Patent Description:
A quality of powder used in additive manufacturing (AM) methods can affect a quality of parts built from the powder. Particle size factors influence flowability and thickness of each powder layer in a build box. For high-performance applications, it can be important to identify additional factors, such as types, numbers, and sizes of particulate contaminants that may be present in the powder. Contaminants may be introduced during powder manufacture, handling, or during the build process itself. Contaminants contained within a batch of powder can become introduced into a part when the contaminants are incorporated into the powder, and the contaminants can remain as discrete particulates or non-fused interfaces that act as stress concentrators.

A presence of contaminates may decrease a life of the part by increasing a likelihood of fatigue crack.

Currently, a human operator uses a microscope to review an additive manufacturing powder sample for foreign object debris (FOD) or contaminants. The human operator uses judgement to identify a quantitative count of FOD in a powder sample. This manual process is time-consuming and tedious, and prone to under-estimating an amount of FOD in an additive manufacturing powder sample. Additionally, when ultraviolet light is used to detect FOD, the human operator's safety is at risk.

<CIT> states, in accordance with its abstract, that systems and methods for reducing charged powder particle scattering in powder-bed fusion (PBF) systems are provided. A PBF apparatus can include a structure that supports a layer of powder material having a plurality of particles of powder. For example, the structure can be a build plate, a build floor, a build piece, etc. The apparatus can also include an energy beam source that generates an energy beam and a deflector that applies the energy beam to fuse an area of the powder material in the layer. The energy beam can electrically charge the particles of powder. The apparatus can also include an electrical system that generates an electrical force between the structure and the charged particles of powder. For example, the electrical system can include a voltage source that applies a first voltage to the structure.

<CIT> states, in accordance with its abstract, that byproduct condensate generated during additive manufacturing is controlled by providing at least one electrode inside a chamber. The condensate may be electrically charged as it is generated or an electrical charge may be imparted to the condensate. The electrode may have either a positive or negative bias to either attract or repel the condensate. The electrode may be located on a wall of the chamber or associated with a transparent window through which a laser beam passes into the chamber.

<CIT> states, in accordance with its abstract, that an appliance for manufacturing a three-dimensional object by means of selective additive manufacturing, comprises, in a housing: a support for depositing successive layers of additive manufacturing powder; a distribution arrangement designed to apply a layer of powder to said support or to a previously consolidated layer; and at least one source for the selective consolidation of a layer of powder applied by the distribution arrangement, characterised in that it comprises at least one protection element designed to trap, by electrical polarisation, ions of loaded vapour in the housing, said element consisting of a material designed to be electrically polarised and arranged in the vicinity of at least one optical/electronic module and/or component to be protected from the deposits, the appliance also comprising a polarisation assembly designed to ensure the electrical polarisation of said protection element during additive manufacturing operations.

<CIT> states, in accordance with its abstract, equipment for the generative manufacture and/or repair of components, in particular of gas turbines, having a solidifying means for the layer-by-layer, local, particularly optical, thermal, and/or chemical solidification of particularly powdered, granular, and/or fluid material, and an electrodeposition means for the electrostatic deposition of particles and/or gas from a region between a layer of material, which is to be solidified or is solidified, and the solidifying means, as well as a method for the generative manufacture and/or repair of components, in particular of gas turbines, by means of such equipment.

<CIT> states, in accordance with its abstract, that a method of forming a three dimensional object comprises: (i) providing a layer <NUM> of particulate material; (ii) providing an amount of a radiation absorbent material, such as carbon black nanoparticles, over a selected surface portion of the layer of particulate material; (iii) providing an amount of a material that comprises a plurality of electrically conductive elements over only part of the selected surface portion; and (iv) providing radiation <NUM> across the selected surface portion so as to sinter a portion of the particulate material of the layer including causing the plurality of electrically conductive elements to become embedded in the portion of material. Step (iv) also includes the step of sintering the portion of material with a previously sintered portion of the material in a prior layer. Steps (i) to (iv) are performed iteratively to form the three dimensional object comprising an electrically conductive track through the object, the track being defined by the electrically conductive elements. Suitably, the electrically conductive elements are carbon nanotubes or elongate graphene plates. An apparatus for forming the three dimensional object is also claimed which comprises one or more printing devices and a radiation source.

<CIT> states, in accordance with its abstract, that a part is manufactured by introducing magnetic particles into a matrix material, and orienting the particles by coupling them with an electromagnetic field. The matrix material (<NUM>) is solidified in patterned layers while the particles remain oriented by the field.

According to the present disclosure, a method, a device and a system as defined in the independent claims are provided. Further embodiments of the invention are defined in the dependent claims. Although the invention is only defined by the claims, the below embodiments, examples, and aspects are present for aiding in understanding the background and advantages of the invention.

An additive manufacturing system for extraction of impurities in an additive manufacturing material is disclosed in claim <NUM>.

A method for extracting impurities in additive manufacturing material is disclosed in claim <NUM>.

Further and not forming part of the claimed invention there is disclosed a method of producing a composition in additive manufacturing material that includes spreading, by a roller, a layer of additive manufacturing material, the layer of the additive manufacturing material including elongated fibers. The method also includes generating an electric field across the layer of additive manufacturing material and, while generating the electric field across the layer of the additive manufacturing material, aligning the elongated fibers within the layer. The method further includes solidifying, by way of an energy source, the layer of additive manufacturing material and aligned elongated fibers.

Still further and not forming part of the claimed invention there is disclosed an additive manufacturing system that includes an additive manufacturing machine for manufacturing a part using additive manufacturing material and a roller for spreading a layer of additive manufacturing material. The layer of the additive manufacturing material includes elongated fibers. The additive manufacturing machine also includes an electric field generator for generating an electric field across the layer of additive manufacturing material and aligning the elongated fibers within the layer. The system additionally includes an energy source for solidifying the layer of additive manufacturing material and aligned elongated fibers.

