolidation device60. Alternatively, additive manufacturing system10may include any number of second consolidation devices60that enable additive manufacturing system10to operate as described herein, including, without limitation, two, three, four, or more second consolidation devices60positioned circumferentially about component24. Alternatively, second consolidation device60may include any component that facilitates consolidation of material using any of the processes and systems described herein.

Second laser device62provides a high-intensity heat source using at least one second energy beam70directed toward second face25of component24. Second laser device62is contained within a second housing72that is coupled to a second mounting system74. Second laser device62may be a dedicated laser device located within second consolidation device60or may be a centrally located laser device which transmits second energy beam70to second housing72via a fiber optic cable. Alternatively, first laser device16may transmit second energy beam70to second housing72via a fiber optic cable. Alternatively, additive manufacturing system10may include a plurality of second consolidation devices60each including a respective second housing72configured to receive second energy beam70from a single second laser device62via fiber optic cables. Alternatively, first consolidation device14and second consolidation device60may be one and the same. That is, first consolidation device14may be configured to operate in the same manner as second consolidation device60such that second consolidation device60is not required. Alternatively, second laser device62may include any component that transmits at least one second energy beam70to at least one second housing72using any of the processes and systems described herein.

Actuator system36is configured to move second mounting system74in the X-direction, the Y-direction, and the Z-direction to cooperate with second scanning mirror66to facilitate fabricating or finishing second face25of component24within additive manufacturing system10. For example, and without limitation, second mounting system74is pivoted about a central point, moved in a linear path, a curved path, and/or rotated to cover a portion of second face25of component24to facilitate directing second energy beam70along second face25of component24. Specifically, actuator system36may move second mounting system74circumferentially about component24. Alternatively, second housing72and second energy beam70are moved in any orientation and manner that enables additive manufacturing system10to function as described herein.

Second scanning motor64is controlled by controller34and is configured to move second scanning mirror66such that second energy beam70is reflected to be incident along a predetermined path along second face25of component24, such as, for example, and without limitation, a linear and/or rotational second scan path78. In the exemplary embodiment, the combination of second scanning motor64and second scanning mirror66forms a two-dimension scan galvanometer. Alternatively, second scanning motor64and second scanning mirror66may include a three-dimension (3D) scan galvanometer, dynamic focusing galvanometer, and/or any other method that may be used to deflect second energy beam70of second laser device62.

As described above with respect to first mounting system32, actuator system36is also configured to move support structure42in a Z-direction (i.e., normal to a top face of build platform38). In some embodiments, actuator system36is also configured to move support structure42in the XY plane. For example, and without limitation, in an alternative embodiment, actuator system36moves support structure42in the XY plane to cooperate with second scanning motor64and second scanning mirror66to direct second energy beam70of second laser device62along second scan path78.

In the exemplary embodiment, additive manufacturing system10is operated to fabricate component24from the CAD file of component24. Second scan path78is generated across the geometry of a plurality of respective layers along second face25of component24. The build parameters are applied along second scan path78to fabricate that layer of component24from particles45used to construct component24.

FIG. 2is a plan schematic view of component24that may be used with additive manufacturing system10.FIG. 3is a section side schematic view of component24taken along line3-3(shown inFIG. 2).FIG. 4is an enlarged schematic view of a region of component24with a down facing face100. In the exemplary embodiment, component24includes a cylindrical second face25. The shape and arrangement of component24and second face25are merely examples, and those of skill in the art will appreciate that component24and second face25may have any configuration that enables additive manufacturing system10to function as described herein. As shown inFIG. 4, component24may include down facing face100.

As shown inFIGS. 1-4, first face44has a first orientation relative to build platform38and second face25has a second orientation relative to build platform38. The first orientation is different than the second orientation. In the exemplary embodiment, first face44is a top build layer and second face25is a face other than the top build layer. The first face44is offset from build platform38in the Z-axis and oriented substantially parallel to build platform38. Second face25is oriented substantially obliquely or orthogonally to both first face44and build platform38. Second face25may be a side of component24or down facing face100of component24. Second face25may be any face of component24that has a different orientation than first face44. Down facing face100includes any exposed face oriented substantially downward or in the Z-direction opposite first face44of build platform38.

Second consolidation device60is configured to finish or consolidate second face25and is positioned about component24such that second energy beam70directed toward second face25. Accordingly, first consolidation device14is offset from build platform38in the Z-axis and second consolidation device60is offset from build platform38in the X-axis, Y-axis, and Z-axis.

As described above, component24is manufactured by dispensing particles45on first face44only in proximity to path40. Component24is manufactured without a surrounding powder bed, clearing the space or volume around component24. As such, there is a clear line of sight to second face25of component24from second consolidation device60. This clear line of sight allows second laser device62, second scanning motor64, and second scanning mirror66to direct second energy beam70toward second face25of component24. Second energy beam70finishes or consolidates second face25of component24during the additive manufacturing process.

