Patent Publication Number: US-2022226896-A1

Title: Systems and methods for removing build material from additively manufactured parts

Description:
CROSS-REFERENCE TO RELATED APPLICATIONS 
     This application is a divisional application of U.S. application Ser. No. 15/860,890 filed Jan. 3, 2018, which is hereby incorporated by reference in its entirety. 
    
    
     BACKGROUND 
     The field of the disclosure relates to generally to additive manufacturing, and more specifically to a method of removing build material from additively manufactured parts. 
     At least some known components or parts manufactured using additive manufacturing techniques, such as electron beam additive printing, include deposits of both un-sintered and partially sintered powder that remains within a build layer after the build layer has been created. The manufactured components must be cleaned to remove the remaining un-sintered and partially sintered powder. 
     Known additive manufacturing processes, specifically Electron Beam Melting (EBM), are known to result in residual amounts of powdered printing medium being left behind within the manufactured components. EBM printing is relatively quick, but requires creation of partially sintered material during the process to manage ‘smoking’ and to provide continuity of the EBM printed solid part and the machine. ‘Smoking’ is the ejection of powder from the powder bed due to the build-up of local electrical charges and repulsive electrostatic forces. This results in loose powder being displaced from the powder bed. The un-sintered and partially sintered powders that are a product of the process are relatively difficult to extract from internal cavities, thus limiting the applicability of EBM printing to relatively simple shapes. Users of EBM printing benefit from the increased build speed of the process, however, due to the difficulty in evacuating un-sintered and partially sintered powders from within printed components, the designs and complexity of manufactured components are constrained by the geometry of internal cavities and shapes. Removal of the un-sintered and partially sintered powders can be accomplished using a variety of known techniques, each with its respective drawbacks and costs. Un-sintered and partially sintered powder can be removed using, for example; suction, a blower, vibration, a fluid or a solvent, and/or an external tool. 
     During the EBM printing process, powder is sintered together to form the component. After the process is completed, both un-sintered and partially sintered powder remain within the internal cavities and in the vicinity of the exterior surface of printed parts. The un-sintered and partially sintered powder must be broken apart and removed from the printed parts Removing un-sintered and partially sintered powder from the printed part requires the implementation of one of any number of costly, time consuming, and laborious processes. For example, current methods to remove powder are strictly in the post-processing phase of manufacturing. Current processes for removing residual powder from a component manufactured using additive manufacture include, but are not limited to: water pumping, slurry pumping, using water jets, chemically assisted ultrasonic testing, chemical dipping, etc. These existing methods are focused around and utilize suction and compressed air nozzles, ultrasonic vibration, and solvents or other fluids for powder removal, and are not effective when removing residual un-sintered powder from a printed part. 
     BRIEF DESCRIPTION 
     In one aspect, a component formed using an additive manufacturing system is provided. The component formed using an additive manufacturing system, the component includes an exterior surface, an interior cavity, at least one powder removal device disposed within the interior cavity and adjacent to the exterior surface, wherein the at least one powder removal device is configured to remove un-sintered and partially sintered powder from the component, and at least one exit port defined in the exterior surface to facilitate egress of the un-sintered and partially sintered powder out of the component. 
     In another aspect, a method for forming a component from a powdered build material is provided. The method includes creating a model of the component, creating a model of at least one powder removal device, integrating the model of the at least one powder removal device into the model of the component, inputting the model of the component into the additive manufacturing system, and operating the additive manufacturing system to build the component including the at least one powder removal device, wherein the at least one powder removal device is configured to remove un-sintered and partially sintered material from the component when the at least one powder removal device is excited. 
     In yet another aspect, a method for removing un-sintered and partially sintered powder from an additively manufactured part is provided. The method includes fabricating, using an additive manufacturing process, a component including at least one powder removal device, exciting the component to cause the at least one powder removal device to remove un-sintered and partially sintered powder from the component. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         FIG. 1  is a schematic view of an exemplary additive manufacturing system. 