The features, functions, and advantages that have been discussed can be achieved independently in various examples or may be combined in yet other examples. Further details of the examples can be seen with reference to the following description and drawings.

The novel features believed characteristic of the illustrative examples are set forth in the appended claims. The illustrative examples, however, as well as a preferred mode of use, further objectives and descriptions thereof, will best be understood by reference to the following detailed description of an illustrative example of the present disclosure when read in conjunction with the accompanying drawings, wherein:.

Disclosed examples will now be described more fully hereinafter with reference to the accompanying drawings, in which some, but not all of the disclosed examples are shown. Indeed, several different examples may be described and should not be construed as limited to the examples set forth herein.

Within examples, methods for detection and extraction of impurities in additive manufacturing material are described that include generating an electric charge through a conductive plate adjacent to additive manufacturing material and attracting impurities to the conductive plate from the additive manufacturing material.

Using methods described herein can enable automated extraction and detection of contamination, such as impurities and/or foreign object debris, in additive manufacturing materials via electrostatic techniques. Conductive plates are utilized to electrostatically attract and extract the impurities from the samples of additive manufacturing materials.

Example methods and systems described herein can remove a need for a human operator to review additive manufacturing powder for contamination or foreign object debris, and enable more accurate identification and quantification of foreign object debris. The amount of foreign object debris in a sample of additive manufacturing material impacts quality and mechanical properties (for example, fatigue life and tensile strength) of a finished additively manufactured part. Thus, determination of an amount of the contamination can be useful in decisions for whether to replace the additive manufacturing material.

The example methods for detection of impurities in additive manufacturing material can be used in an additive manufacturing system, for example. An example additive manufacturing system can include an additive manufacturing machine for manufacturing a part using additive manufacturing material and a conductive plate adjacent to the additive manufacturing material. An example system further includes an energy source for distributing an electric charge through the conductive plate adjacent to the additive manufacturing material. Distributing the electric charge through the conductive plate attracts impurities from the additive manufacturing material to the conductive plate.

Referring now to the figures, <FIG> illustrates a system <NUM> for extraction and detection of impurities in additive manufacturing material, according to an example implementation. The system <NUM> includes an additive manufacturing machine <NUM> for manufacturing a part using additive manufacturing material <NUM> and a conductive plate <NUM> adjacent to the additive manufacturing material <NUM>. The system <NUM> further includes an energy source <NUM> for distributing an electric charge through the conductive plate <NUM> adjacent to the additive manufacturing material <NUM>. Distributing the electric charge through the conductive plate <NUM> attracts impurities <NUM> from the top layer <NUM> of the additive manufacturing material <NUM> to the conductive plate <NUM>.

The additive manufacturing material <NUM> is included within a container <NUM>, and can include many types of materials, such as a polymer (e.g., polycarbonate, nylon, epoxy resin), a ceramic (silica or glass), and a metal (steel, titanium alloy, aluminum alloys, etc.), for example. The additive manufacturing material <NUM> can be in many forms as well, such as powder, liquid, or a combination.

The conductive plate <NUM> may be transparent or translucent. In some examples, the conductive plate <NUM> may include a conductive glass or polymer plate, such as indium tin oxide, or a conductive polymer such as Poly(<NUM>,<NUM>-ethylenedioxythiophene)-tetramethacrylate) PEDOT-TMA), poly(<NUM>,<NUM>-ethylenedioxythiophene) polystyrene sulfonate (PEDOT:PSS), or Poly(<NUM>,<NUM>-ethylenedioxythiophene) (PEDOT). The conductive plate <NUM> is coupled to the energy source <NUM>, such that the energy source <NUM> can distribute an electric charge across the conductive plate <NUM>. The impurities <NUM> are fibers, which are attracted to the electrostatic charge created by the energy source <NUM> and distributed across the conductive plate <NUM> and light enough to lift from the additive manufacturing material <NUM> to the conductive plate <NUM>. The additive manufacturing material <NUM> is not be attracted to the electrostatic charge and remains in the container <NUM>.

The conductive plate <NUM> is mounted above the container <NUM> of additive manufacturing material <NUM>. Additionally, the additive manufacturing material <NUM> includes a top layer <NUM> of the additive manufacturing material <NUM>, such that the conductive plate <NUM> attracts the impurities <NUM> on the top layer <NUM>. When exposed to the conductive plate <NUM>, the impurities <NUM> will lift from the container <NUM> to the conductive plate <NUM>.

The system <NUM> further includes a light source <NUM> for illuminating the conductive plate <NUM> and a camera <NUM> for capturing image data of the conductive plate <NUM> and/or impurities. The light source <NUM> and the camera <NUM> can be mounted to illuminate the conductive plate <NUM> and acquire the image data, and thus, the light source <NUM> and the camera <NUM> can be mounted over a container of the additive manufacturing material <NUM>. Additionally, the camera <NUM> is coupled to a computing device <NUM> having one or more processors configured to execute instructions stored in memory <NUM> for processing the image data to determine an amount of impurities on the conductive plate <NUM>. In addition, data from numerous samples over time can be accumulated in the memory <NUM> so that machine learning can be used to improve the identification of FOD.

In some examples, the light source <NUM> and the camera <NUM> are communicatively coupled to the computing device <NUM>. For example, the light source <NUM> and the camera <NUM> may be in wired or wireless communication with the computing device <NUM>. The computing device <NUM> can send instructions to and control operation of the light source <NUM> and the camera <NUM>, and the light source <NUM> and the camera <NUM> can provide outputs to the computing device <NUM>.

The light source <NUM> can produce a collimated light beam <NUM>. The collimated light beam <NUM> has parallel or substantially parallel rays, and therefore will spread minimally as it propagates.

