Rotating relative recoater and part orientation

Abstract

A system for additive manufacturing includes a build chamber including a sidewall and a build plate cooperating to define a build volume, wherein the build chamber is configured to house a part and unfused feedstock powder during a build. An energy source is mounted for movement relative to the build chamber, wherein the energy source is configured to selectively sinter the feedstock powder. A recoater is mounted for movement relative to the build chamber, wherein the recoater is configured to deposit successive layers of the feedstock powder for sintering to the part. A rotational actuator is in operable communication with the build chamber and the recoater configured to rotate the build chamber relative to the recoater.

Description

BACKGROUND OF THE INVENTION1. Field of the Invention[0001]The present disclosure relates to additive manufacturing, and more particularly to controlling geometries in additive manufacturing techniques such as laser powder bed fusion, electron beam additive manufacturing, and the like.2. Description of Related Art[0002]Laser powder bed fusion additive manufacturing and electron beam additive manufacturing use directed energy in conjunction with powder feedstock to form a sintered structure. The energy source, e.g., the laser beam or electron beam, excites the target material to the point of phase-change. This melt-pool process, coupled with an active toolpath effectively welds a single layer of powder feedstock into a solid state. Once one layer has been formed, a recoater pushes a thin layer of powder feedstock across the build surface and the process repeats.[0003]Build quality is often dependent on the orientation of the part with respect to the recoater. Due to the movement of th...

AI Technical Summary

Benefits of technology

The patent describes a method for reducing ripples and errors in a part during a build using a soft recoater. The controller selects an approach angle on a layer by layer basis to reduce or eliminate interactions between the recoater and a melt pool formed in the part. This results in a smoother build and reduces the likelihood of errors in the final part.

Problems solved by technology

Due to the movement of the recoater over recently fused layers of the build, the properties of the part build can be negatively affected by part orientation.

As such, part designs have to be developed knowing that certain features may build poorly and this limits the design space.

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