         FIG. 2  is a flow diagram of a method for manufacturing a component containing powder removal devices and using an additive manufacturing system such as the manufacturing system of  FIG. 1 . 
         FIG. 3  is a flow diagram of a method for removing powder from a manufactured component. 
         FIG. 4A  is a perspective view of an exemplary powder removal device manufactured using an additive manufacturing system, such as the additive manufacturing system of  FIG. 1 ; 
         FIG. 4B  is a perspective view of an alternative exemplary powder removal device manufactured using an additive manufacturing system, such as the additive manufacturing system of  FIG. 1 ; 
         FIG. 4C  is a perspective view of an alternative exemplary powder removal device manufactured using an additive manufacturing system, such as the additive manufacturing system of  FIG. 1 ; 
         FIG. 4D  is a perspective view of an alternative exemplary powder removal device manufactured using an additive manufacturing system, such as the additive manufacturing system of  FIG. 1 ; 
         FIG. 4E  is a perspective view of an alternative exemplary powder removal device manufactured using an additive manufacturing system, such as the additive manufacturing system of  FIG. 1 ; 
         FIG. 4F  is a perspective view of an alternative exemplary powder removal device manufactured using an additive manufacturing system, such as the additive manufacturing system of  FIG. 1 ; 
         FIG. 5A  is an image of a component prior to the powder removal process of  FIG. 3 ; 
         FIG. 5B  is an image of the component of  FIG. 5A  having undergone the powder removal method of  FIG. 3 ; and 
         FIG. 6  is a perspective view of a vibratory bowl that can be used to implement the method of  FIG. 3  to excite powder removal devices and remove powder from a component. 
     
    
    
     DETAILED DESCRIPTION 
     The methods and systems described herein overcome at least some disadvantages of known methods for removing un-sintered and partially sintered powder from components printed using additive manufacturing techniques. More specifically, the methods and systems described herein enable additive manufacture of a component that includes built-in powder removal tools referred to herein as powder removal devices. Additionally or alternatively, the methods and systems enable additive manufacture of a component that is characterized by an as-printed part that contains powder removal devices which, when excited, facilitate the removal of un-sintered and partially sintered powder that is generated during the additive manufacturing process. Moreover, in some embodiments, the post build processing of the component is performed at least partially within a vibratory bowl or other structure capable of moving the component to excite the powder removal devices within the component to facilitate removal of the un-sintered and partially sintered powder. 
     This method takes advantage of the additive manufacturing process by integrating a powder removal tool into the manufacture of the printed part by creating internal structures manufactured within the desired component during the printing process. When mechanically agitated, i.e., when excited by a vibratory tool such as a laboratory table or bowl, the internal structures break apart the powder surrounding them, and exit the part through an exit port. Accordingly, this method provides a cost effective approach to evacuating residual powder that remains after the printing process. This method will economically increase the component design space that is available to users utilizing EBM machines. Additionally, this method can be applied to a wide range of designs, subsequently expanding the applicability and usefulness of high speed EBM printing by increasing the variety of parts that an EBM machine is capable of printing. Further the present methods can be applied to any additive manufacturing method, not just EBM, to facilitate clearing un-sintered and partially sintered powder at a relatively low cost. Additionally, this method provides a cost effective way of removing un-sintered powder from the internal cavities and external surfaces of a printed part in a cost effective manner that does not require doesn&#39;t require external processes (i.e., abrasive blasting, pneumatics, or mechanical picking). 