In examples where impurities <NUM> are present on the conductive plate <NUM>, the impurities <NUM> on the conductive plate <NUM> will reflect a portion of light from the light source <NUM> rather than pass through the conductive plate <NUM> which is transparent or translucent. In other words, the conductive plate <NUM> may be configured to reflect scattered light where impurities <NUM> are present while the remaining direct light from the light source <NUM> passes through the conductive plate <NUM>. This allows detection and identification of the impurities <NUM>.

The camera <NUM> may be a hi-resolution camera for capturing images. In an example, the camera <NUM> acquires image data (or otherwise collect or obtains image data), which includes pixels or voxels. The camera <NUM> (or the computing device <NUM>) may then generate or produce images based on the acquired image data. A representation of the impurities <NUM> on the conductive plate <NUM> is then included in the images, for example.

The computing device <NUM> receives the image data from the camera <NUM>, and processes the image data to determine an amount of impurities <NUM> on the conductive plate <NUM>. To perform the functions noted above, the computing device <NUM> includes a processor <NUM> and memory <NUM>. The computing device <NUM> may also include hardware to enable communication within the computing device <NUM> and between the computing device <NUM> and other devices (not shown). The hardware may include transmitters, receivers, and antennas, for example.

The memory <NUM> may take the form of non-transitory computer readable media, such as one or more computer-readable storage media that can be read or accessed by the one or more processors <NUM>. The computer-readable storage media can include volatile and/or non-volatile storage components, such as optical, magnetic, organic or other memory or disc storage, which can be integrated in whole or in part with the one or more processors <NUM>. The memory <NUM> can thus be considered non-transitory computer readable media. In some examples, the memory <NUM> can be implemented using a single physical device (e.g., one optical, magnetic, organic or other memory or disc storage unit), while in other examples, the memory <NUM> can be implemented using two or more physical devices. The memory <NUM> thus is a computer readable medium, and instructions are stored thereon. The instructions include computer executable code.

The one or more processors <NUM> may be general-purpose processors or special purpose processors (e.g., digital signal processors, application specific integrated circuits, etc.). The one or more processors <NUM> can be configured to execute the instructions (e.g., computer-readable program instructions) that are stored in the memory <NUM> and are executable to provide the functionality of the computing device <NUM> described herein.

The computing device <NUM> and/or the processors <NUM> outputs data indicative of the amount of impurities <NUM> on the conductive plate <NUM>. This data may additionally include information about the size, shape, or position of the impurities <NUM> on the conductive plate <NUM>. As described above, this information may be determined based on the amount of light scattered or reflected from the light source <NUM>.

In operation, when the instructions are executed by the one or more processors <NUM> of the computing device <NUM>, the one or more processors <NUM> are caused to perform functions for receiving the image data from the camera <NUM>, and processing the image data to determine an amount of impurities on the conductive plate <NUM>.

Now referring to <FIG>, a conductive plate <NUM> including a plate <NUM> and mirror <NUM>, according to an example implementation. In some examples, the mirror <NUM> is thin enough to allow light to pass through (e.g., translucent). The mirror <NUM> may also be semi-transparent or reflective on one side and transparent on the other side (e.g., a one-way mirror). The plate <NUM> may be translucent or transparent such that light from the light source <NUM> passes through. The plate <NUM> and/or the mirror <NUM> are electrically conductive such that the electric charge generating by the energy source <NUM> distributes the electric charge across the plate <NUM> and/or mirror and attracts the impurities <NUM> from the additive manufacturing material <NUM>. In some examples, the conductive plate <NUM> may just include the mirror <NUM>.

Where no impurities are present on the conductive plate <NUM>, a portion <NUM> of the collimated light beam <NUM> shone on the conductive plate <NUM> passes through the plate and the mirror <NUM> and a portion <NUM> of the light beam <NUM> may be reflect. In contrast, shining the collimated light beam <NUM> where an impurity <NUM> is present produces a scattered light site <NUM>. The scattering light site <NUM> can be detected by the camera <NUM> and identified by the computing device <NUM> (shown in <FIG>). The computing device <NUM> may identify information about the size, shape, or position of the impurities <NUM> on the conductive plate <NUM>, as described above.

Now referring to <FIG>, a conductive plate <NUM> including waveguides, according to example implementations. Within examples, the conductive plate <NUM> can include a first set of waveguides <NUM> and a second set of waveguides <NUM> on a surface of the conductive plate <NUM>. The first set of waveguides <NUM> and second set of waveguides <NUM> may intersect at intersection region <NUM>.

Within examples, the conductive plate <NUM> can include a first optical emitter <NUM> at a first end of the first set of waveguides <NUM> and a first optical receiver <NUM> at the second end of the first set of waveguides <NUM>. The first optical emitter <NUM> can emit light through the first set of waveguides <NUM>. The first optical receiver <NUM> can measure light received from the first optical emitter <NUM> that has traveled through the first set of waveguides <NUM>.

Additionally, the conductive plate <NUM> can include a second optical emitter <NUM> at a first end of the second set of waveguides <NUM> and a second optical receiver <NUM> at the second end of the second set of waveguides <NUM>. The second optical emitter <NUM> can emit light through the second set of waveguides <NUM>. The first optical receiver <NUM> can measure light received from the first optical emitter <NUM> that has traveled through the first set of waveguides <NUM>.

The first optical emitter <NUM>, first optical receiver <NUM>, second optical emitter <NUM>, and/or the second optical receiver <NUM> may be coupled to a computing device (such as computing device <NUM> shown in <FIG>) having one or more processors (such as computing device <NUM> shown in <FIG>) configured to execute instructions stored in memory (such as memory <NUM> shown in <FIG>) for processing. Further, in some examples, the first optical emitter <NUM> and second optical emitter <NUM> and the first optical receiver <NUM> and second optical receiver <NUM> are communicatively coupled to the computing device <NUM>. For example, the first optical emitter <NUM> and second optical emitter <NUM> and the first optical receiver <NUM> and second optical receiver <NUM> may be in wired or wireless communication with the computing device <NUM>. The computing device <NUM> can send instructions to and control operation of the first optical emitter <NUM> and second optical emitter <NUM> and the first optical receiver <NUM> and second optical receiver <NUM>, and the first optical emitter <NUM> and second optical emitter <NUM> and the first optical receiver <NUM> and second optical receiver <NUM> can provide outputs to the computing device <NUM>.