During operations, first consolidation device14consolidates plurality of particles45of first face44into three forms of particles: consolidated particles or consolidated portions; sintered, unconsolidated particles; and unconsolidated particles. Consolidated particles are consolidated portions of second face25that are rough or unfinished. That is, the consolidated portion of second face25is solid, consolidated metal that is rough or unfinished. Sintered, unconsolidated particles are sintered powdered material within second face25. The sintered, unconsolidated powdered material within second face25is powdered material that is a part of second face25, but is still in powdered form. Unconsolidated particles are powdered particles positioned on second face25that have not been sintered into second face25or consolidated into second face25. As first consolidation device14manufactures component24, second consolidation device60is simultaneously manufacturing second face25such that a finished second face25is manufactured and no supporting structures are required. Second consolidation device60finishes second face25by directing second energy beam70directed toward second face25such that the consolidated portion of second face25is consolidated into a smooth second face25; the sintered, unconsolidated particles are consolidated into second face25; and the unconsoldiated particles positioned on second surface25are consolidated into second surface25. Specifically, second energy beam70melts a portion of the consolidated portion of second face25such that surface tension causes the melted portion to consolidated into a smooth surface. Simultaneously, second energy beam70is melting the sintered, unconsolidated particles and the unconsolidated particles such that they are incorporated into the smooth second face25.

Alternatively, first consolidation device14and second consolidation device60may be one and the same. That is, first consolidation device14may be configured to operate in a manner similar to second consolidation device60such that second consolidation device60is not required. Specifically, actuator system36is configured to move first mounting system32and first consolidation device14as described herein with respect second consolidation device60such that first consolidation device14is configured to finish or consolidate second face25.

Typically, once component24has been substantially manufactured by additive manufacturing system10, first consolidation device14is used to smooth or finish the final top face of component24. However, because first consolidation device14is offset from component24along the Z-axis, first consolidation device14can only finish the top build layer of component24. Second faces25of component24are typically finished in another finishing process (e.g. polishing or sanding). However, because second consolidation device60is positioned about component24such that second energy beam70is directed toward second face25of component24, second consolidation device60can finish second face25while first consolidation device14is simultaneously manufacturing the rest of component24, eliminating an extra manufacturing step.

Typically, a powder bed would surround and support second face25or down facing face100of component24during the manufacturing process. The powder bed would prevent second face25or down facing face100from collapsing. However, because second consolidation device60is positioned such that second energy beam70is directed toward either second face25or down facing face100, second consolidation device60can consolidate second face25or down facing face100while first consolidation device14is simultaneously manufacturing the rest of component24, eliminating the need for a support structure. That is, while first consolidation device14is manufacturing first face44, second consolidation device60is simultaneously manufacturing second face25or down facing face100a distance102offset from first face44in the Z-axis toward build platform38such that second face25or down facing face100solidifies as component24is being manufactured. Consolidating second face25or down facing face100in close proximity to first face44hardens second face25or down facing face100before second face25or down facing face100collapses. As such, support structures are not required to manufacture component24with second face25or down facing face100. The elimination of support structures to manufacture components24with second face25or down facing face100increases build speeds because additive manufacturing system10is not required to construct support structures during the manufacturing process. Additionally, the elimination of support structures also reduces the quantity of raw material necessary to construct component24because support structures are not required.

During manufacture of component24, melt pool dynamics may cause defects within component24. Because second consolidation device60is positioned such that second energy beam70is directed toward second face25of component24, second consolidation device60may provide additional melt pool dynamic management capabilities which may reduce defects within component24.

FIG. 5is a block diagram of controller34that may be used to operate additive manufacturing system10(shown inFIG. 1). In the exemplary embodiment, controller34is any type of controller typically provided by a manufacturer of additive manufacturing system10to control operation of additive manufacturing system10. Controller34executes operations to control the operation of additive manufacturing system10based at least partially on instructions from human operators. Controller34includes, for example, a 3D model of component24to be fabricated by additive manufacturing system10. Operations executed by controller34include controlling power output of first and second laser devices16and62(shown inFIG. 1) and adjusting first and second mounting systems32and74and/or support structure42, via actuator system36(all shown inFIG. 1) to control the scanning velocity of first and second energy beams28and70. Controller34is also configured to control first and second scanning motors18and64to direct first and second scanning mirrors20and66to further control the scanning velocity of first and second energy beams28and70within additive manufacturing system10. In alternative embodiments, controller34may execute any operation that enables additive manufacturing system10to function as described herein.

In the exemplary embodiment, controller34includes a memory device300and a processor302coupled to memory device300. Processor302may include one or more processing units, such as, without limitation, a multi-core configuration. Processor302is any type of processor that permits controller34to operate as described herein. In some embodiments, executable instructions are stored in memory device300. Controller34is configurable to perform one or more operations described herein by programming processor302. For example, processor302may be programmed by encoding an operation as one or more executable instructions and providing the executable instructions in memory device300. In the exemplary embodiment, memory device300is one or more devices that enable storage and retrieval of information such as executable instructions or other data. Memory device300may include one or more computer readable media, such as, without limitation, random access memory (RAM), dynamic RAM, static RAM, a solid-state disk, a hard disk, read-only memory (ROM), erasable programmable ROM, electrically erasable programmable ROM, or non-volatile RAM memory. The above memory types are exemplary only, and are thus not limiting as to the types of memory usable for storage of a computer program.