     Additive manufacturing processes and systems include, for example, and without limitation, vat photopolymerization, powder bed fusion, binder jetting, material jetting, sheet lamination, material extrusion, directed energy deposition and hybrid systems. These processes and systems include, for example, and without limitation, SLA—Stereolithography Apparatus, DLP—Digital Light Processing, 3SP—Scan, Spin, and Selectively Photocure, CLIP—Continuous Liquid Interface Production, SLS—Selective Laser Sintering, DMLS—Direct Metal Laser Sintering, SLM—Selective Laser Melting, EBM—Electron Beam Melting, SHS—Selective Heat Sintering, MJF—Multi-Jet Fusion, 3D Printing, Voxeljet, Polyjet, SCP—Smooth Curvatures Printing, MJM—Multi-Jet Modeling Projet, LOM—Laminated Object Manufacture, SDL—Selective Deposition Lamination, UAM—Ultrasonic Additive Manufacturing, FFF—Fused Filament Fabrication, FDM—Fused Deposition Modeling, LMD—Laser Metal Deposition, LENS—Laser Engineered Net Shaping, DMD—Direct Metal Deposition, Hybrid Systems, and combinations of these processes and systems. These processes and systems may employ, for example, and without limitation, all forms of electromagnetic radiation, heating, sintering, melting, curing, binding, consolidating, pressing, embedding, and combinations thereof. 
     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. 
     In the following specification and the claims, reference will be made to a number of terms, which shall be defined to have the following meanings. 
     The singular forms “a”, “an”, and “the” include plural references unless the context clearly dictates otherwise. 
     “Optional” or “optionally” means that the subsequently described event or circumstance may or may not occur, and that the description includes instances where the event occurs and instances where it does not. 
     Approximating language, as used herein throughout the specification and claims, may be applied to modify any quantitative representation that could permissibly vary without resulting in a change in the basic function to which it is related. Accordingly, a value modified by a term or terms, such as “about,” “substantially,” and “approximately,” are not to be limited to the precise value specified. In at least some instances, the approximating language may correspond to the precision of an instrument for measuring the value. Here and throughout the specification and claims, range limitations may be combined and/or interchanged, such ranges are identified and include all the sub-ranges contained therein unless context or language indicates otherwise. 
     Additionally, unless otherwise indicated, the terms “first,” “second,” etc. are used herein merely as labels, and are not intended to impose ordinal, positional, or hierarchical requirements on the items to which these terms refer. Moreover, reference to, for example, a “second” item does not require or preclude the existence of, for example, a “first” or lower-numbered item or a “third” or higher-numbered item. 
     As used herein, the terms “processor” and “computer,” and related terms, e.g., “processing device,” “computing device,” and “controller” are not limited to just those integrated circuits referred to in the art as a computer, but broadly refers to a microcontroller, a microcomputer, a programmable logic controller (PLC), and application specific integrated circuit, and other programmable circuits, and these terms are used interchangeably herein. In the embodiments described herein, memory may include, but it not limited to, a computer-readable medium, such as a random access memory (RAM), a computer-readable non-volatile medium, such as a flash memory. Alternatively, a floppy disk, a compact disc—read only memory (CD-ROM), a magneto-optical disk (MOD), and/or a digital versatile disc (DVD) may also be used. Also, in the embodiments described herein, additional input channels may be, but are not limited to, computer peripherals associated with an operator interface such as a mouse and a keyboard. Alternatively, other computer peripherals may also be used that may include, for example, but not be limited to, a scanner. Furthermore, in the exemplary embodiment, additional output channels may include, but not be limited to, an operator interface monitor. 
     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 term “non-transitory computer-readable media” is intended to be representative of any tangible computer-based device implemented in any method of technology for short-term and long-term storage of information, such as, computer-readable instructions, data structures, program modules and sub-modules, or other data in any device. Therefore, the methods described herein may be encoded as executable instructions embodied in a tangible, non-transitory, computer-readable medium, including, without limitation, a storage device and/or a memory device. Such instructions, when executed by a processor, cause the processor to perform at least a portion of the methods described herein. Moreover, as used herein, the term “non-transitory computer-readable media” includes all tangible, computer-readable media, including, without limitation, non-transitory computer storage devices, including without limitation, volatile and non-volatile media, and removable and non-removable media such as firmware, physical and virtual storage, CD-ROMS, DVDs, and any other digital source such as a network or the Internet, as well as yet to be developed digital means, with the sole exception being transitory, propagating signal. 