The one or more processors <NUM> can determine information and data about the impurities <NUM>, such as the size shape, or position of the impurities <NUM> on the conductive plate <NUM> based on the light received at the first optical receiver <NUM> and/or second optical receiver <NUM>. For example, the longer the length of the impurity <NUM> is, the more waveguides the impurity <NUM> will interfere with, affecting the light detected at, for example, the first optical receiver <NUM>. Additionally, the intersection region <NUM> enables the comparison of the detected interferences to determine location and size of the impurities <NUM>. For example, the computing device <NUM> may recreate the grid of the intersection region <NUM> using data of light detected at each of the first optical receiver <NUM> and the second optical receiver <NUM>.

In some examples utilizing waveguides to locate and identify impurities, the additive manufacturing system may not include the light source <NUM> and/or camera <NUM>, as the first optical emitter <NUM> and second optical emitter <NUM> and the first optical receiver <NUM> and second optical receiver <NUM> can determine information about the impurities <NUM> without the light source <NUM> and/or camera <NUM>. Such examples do not fall under the scope of the claimed invention.

Now referring to <FIG>, a cross-sectional view of waveguides according to example implementations. The waveguides shown in <FIG> represent either or both the first set of waveguides <NUM> and/or the second set of waveguides <NUM>. As shown in <FIG>, the first and/ second set of waveguides <NUM>, <NUM> can include waveguides <NUM> within a substrate, such as glass. Within examples, the waveguides <NUM> may be fused silica.

<FIG> shows a flowchart of an example of a method <NUM> for extraction and detection of impurities in additive manufacturing material, according to an example implementation. Method <NUM> shown in <FIG> presents an example of a method that could be used with the system <NUM> shown in <FIG>, and with the conductive plate <NUM> shown in <FIG>, for example. Further, devices or systems may be used or configured to perform logical functions presented in <FIG>. In some instances, components of the devices and/or systems may be configured to perform the functions such that the components are actually configured and structured (with hardware and/or software) to enable such performance. In other examples, components of the devices and/or systems may be arranged to be adapted to, capable of, or suited for performing the functions, such as when operated in a specific manner. Method <NUM> may include one or more operations, functions, or actions as illustrated by one or more of blocks <NUM>-<NUM>. Although the blocks are illustrated in a sequential order, these blocks may also be performed in parallel, and/or in a different order than those described herein. Also, the various blocks may be combined into fewer blocks, divided into additional blocks, and/or removed based upon the desired implementation.

It should be understood that for this and other processes and methods disclosed herein, flowcharts show functionality and operation of one possible implementation of present examples. In this regard, each block or portions of each block may represent a module, a segment, or a portion of program code, which includes one or more instructions executable by a processor for implementing specific logical functions or steps in the process. The program code may be stored on any type of computer readable medium or data storage, for example, such as a storage device including a disk or hard drive. Further, the program code can be encoded on a computer-readable storage media in a machine-readable format, or on other non-transitory media or articles of manufacture. The computer readable medium may include non-transitory computer readable medium or memory, for example, such as computer-readable media that stores data for short periods of time like register memory, processor cache and Random Access Memory (RAM). The computer readable medium may also include non-transitory media, such as secondary or persistent long term storage, like read only memory (ROM), optical or magnetic disks, compact-disc read only memory (CD-ROM), for example. The computer readable media may also be any other volatile or non-volatile storage systems. The computer readable medium may be considered a tangible computer readable storage medium, for example.

In addition, each block or portions of each block in <FIG>, and within other processes and methods disclosed herein, may represent circuitry that is wired to perform the specific logical functions in the process. Alternative implementations are included within the scope of the examples of the present disclosure in which functions may be executed out of order from that shown or discussed, including substantially concurrent or in reverse order, depending on the functionality involved, as would be understood by those reasonably skilled in the art.

At block <NUM>, the method <NUM> includes generating an electric charge through a conductive plate adjacent to additive manufacturing material.

At block <NUM>, the method <NUM> includes attracting impurities to the conductive plate from the additive manufacturing material while generating the electric charge through the conductive plate.

The method <NUM> further includes determining an amount of impurities on the conductive plate. Determining the amount of impurities further includes illuminating, by a light source, the conductive plate with light, causing a camera to acquire image data of the conductive plate, and processing the image data to determine the amount of impurities on the conductive plate.

In further examples, detecting the amount of impurities on the conductive plate can include detecting a number of scattered light sites. In these examples, distributing the electric charge through a conductive plate can include distributing the electric charge through a glass plate and a mirror coupled to the glass plate. The mirror can reflect scattered light sites where impurities are present.

Within other examples, method <NUM> can further include emitting light, by an optical emitter, along waveguides on the conductive plate, where the optical emitter is adjacent to a first end of the waveguides, measuring, by an optical receiver, light received at a second end of the waveguides, and determining, by a processor, at least one of a size, shape, or position of the impurities on the conductive plate based on the light emitted by the optical emitter compared to the light received by the optical receiver.

Further, the optical emitter can be a first optical emitter, the waveguides can be a first set of waveguides, and the optical receiver can a first optical receiver. Method <NUM> can further include emitting light, by a second optical emitter, along a second set of waveguides on the conductive plate, where the second optical emitter is adjacent to a first end of the second set of waveguides, and where the second set of waveguides intersects with the first set of waveguides. Method <NUM> can further include measuring, by a second optical receiver, light received at a second end of the waveguides and determining, by the processor, at least one of the size, shape, or position of the impurities based on the light emitted by the second optical emitter compared to the light received by the second optical receiver.