Memory device300may be configured to store any type of data, including, without limitation, build parameters associated with component24. In some embodiments, processor302removes or “purges” data from memory device300based on the age of the data. For example, processor302may overwrite previously recorded and stored data associated with a subsequent time or event. In addition, or alternatively, processor302may remove data that exceeds a predetermined time interval. In addition, memory device300includes, without limitation, sufficient data, algorithms, and commands to facilitate monitoring of build parameters and the geometric conditions of component24being fabricated by additive manufacturing system10.

In some embodiments, controller34includes a presentation interface304coupled to processor302. Presentation interface304presents information, such as the operating conditions of additive manufacturing system10, to a user306. In one embodiment, presentation interface304includes a display adapter (not shown) coupled to a display device (not shown), such as a cathode ray tube (CRT), a liquid crystal display (LCD), an organic LED (OLED) display, or an “electronic ink” display. In some embodiments, presentation interface304includes one or more display devices. In addition, or alternatively, presentation interface304includes an audio output device (not shown), for example, without limitation, an audio adapter or a speaker (not shown).

In some embodiments, controller34includes a user input interface308. In the exemplary embodiment, user input interface308is coupled to processor302and receives input from user306. User input interface308may include, for example, without limitation, a keyboard, a pointing device, a mouse, a stylus, a touch sensitive panel, such as, without limitation, a touch pad or a touch screen, and/or an audio input interface, such as, without limitation, a microphone. A single component, such as a touch screen, may function as both a display device of presentation interface304and user input interface308.

In the exemplary embodiment, a communication interface310is coupled to processor302and is configured to be coupled in communication with one or more other devices, such as first laser device16, and to perform input and output operations with respect to such devices while performing as an input channel. For example, communication interface310may include, without limitation, a wired network adapter, a wireless network adapter, a mobile telecommunications adapter, a serial communication adapter, or a parallel communication adapter. Communication interface310may receive a data signal from or transmit a data signal to one or more remote devices. For example, in some embodiments, communication interface310of controller34may transmit/receive a data signal to/from actuator system36.

Presentation interface304and communication interface310are both capable of providing information suitable for use with the methods described herein, such as, providing information to user306or processor302. Accordingly, presentation interface304and communication interface310may be referred to as output devices. Similarly, user input interface308and communication interface310are capable of receiving information suitable for use with the methods described herein and may be referred to as input devices.

FIG. 6is a flow chart illustrating a method500for fabricating component24. Referring toFIGS. 1-5, method500includes depositing502particles45onto build platform38. Method500also includes distributing504particles45to form first face44. Method500further includes operating506at least one first consolidation device14to consolidate a first plurality of particles45along first scan path40along first face44. First face44has a first orientation. Method500also includes operating508at least one second consolidation device60to consolidate or finish a second plurality of particles along a second scan path78along second face25of component24. Second face25has a second orientation different from the first orientation.

The embodiments described herein include an additive manufacturing system including a first consolidation device and a second consolidation device. The first consolidation device directs a first energy beam toward a first face of the component. The first face has a first orientation relative to a build plate. The second consolidation device directs a second energy beam toward a second face. The second face has a second orientation relative to the build plate different from the first orientation. In the embodiments described herein, the first face is a top build layer of the component and the second face is a face other than the top build layer of the component. The top build layer is offset from the build plate in the Z-axis and oriented substantially parallel to the build plate. The second face is oriented obliquely to both the first face and the build plate. Some examples of the second face include a side of the component or a down face of the component. Accordingly, the first consolidation device is offset from the build plate in the Z-axis and the second consolidation device is offset from the build plate in the X-axis, Y-axis, and Z-axis such that the second consolidation device is positioned circumferentially about the component. The arrangement of the first and second consolidation devices allows the additive manufacturing system to manufacture the component without a surrounding powder bed or support structures. The arrangement of the first and second consolidation devices also allows the second face to be manufactured by the second consolidation device as the first face is manufactured by the first consolidation device. The second consolidation device also finishes or smooths the second face while the first consolidation device manufactures and finishes the first face. As such, the arrangement of the first and second consolidation devices reduces the time, costs, and raw materials required to manufacture the component.

An exemplary technical effect of the methods, systems, and apparatus described herein includes at least one of: a) reducing the amount of raw materials required to manufacture a component, b) reducing the time required for additively manufacturing a component, c) finishing a second face of a component, and d) reducing the cost of additively manufacturing a component.

Exemplary embodiments of additive manufacturing system including a second consolidation device positioned around a component are described above in detail. The additive manufacturing systems, and methods of using and manufacturing such systems are not limited to the specific embodiments described herein, but rather, components of systems and/or steps of the methods may be utilized independently and separately from other components and/or steps described herein. For example, the methods may also be used in combination with other additive manufacturing systems, and are not limited to practice with only the additive manufacturing systems, and methods as described herein. Rather, the exemplary embodiment can be implemented and utilized in connection with many other electronic systems.