     Furthermore, as used herein, the term “real-time” refers to at least one of the time of occurrence of the associated events, the time of measurement and collection of predetermined data, the time to process the data, and the time of a system response to the events and the environment. In the embodiments described herein, these activities and events occur substantially instantaneously. 
     With reference to  FIG. 1 , in the exemplary embodiment, additive manufacturing system  100  is an Electron Beam Melting (EBM) system. In alternative embodiments, additive manufacturing system  100  is any other suitable additive manufacturing system, including, without limitation, one of a Direct Metal Laser Sintering (DMLS) system, Direct Metal Laser Melting (DMLM) system, a Selective Laser Sintering (SLS) system, a Direct Metal Laser Deposition (DMLD) system, a Direct Metal Laser Deposition (DMLD) system, and a LaserCusing® system. In the exemplary embodiment, additive manufacturing system  100  includes a build fixture  110 , a build plate  101  oriented within build fixture  110  and configured to support component  102 , an electron beam system  106  configured to generate an electron beam  107 , a scanner system  108  configured to selectively direct electron beam  107  across build fixture  110  at a preselected scan speed, a powder delivery system  112 , a powder coater  118 , and a controller  120 . 
     In the exemplary embodiment, powder coater  118  is movable, upon instruction by controller  120 , to transfer material  104  in powdered form  114  from powder delivery system  112  to build fixture  110 . For example, in the exemplary embodiment, powder delivery system  112  includes a piston  122  operable, upon instruction by controller  120 , to raise a selected thickness of material  104  in powdered form  114  above an edge  124  of powder delivery system  112 , and powder coater  118  is sweepable along edge  124  to capture the selected thickness of material  104  in powdered form  114  and deliver it to build fixture  110 . Powder coater  118  is further operable to deposit the captured material  104  in powdered form  114  atop build fixture  110  as a build layer  116 . Moreover, build fixture  110  is operable, upon instruction by controller  120 , to reposition build plate  101  to receive build layer  116  atop previously deposited layers of material  104 . For example, in the exemplary embodiment, build fixture  110  includes a piston  126  operable, upon instruction by controller  120 , to lower build plate  101  a preselected distance below an edge  128  of build fixture  110  to accommodate receipt of build layer  116  from powder coater  118 . In alternative embodiments, additive manufacturing system  100  is configured to deposit material  104  in powdered form  114  onto build layer  116  in any manner that enables component  102  to be formed as described herein. 
     In the exemplary embodiment, electron beam system  106  is configured, upon instruction by controller  120 , to generate electron beam  107  having a preselected energy sufficient to at least partially melt material  104  in powdered form  114  at preselected regions of build layer  116 , such that the preselected regions fuse with material  104  in a layer immediately below build layer  116 . In the exemplary embodiment, electron beam system  106  includes a yttrium-based solid state laser. In alternative embodiments, electron beam system  106  includes any suitable source for electron beam  107  that enables component  102  to be formed as described herein. Additionally, although additive manufacturing system  100  is described as including a single electron beam system  106 , it should be understood that additive manufacturing system  100  may include more than one electron beam system  106 . In some embodiments, for example, additive manufacturing system  100  includes a first electron beam system  106  having a first power and a second electron beam system  106  having a second power different from the first power. In other embodiments, additive manufacturing system  100  includes any combination of electron beam systems  106  each having any suitable power that enables component  102  to be formed as described herein. 
     In the exemplary embodiment, scanner system  108  is configured, upon instruction by controller  120 , to selectively direct electron beam  107  to preselected regions of build layer  116  that correspond to portions of component  102 , such that the preselected regions fuse with material  104  in a layer immediately below build layer  116 . For example, scanner system  108  includes a suitable sensor, such as at least one of a two-dimension (2D) scan galvanometer, a three-dimension (3D) scan galvanometer, and a dynamic focusing scan galvanometer (not shown), to determine a position and orientation of build layer  116  with respect to electron beam  107 . In alternative embodiments, scanner system  108  is configured to selectively direct electron beam  107  to the preselected regions of build layer  116  in any suitable fashion that enables additive manufacturing system  100  to function as described herein. 