Further, manufacturers employing powder-based additive manufacturing can utilize example methods and system described herein to define a stable and repeatable process used to extract and detect impurities from additive manufacturing material.

Within non-claimed examples, methods for producing a composition of additive manufacturing material involve spreading, by a roller, a layer of additive manufacturing material, the layer including elongated fibers. Example methods further include generating an electric field across the layer of additive manufacturing material and aligning the elongated fibers within the layer. Example methods can additionally include solidifying, by way of an energy source, the layer of additive manufacturing material and aligned elongated fibers.

Generally, the additive manufacturing machine operates by manufacturing parts in a layer-wise construction of a plurality of layers of material. Additive manufacturing may involve applying liquid or powder material to a work area, and then performing a combination of sintering, curing, melting, and/or cutting to create a layer. The process is repeated up to several thousand times to construct a desired finished part or apparatus. The additive manufacturing machine may include components, such as a printing head or printer nozzle, control mechanisms (e.g., computing device), molds, etc., depending on a type of manufacturing being used. A range of processes finding industrial applications for additive manufacturing includes direct metal deposition, electron beam melting, polymer processes such as fused filament fabrication (FFF), fused deposition (FDM), Solid Ground Curing (SGC), Laminated Object Manufacturing (LOM), and select laser sintering (SLS) or selective laser melting (SLM), among others. The additive manufacturing machine may include components specific to any of these processes, or in some examples, the additive manufacturing machine may include hybrid machine tools to combine additive manufacturing with subtractive machining. The additive manufacturing machine may additionally include a laser metal powder bed where a laser melts down the metal powder in material layers (e.g., direct metal laser sintering, selective laser melting).

The part produced using the additive manufacturing machine is built up by laying down a layer of material on a build platform layer-by-layer. This process provides properties comparable to that of a casting.

Example methods and systems which do not form part of the claimed invention described herein enable alignment of fibers within the layers of the additive manufacturing material. The additive manufacturing material and the resulting manufactured part or apparatus, may then have enhanced isotropic or anisotropic structural, electronic, and/or thermal properties.

The example methods for producing the composition of additive manufacturing material can be used in an additive manufacturing system, for example. An example additive manufacturing system can include an additive manufacturing machine for manufacturing a part using additive manufacturing material and a roller for spreading a layer of additive manufacturing material, where the additive manufacturing material includes elongated fibers. An example system further includes an electric field generator for generating an electric field across the layer of additive manufacturing material and aligning the elongated fibers within the layer and an energy source for solidifying the layer of additive manufacturing material and aligned elongated fibers.

Now referring to <FIG>, an additive manufacturing system not falling under the scope of the claimed invention for producing an additive manufacturing material compound. The system <NUM> includes an additive manufacturing machine <NUM> for manufacturing a part using additive manufacturing material and a roller <NUM> for spreading a layer <NUM> of additive manufacturing material, where the layer <NUM> of the additive manufacturing material includes elongated fibers <NUM>. The system <NUM> further includes an electric field generator <NUM>, <NUM> for generating an electric field <NUM> across the layer <NUM> of additive manufacturing material and aligning the elongated fibers <NUM> within the layer <NUM>. The system <NUM> further includes an energy source <NUM> for solidifying the layer <NUM> of additive manufacturing material and aligned elongated fibers <NUM>.

The elongated fibers <NUM> may be added to the additive manufacturing material powder <NUM> in a bin <NUM>. Within examples, elongated fibers <NUM> can include silicon fibers, zinc oxide fibers, polyethylene fibers, or carbon fibers. In some example implementations, the elongated fibers <NUM> may all be the material (e.g., silicon fibers). In alternative examples, the elongated fibers <NUM> can include a combination of materials (e.g., silicon fibers and carbon fibers). Further, in some examples, the elongated fibers <NUM> may include wires, microwires, nanowires, fibers, microfibers, or nanofibers.

In practice, the roller <NUM> can gather the top surface <NUM> of the additive manufacturing material powder <NUM> and the elongated fibers <NUM> and spread a layer of the additive manufacturing material powder <NUM> and the elongated fibers <NUM> into bin <NUM> for alignment and solidifying. This process can be repeated, for example, as a bed <NUM> of the bin raises upwards and the roller <NUM> travels from bin <NUM> to bin <NUM> to create article <NUM>. The article <NUM> can include a plurality of layers of solidified powder and elongated fibers <NUM>.

Within examples, the electric field generator <NUM>, <NUM> can be, for example, a Van de Graff generator, among other examples. The electric field generator <NUM>,<NUM> can be mounted above bin <NUM>. Within examples, the electric field <NUM> causes the elongated fibers <NUM> to align in the direction of the electric field <NUM>. This results in alignment of the elongated fibers <NUM> within the layer <NUM> of the additive manufacturing material. Alignment of the elongated fibers <NUM> within the layer <NUM> can produce a composition with anisotropic mechanical, thermal, and/or optical properties. For example, the layer <NUM> of additive manufacturing material may conduct heat in one direction and not the other. Additionally, within examples, the electric field generator <NUM>, <NUM> may be mounted such that it can be rotated about the bin <NUM> and thus create an electric field in directions.

Within examples, the energy source <NUM> can emit beam <NUM> which can be a laser beam or electron beam, for example. In either example, the energy source <NUM> is configured to solidify the layer <NUM> of additive manufacturing material and the aligned elongated fibers <NUM>. It is desirable to solidify the elongated fibers <NUM> to retain the alignment created by the electric field <NUM> and resulting desired qualities of the material (e.g., conduct heat in one direction and not the other).