     Controller  120  is operably coupled to each of build fixture  110 , electron beam system  106 , scanner system  108 , powder delivery system  112 , and powder coater  118  to implement additive manufacturing system  100  as a computer numerically controlled (CNC) machine. In the exemplary embodiment, to form component  102 , controller  120  receives a computer design model of component  102  and generates a build file in which the computer design model is “sliced” into a series of thin, parallel planes, such that a distribution of material  104  within each plane is defined. Controller  120  then provides command signals to, and receives feedback from, build fixture  110 , electron beam system  106 , scanner system  108 , powder delivery system  112 , and powder coater  118  as necessary to deposit and fuse successive layers of material  104  in accordance with the model slices to form component  102 . For example, controller  120  is configured to control build fixture  110 , powder delivery system  112 , and powder coater  118  to provide material  104  in powdered form  114  for each successive build layer  116 , and to control the power output of electron beam system  106  and the position, movement, and scan speed of scanner system  108 , such that electron beam  107  follows a predetermined path along each build layer  116 , such that material  104  is selectively fused to form each layer of component  102  having a fused layer thickness in accordance with the build file. 
     In the exemplary embodiment, component  102  as formed includes an exterior surface  103 , an interior cavity  105 , at least one powder removal device  109  disposed within interior cavity  105  and adjacent to exterior surface  103 , wherein the at least one powder removal device  109  is configured to remove un-sintered and partially sintered powder  114  from component  102  when the at least one powder removal device  109  is excited, and at least one exit port  11  defined in exterior surface  103  to facilitate egress of un-sintered and partially sintered powder  114  out of component  102 . In the exemplary embodiment, powder removal devices  109  are configured to remove un-sintered and partially sintered powder  114  from within build layers  116  of component  102  through exit port  111 , which can be one of a preexisting design feature in component  102  and a feature added to the model for component  102  prior to manufacture that facilitates exit of powder removal devices  109 , un-sintered and partially sintered powders  114  from within component  102   
     In the exemplary embodiment, powder removal devices  109  have customizable geometry, such that they can be shaped in any form suitable to facilitate removing un-sintered and partially sintered powder from within component  102 . Additionally, powder removal devices  109  are sized such that powder removal devices  109  are capable of exiting component  102  through at least one exit port  111 . Powder removal devices  109  may have an asymetric or symmetric geometry. In the exemplary embodiment, powder removal devices  109  are manufactured within build layers  116  of component  102  during the additive manufacturing process. Additionally, powder removal devices  109  are separate from component  102  and not attached to component  102  in the exemplary embodiment. Alternatively, powder removal devices  109  may be tethered to an adjacent surface of component  102  (e.g., by a relatively thin piece of material), such that powder removal devices  109  detach from component  102  when vibrated. In the exemplary embodiment, powder removal devices  109  have a size between and including approximately 40 microns and approximately 100 microns. Further, in some embodiments powder removal devices  109  include a plurality of powder removal devices  109  arranged in relation to one another such that powder removal devices  109  interact with one another to facilitate breaking up un-sintered and partially sintered powder  114  when powder removal devices  109  are excited (e.g. by vibrational means, such as vibratory bowl  600  (shown in  FIG. 6 )). 
     In the exemplary embodiment, controller  120  is implemented using one or more electronic computing devices. Such devices typically include at least one processing device (not shown) such as a general purpose central processing unit (CPU), a graphics processing unit (GPU), a microcontroller, a reduced instruction set computer (RISC) processor, an application specific integrated circuit (ASIC), a programmable logic circuit (PLC), a field programmable gate array (FPGA), a digital signal processing (DSP) device, and/or any other circuit or processing device capable of executing the functions described herein. The methods described herein may be encoded as executable instructions embodied in a computer readable medium, including, without limitation, a non-transitory storage device and/or a memory device coupled to the at least one processor. Such instructions, when executed by the controller or processing device, cause the controller or processing device to perform at least some of the method steps described herein. Although controller  120  is illustrated as a discrete system, controller  120  may be implemented at least partially by at least one processor embedded within any of build fixture  110 , electron beam system  106 , scanner system  108 , powder delivery system  112 , and powder coater  118 , and any other suitable computing devices. The above examples are exemplary only, and thus are not intended to limit in any way the definition and/or meaning of the terms controller and processing device. 
     As noted above, geometric characteristics of components built using typical additive manufacturing processes may be limited. In particular, components built using EBM printing may be constrained by the amount of un-sintered and partially sintered powder present within the interior cavities  105 , or existing on the exterior surfaces  103  of such components. However, in some embodiments, additive manufacturing system  100  as described herein is configured to produce a component  102  and powder removal devices  109  positioned within component  102 , such that component  102  requires only a post processing excitation, such as a vibratory procedure performed after removal from build plate  101  to remove the un-sintered and partially sintered powder  114  from component  102  using powder removal devices  109 . 
     For example, in certain embodiments, controller  120  is configured to operate at least electron beam system  106  and scanner system  108  using preselected operating parameters that result in the creation of powder removal devices  109  having the required size to facilitate excitation of surrounding particles of un-sintered and partially sintered powder  114 . Thus, powder removal devices  109  are capable of breaking apart un-sintered and partially sintered powder  114  within cavities and on surfaces of component  102 . For example, in one embodiment, the preselected operating parameters may include a power of electron beam  107  generated by electron beam system  106  in a range from about 100 watts to about 2,000 watts, and a scan speed of scanner system  108  in a range of from about 50 millimeters per second to about 2,000 millimeters per second, such that a thickness of each fused build layer  116  of component  102  is in a range from about 10 micrometers to about 1,000 micrometers, and the size of each powder removal device  109  is in a range from about 20 micrometers to about 3000 micrometers. 
     In the exemplary embodiment, the preselected operating parameters result in generating a component  102  and powder removal devices  109  that can be removed from build plate  101 , and excited such that un-sintered and partially sintered powder  114  is broken apart and dislodged by powder removal devices  109  and is subsequently expunged from component  102 . The inclusion of powder removal devices  109  and the subsequent excitation of powder removal devices  109  enables the manufacture of more complex geometries of component  102 , and reduces the time and cost required to remove un-sintered powder  114  from component  102 , as compared to builds using typical operating parameters and powder removal tools. 
       FIG. 2  is a flow diagram of a method  200  for manufacturing a component, such as component  102  (shown in  FIG. 1 ) containing powder removal devices, such as powder removal devices  109  (shown in  FIG. 1 ) and using an additive manufacturing system, such as EBM system  100 . With reference to  FIG. 2 , in the exemplary embodiment, method  200  includes creating  202  a model of the component such as component  102 , creating  204  a model of at least one powder removal device, such as powder removal device  109 , integrating  206  the model of the at least one powder removal device  109  into the model of the component  102 , inputting  208  the model of the component into an additive manufacturing system, such as additive manufacturing system  100 , and operating  210  the additive manufacturing system  100  to build the component  102  including the at least one powder removal device  109 , wherein the at least one powder removal device  109  is configured to remove un-sintered and partially sintered material, such as un-sintered and partially sintered powder  114  from component  102  when the at least one powder removal device  109  is excited. 
     Additive manufacturing system  100  may be operated such that there is a beam diameter in a range from about 10 micrometers to about 1,000 micrometers. Further, additive manufacturing system  100  may be operated such that there is a particle size in a range from about 10 micrometers to about 1,000 micrometers. Powder removal devices  109  have a size that is equivalent to approximately the size of two to three particles melded together. Further, powder removal device  109  may be tethered to an adjacent surface of component  102 , such that powder removal devices  109  is configured to detach the adjacent surface when vibrated. In the exemplary embodiment, powder removal device  109  is unattached to component  102 . 