This process may be repeated a number of times for a plurality of layers. A bed <NUM> of bin <NUM> may lower to allow more layers of additive manufacturing material powder <NUM> to be spread. In these examples, a second layer of additive manufacturing material (e.g., second layer <NUM>) where the second layer <NUM> of the additive manufacturing material includes a second set of elongated fibers <NUM>. The electric field generator <NUM>, <NUM> is configured to generate a second electric field across the second layer <NUM> of additive manufacturing material and align the second set of elongated fibers <NUM> in the direction of the electric field <NUM>, as described above. The energy source <NUM> is then configured to solidify the second layer <NUM> of additive manufacturing material and the second set of elongated fibers.

Further, within examples, the alignment of elongated fibers <NUM> within each layer may vary. For example, the electric field generator may align the elongated fibers <NUM> in the layer <NUM>, which can, for purposes of example, be considered the first layer, in a first direction based on the direction of the electric field <NUM>. The electric field generator <NUM>, <NUM> may rotate to align the elongated fibers <NUM> of the second layer <NUM> in a second direction, different than the first direction. Accordingly, the elongated fibers <NUM> may be aligned in a different direction in each layer (e.g., the electrical field generator <NUM>, <NUM> may gradually rotate as new layers of additive manufacturing material powder are spread, aligned, and solidified), resulting in a twisted, chiral, spiral-like, or heliacal structures. Alternatively, the elongated fibers <NUM> direction aligns within multiple layers (i.e., the elongated fibers <NUM> are aligned with each other across multiple layers). This may be desirable to increase torsional rigidity the solidified material, for example.

<FIG> shows a flowchart of an example of a method <NUM> not falling under the scope of the claimed invention for producing a composition of additive manufacturing material, according to an example implementation. Method <NUM> shown in <FIG> presents an example of a method that could be used with the system <NUM> shown in <FIG>. Further, devices or systems may be used or configured to perform logical functions presented in <FIG>. In some instances, components of the devices and/or systems may be configured to perform the functions such that the components are actually configured and structured (with hardware and/or software) to enable such performance. In other examples, components of the devices and/or systems may be arranged to be adapted to, capable of, or suited for performing the functions, such as when operated in a specific manner. Method <NUM> may include one or more operations, functions, or actions as illustrated by one or more of blocks <NUM>-<NUM>. Although the blocks are illustrated in a sequential order, these blocks may also be performed in parallel, and/or in a different order than those described herein. Also, the various blocks may be combined into fewer blocks, divided into additional blocks, and/or removed based upon the desired implementation.

At block <NUM>, the method <NUM> includes spreading, by a roller, a layer of additive manufacturing material, wherein the layer of the additive manufacturing material comprises elongated fibers.

At block <NUM>, method <NUM> includes generating an electric field across the layer of additive manufacturing material.

At block <NUM>, method <NUM> involves aligning the elongated fibers within the layer while generating the electric field across the layer of the additive manufacturing material. Within examples, block <NUM> may further involve.

At block <NUM>, method <NUM> includes solidifying, by way of an energy source, the layer of additive manufacturing material and aligned elongated fibers.

Within examples, the layer of additive manufacturing material is a first layer of additive manufacturing material, the electric field is a first electric field, and the elongated fibers are a first set of elongated fibers. In these examples, method <NUM> includes spreading, by the roller, a second layer of additive manufacturing material, where the second layer of the additive manufacturing material comprises a second set of elongated fibers. Method <NUM> may then involve aligning the first set of elongated fibers in a first direction, and aligning the second set of elongated fibers comprises aligning the second set of elongated fibers in a second direction, different from the first direction.

By the term "substantially" and "about" used herein, it is meant that the recited characteristic, parameter, or value need not be achieved exactly, but that deviations or variations, including for example, tolerances, measurement error, measurement accuracy limitations and other factors known to skill in the art, may occur in amounts that do not preclude the effect the characteristic was intended to provide.

Different examples of the system(s), device(s), and method(s) disclosed herein include a variety of components, features, and functionalities. It should be understood that the various examples of the system(s), device(s), and method(s) disclosed herein may include any of the components, features, and functionalities of any of the other examples of the system(s), device(s), and method(s) disclosed herein in any combination or any sub-combinations.

There is disclosed an additive manufacturing system (<NUM>) for extraction of impurities (<NUM>) in additive manufacturing material (<NUM>), the system (<NUM>) comprising: an additive manufacturing machine (<NUM>) for manufacturing a part using additive manufacturing material (<NUM>); a conductive plate (<NUM>) adjacent to the additive manufacturing material (<NUM>); and an energy source (<NUM>) for distributing an electric charge through the conductive plate (<NUM>) adjacent to the additive manufacturing material (<NUM>), wherein distributing the electric charge through the conductive plate (<NUM>) attracts impurities (<NUM>) from the additive manufacturing material (<NUM>) to the conductive plate (<NUM>).

The additive manufacturing system (<NUM>) further comprises: a light source (<NUM>) for illuminating the conductive plate (<NUM>) with light; and a camera (<NUM>) for capturing image data of the conductive plate (<NUM>).

The additive manufacturing system (<NUM>) further comprises: a computing device (<NUM>) having one or more processors (<NUM>) configured to execute instructions stored in memory (<NUM>) for processing the image data to determine an amount of impurities (<NUM>) on the conductive plate (<NUM>).

Preferably, the conductive plate (<NUM>) comprises: a glass plate (<NUM>); and a mirror (<NUM>) coupled to the glass plate (<NUM>), wherein the mirror (<NUM>) is configured to reflect scattered light sites (<NUM>) where the impurities (<NUM>) are present.

Preferably, the conductive plate (<NUM>) comprises conductive glass or polymer.