       FIG. 3  is a flow diagram of a method  300  for removing powder, such as un-sintered and partially sintered powder  114  (shown in  FIG. 1 ) from an additively manufactured part, such as component  102 . With reference to  FIG. 3 , in the exemplary embodiment, method  300  includes fabricating  302 , using an additive manufacturing process, a component  102  including at least one powder removal device  109 . Method  300  further includes exciting  304  component  102 , causing the at least one powder removal device  109  to remove un-sintered and partially sintered powder  114  from component  102 . 
     In the exemplary embodiment, exciting  304  is performed such that component  102  (shown in  FIG. 1 ) is vibrated at a rate in a range from about 40 hertz to about 70 hertz. Additionally, in the exemplary embodiment, exciting  304  is performed such that component  102  is vibrated at a vibration amplitude having an acceleration in a range from about 29.4 meters per second squared (m/s 2 ) to about 39.2 m/s 2 . Additionally, in the exemplary embodiment, exciting  304  is performed such that component  102  is vibrated at a vibration amplitude having a displacement in a range from about 0.0254 millimeters (mm) to about 0.127 mm. Further, in the exemplary embodiment, exciting  304  is performed such that component  102  is excited such that a structural integrity component  102  is not compromised. Additionally or alternatively, exciting  304  component  102  includes vibrating  306  component  102  at a resonance frequency of component  102 . 
       FIGS. 4A-4F  are perspective views of alternative exemplary powder removal devices, such as powder removal device  109  manufactured using an additive manufacturing system, such as additive manufacturing system  100 . With reference to  FIGS. 4A-4F , powder removal devices  109  (shown in  FIG. 1 ) may have a variety of geometric shapes. The shape of powder removal devices  109  may vary depending on the feature of the component  102  (shown in  FIG. 1 ) being printed. For example, if the general shape of component  102  is complicated and contains intricate features or internal passages, the shape of powder removal devices  109  may be designed to facilitate removing un-sintered and partially sintered powder  114  given the geometric constraints of any features or internal passages of component  102 . Additionally, if the general shape of component  102  is less complicated, the shape of powder removal devices  109  may be less critical. Further, if component  102  includes a series of tubes, or connected parts, various shapes may be strategically employed to insure the removal and exit of un-sintered and partially sintered powder  114  (shown in  FIG. 1 ) and powder removal devices  109  from component  102 . Additionally, powder removal devices  109  may have symmetrical or asymmetrical shapes and features. Powder removal devices  109  with both asymmetrical and symmetrical features are effective at removing un-sintered and partially sintered powder  114  from within component  102 , however, asymmetrical features have the added advantage of more easily agitating powder removal devices  109  thus initiating the removal of un-sintered and partially sintered powder  114 . 
     With reference to  FIG. 4A , one exemplary powder removal device  400  has a spheroid shape. With reference to  FIG. 4B , another exemplary powder removal device  402  has a prism shape. With reference to  FIG. 4C , another exemplary powder removal device  404  has an ellipsoid shape combined with an annular disk shape. With reference to  FIG. 4D , another exemplary powder removal device  406  has a Mobius loop shape. With reference to  FIG. 4E , another exemplary powder removal device  408  has a cylindrical shape. With reference to  FIG. 4F , another exemplary powder removal device  410  has a cuboid shape. Alternatively, powder removal devices  109  (shown in  FIG. 1 ) may have any suitable shape. 
       FIGS. 5A and 5B  are images of a component  500  in a pre-processed and post-processed state, respectively.  FIG. 5A  shows a component  500  formed using method  200  (shown in  FIG. 2 ). As a result of the EBM printing process, un-sintered and partially sintered powder  114  remains among the build layers  116  and on the surfaces of the printed part. This results in component  500  having a visibly rough exterior surface  502  and interior cavity  504 .  FIG. 5B  shows component  500  after having undergone method  300  for removing un-sintered and partially sintered powder from printed component  500  using powder removal devices  109  (shown in  FIG. 1 ). When compared to  FIG. 5A , component  500  has a visibly smoother appearance on exterior surface  502  and interior cavity  504 . 
       FIG. 6  is an image of a vibratory bowl  600  that may be used during method  300  (shown in  FIG. 3 ) to excite powder removal devices  109  (shown in  FIG. 1 ) and remove un-sintered and partially sintered powder  114  from within a component, such as component  102  (shown in  FIG. 1 ), that has been manufactured using a method, such as method  200  (shown in  FIG. 2 ). In the exemplary embodiment, vibratory bowl  600  can be configured to receive a component  102  and can be vibrated at a rate in the range from about 40 hertz to about 70 hertz. Additionally, or alternatively the interior of vibratory bowl  600  can have a fixed receptacle or possess a cushioned bed to receive component  102 . Once component  102  is secured into vibratory bowl  600 . A motor drives vibratory bowl  600  such that all un-sintered and partially sintered powder  114  exits component  102 . Upon completion of the vibration, component  102  is removed from vibratory bowl  600  while the un-sintered and partially sintered powder remains in vibratory bowl  600 . 
     The above-described embodiments overcome at least some disadvantages of known methods for removing un-sintered and partially sintered powder from components printed using additive manufacturing techniques. Specifically, the embodiments takes advantage of the additive manufacturing process by allowing for a powder removal tool to be integrated into the manufacture of the printed part by creating internal structures manufactured within the desired component during the printing process that when mechanically agitated, i.e, when excited by a vibratory tool such as a laboratory table or bowl, break apart the powder surrounding them, and egress their way out of the part through an exit port. The embodiments described herein provide a cost effective approach to evacuating un-sintered and partially sintered powder that remains after the printing process. Additionally, the embodiments can be applied to a wide range of designs, subsequently expanding the applicability and usefulness of high speed EBM printing by increasing the variety of parts an EBM machine is capable of printing. The embodiments can be applied to any additive manufacturing method, not just EBM, to facilitate clearing internal features of their powder or sintered material at a relatively low cost. The embodiments provides a cost effective way of removing un-sintered and partially sintered powder from the internal cavities and exterior surfaces of a printed part in a cost effective manner that does not require external processes i.e., abrasive blasting, pneumatics, or mechanical picking. 
     An exemplary technical effect of the methods, systems, and apparatus described herein includes at least one of: a) a cost effective approach to evacuating un-sintered and partially sintered powder that remains after the printing process, and b) a powder removal tool integrated into the manufacture of the printed part. 
     The methods, systems, and compositions disclosed herein are not limited to the specific embodiments described herein, but rather, steps of the methods, elements of the systems, and/or elements of the compositions may be utilized independently and separately from other steps and/or elements described herein. For example, the methods, systems, and compositions are not limited to practice with only an additive manufacturing system as described herein. Rather, the methods, systems, and compositions may be implemented and utilized in connection with many other applications and additive manufacturing systems. 
     Although specific features of various embodiments may be shown in some drawings and not in others, this is for convenience only. Moreover, references to “one embodiment” in the above description are not intended to be interpreted as excluding the existence of additional embodiments that also incorporate the recited features. In accordance with the principles of the disclosure, any feature of a drawing may be referenced and/or claimed in combination with any feature of any other drawing. 
     This written description uses examples, including the best mode, to enable any person skilled in the art to practice the disclosure, including making and using any devices or systems and performing any incorporated methods. The patentable scope of the disclosure is defined by the claims, and may include other examples that occur to those skilled in the art. Such other examples are intended to be within the scope of the claims if they have structural elements that do not differ from the literal language of the claims, or if they include equivalent structural elements with insubstantial differences from the literal languages of the claims.