Preferably, the additive manufacturing system (<NUM>) further comprises: waveguides (<NUM>) on the conductive plate (<NUM>); an optical emitter (<NUM>) at a first end of the waveguides (<NUM>) for emitting light through the waveguides (<NUM>); an optical receiver (<NUM>) at a second end of the waveguides (<NUM>) for measuring light received from the optical emitter (<NUM>); and a processor (<NUM>) for determining at least one of a size, shape, or position of the impurities (<NUM>) on the conductive plate (<NUM>) based on the light emitted by the optical emitter (<NUM>) compared to the light received by the optical receiver (<NUM>).

Preferably, the waveguides are a first set of waveguides (<NUM>), the optical emitter (<NUM>) is a first optical emitter (<NUM>), the optical receiver is a first optical receiver (<NUM>), and wherein the additive manufacturing system (<NUM>) further comprises: a second set of waveguides (<NUM>) on the conductive plate (<NUM>), wherein the second set of waveguides (<NUM>) intersects with the first set of waveguides (<NUM>); a second optical emitter (<NUM>) at a first end of the second set of waveguides (<NUM>) for emitting light through the second set of waveguides (<NUM>); a second optical receiver (<NUM>) at a second end of the second set of waveguides (<NUM>) for measuring light from the second optical emitter (<NUM>); and wherein the processor (<NUM>) is configured to determine at least one of the size, shape, or position of the impurities (<NUM>) on the conductive plate (<NUM>) based on the light emitted by the first optical emitter (<NUM>) compared to the light received by first the optical receiver (<NUM>) and the light emitted by the second optical emitter (<NUM>) compared to the light received by second the optical receiver (<NUM>).

There is disclosed a method (<NUM>) for extracting impurities (<NUM>) in additive manufacturing material (<NUM>), the method comprising: generating an electric charge through a conductive plate (<NUM>) adjacent to the additive manufacturing material (<NUM>); and while generating the electric charge through the conductive plate (<NUM>), attracting the impurities (<NUM>) to the conductive plate (<NUM>) from the additive manufacturing material (<NUM>).

The method further comprises determining an amount of the impurities (<NUM>) on the conductive plate (<NUM>), wherein determining the amount of the impurities (<NUM>) further comprises: illuminating, by a light source (<NUM>), the conductive plate (<NUM>) with light; while illuminating the conductive plate (<NUM>) with the light, causing a camera (<NUM>) to acquire image data of the conductive plate (<NUM>); and processing the image data to determine the amount of the impurities (<NUM>) on the conductive plate (<NUM>).

Preferably, determining the amount of the impurities (<NUM>) on the conductive plate (<NUM>) comprises: detecting a number of scattered light sites (<NUM>).

Preferably, distributing the electric charge through the conductive plate (<NUM>) comprises distributing the electric charge through a glass plate and a mirror coupled to the glass plate (<NUM>), wherein the mirror (<NUM>) is configured to reflect scattered light sites (<NUM>) where the impurities (<NUM>) are present.

Preferably, the method further comprises: emitting light, by an optical emitter (<NUM>), along waveguides (<NUM>) on the conductive plate (<NUM>), wherein the optical emitter (<NUM>) is adjacent to a first end of the waveguides (<NUM>); measuring, by an optical receiver, light received at a second end of the waveguides (<NUM>); and determining, by a processor (<NUM>), at least one of a size, shape, or position of the impurities on the conductive plate (<NUM>) based on the light emitted by the optical emitter (<NUM>) compared to the light received by the optical receiver (<NUM>).

Preferably, the optical emitter (<NUM>) is a first optical emitter (<NUM>), the waveguides (<NUM>) are a first set of waveguides (<NUM>), the optical receiver (<NUM>) is a first optical receiver (<NUM>), and wherein the method further comprises: emitting light, by a second optical emitter (<NUM>), along a second set of waveguides (<NUM>) on the conductive plate (<NUM>), wherein the second optical emitter (<NUM>) is adjacent to a first end of the second set of waveguides (<NUM>), and wherein the second set of waveguides (<NUM>) intersects with the first set of waveguides (<NUM>); measuring, by an optical receiver (<NUM>), light received at a second end of the waveguides; and determining, by the processor (<NUM>), at least one of the size, shape, or position of the impurities based on the light emitted by the second optical emitter (<NUM>) compared to the light received by the optical receiver (<NUM>).

Preferably, distributing the electric charge through the conductive plate (<NUM>) comprises distributing the electric charge through a conductive glass plate.

There is disclosed a method (<NUM>) not falling under the scope of the claimed invention of producing a composition in additive manufacturing material (<NUM>) comprising: spreading, by a roller (<NUM>), a layer (<NUM>) of the additive manufacturing material (<NUM>), wherein the layer (<NUM>) of the additive manufacturing material (<NUM>) comprises elongated fibers (<NUM>); generating an electric field (<NUM>) across the layer (<NUM>) of the additive manufacturing material (<NUM>); while generating the electric field (<NUM>) across the layer (<NUM>) of the additive manufacturing material (<NUM>), aligning the elongated fibers (<NUM>) within the layer (<NUM>); and solidifying, by way of an energy source (<NUM>), the layer (<NUM>) of the additive manufacturing material (<NUM>) and aligned elongated fibers (<NUM>).

Preferably, the layer (<NUM>) of the additive manufacturing material (<NUM>) is a first layer (<NUM>) of additive manufacturing material (<NUM>), the electric field (<NUM>) is a first electric field (<NUM>), and the elongated fibers (<NUM>) are a first set of elongated fibers (<NUM>), and wherein the method (<NUM>) further comprises: spreading, by the roller (<NUM>), a second layer (<NUM>) of additive manufacturing material (<NUM>), wherein the second layer (<NUM>) of the additive manufacturing material (<NUM>) comprises a second set of elongated fibers (<NUM>); generating a second electric field (<NUM>) across the second layer (<NUM>) of the additive manufacturing material (<NUM>); while generating the electric field (<NUM>) across the second layer (<NUM>) of the additive manufacturing material (<NUM>), aligning the second set of elongated fibers (<NUM>) within the second layer (<NUM>); and solidifying, by way of the energy source (<NUM>), the second layer (<NUM>) of additive manufacturing material (<NUM>) and second set of aligned elongated fibers (<NUM>).

Preferably, aligning the first set of elongated fibers (<NUM>) comprises aligning the first set of elongated fibers (<NUM>) in a first direction, and aligning the second set of elongated fibers (<NUM>) comprises aligning the second set of elongated fibers (<NUM>) in a second direction, different from the first direction.

Preferably, aligning the elongated fibers (<NUM>) within the layer comprises aligning at least one of silicon fibers, zinc oxide fibers, polyethylene fibers, or carbon fibers.

Preferably, solidifying, by way of the energy source (<NUM>), the layer of the additive manufacturing material (<NUM>) and aligned elongated fibers (<NUM>) comprises solidifying, by way of a laser, the layer of the additive manufacturing material (<NUM>) and aligned elongated fibers (<NUM>).

Preferably, solidifying, by way of the energy source (<NUM>), the layer of the additive manufacturing material and aligned elongated fibers (<NUM>) comprises solidifying, by way of an electron beam (<NUM>), the layer of the additive manufacturing material (<NUM>) and aligned elongated fibers (<NUM>).

There is disclosed an additive manufacturing system (<NUM>) not falling under the scope of the claimed invention, the system comprising: an additive manufacturing machine (<NUM>) for manufacturing a part using additive manufacturing material (<NUM>); a roller (<NUM>) for spreading a layer of additive manufacturing material (<NUM>), wherein the layer of the additive manufacturing material (<NUM>) comprises elongated fibers (<NUM>); an electric field generator (<NUM>) for generating an electric field (<NUM>) across the layer of additive manufacturing material (<NUM>) and aligning the elongated fibers (<NUM>) within the layer; and an energy source (<NUM>) for solidifying the layer of additive manufacturing material (<NUM>) and aligned elongated fibers (<NUM>).

Preferably, the layer (<NUM>) of additive manufacturing material (<NUM>) is a first layer (<NUM>) of additive manufacturing material (<NUM>), the electric field (<NUM>) is a first electric field (<NUM>), and the elongated fibers (<NUM>) are a first set of elongated fibers (<NUM>), and wherein the system further comprises: a second layer (<NUM>) of additive manufacturing material (<NUM>), wherein the second layer (<NUM>) of the additive manufacturing material (<NUM>) comprises a second set of elongated fibers (<NUM>); wherein the electric field generator (<NUM>) is configured to generate a second electric field (<NUM>) across the second layer (<NUM>) of additive manufacturing material (<NUM>) and align the second set of elongated fibers (<NUM>); and wherein the energy source (<NUM>) is configured to solidify the second layer (<NUM>) of additive manufacturing material (<NUM>) and the second set of elongated fibers (<NUM>).

Preferably, the first set of elongated fibers (<NUM>) are aligned in a first direction and the second set of elongated fibers (<NUM>) are aligned in a second direction, different than the first direction.

Preferably, the elongated fibers (<NUM>) within the layer (<NUM>) of additive manufacturing material (<NUM>) comprise at least one of silicon fibers, zinc oxide fibers, polyethylene fibers, or carbon fibers.

Preferably, the energy source (<NUM>) comprises at least one of a laser or an electron beam (<NUM>).

There is disclosed an article (<NUM>) not falling under the scope of the claimed invention, produced using an additive manufacturing process, the article (<NUM>) comprising: a first layer (<NUM>) of solidified powder comprising additive manufacturing material (<NUM>) and a first set of elongated fibers (<NUM>) aligned in a first direction; and a second layer (<NUM>) of solidified powder comprising additive manufacturing material (<NUM>) and second set of elongated fibers (<NUM>) aligned in a second direction.

Preferably, the elongated fibers (<NUM>) comprise wires, microwires, nanowires, fibers, microfibers, or nanofibers.

Preferably, the article (<NUM>) comprises anisotropic mechanical, electronic, magnetic, optical, or thermal properties.

Preferably, the first direction is different than the second direction.

Preferably, the first direction aligns with the second direction.

Claim 1:
An additive manufacturing system (<NUM>) for extraction of impurities (<NUM>) in an additive manufacturing material (<NUM>), the system (<NUM>) comprising:
a container (<NUM>) within which the additive manufacturing material (<NUM>) is included, wherein the additive manufacturing material (<NUM>) is a powder or liquid;
an additive manufacturing machine (<NUM>) for manufacturing a part using the additive manufacturing material (<NUM>) included in the container (<NUM>);
a conductive plate (<NUM>) is mounted above the container (<NUM>) adjacent to the additive manufacturing material (<NUM>);
an energy source (<NUM>) configured for distributing an electric charge through the conductive plate (<NUM>) adjacent to the additive manufacturing material (<NUM>), wherein distributing the electric charge through the conductive plate (<NUM>) attracts impurities (<NUM>), which are fibers, from a top layer (<NUM>) of the additive manufacturing material (<NUM>) to the conductive plate (<NUM>), wherein the impurities (<NUM>) are light enough to lift from the additive manufacturing material (<NUM>) to the conductive plate (<NUM>) while the additive manufacturing material (<NUM>) is not attracted to the electrostatic charge and remains in the container (<NUM>);
a light source (<NUM>) for illuminating the conductive plate (<NUM>) with light;
a camera (<NUM>) for capturing image data of the conductive plate (<NUM>); and
a computing device (<NUM>) having one or more processors (<NUM>) configured to execute instructions stored in memory (<NUM>) for processing the image data to determine an amount of impurities (<NUM>) on the conductive plate (<NUM>), wherein the camera (<NUM>) is coupled to the computing device (<NUM>).