System and method for additive manufacturing of objects

Abstract

A system and method for additively manufacturing an object, the method comprising the steps of: (1) selectively depositing build powder inside a build contour of the object to form build powder segments of a foam layer; and (2) selectively depositing support powder outside the build contour to form support powder segments of a foam layer. According to the method, the build powder comprises a build powder composition, the support powder comprises a support powder composition, and the build powder composition and the support powder composition are different.

Description

Technical Field

[0001] This disclosure relates generally to additive manufacturing, more specifically to systems and methods for powder bed additive manufacturing, and even more specifically to powder bed additive manufacturing systems and methods for manufacturing objects having compositional gradients. Background Technology

[0002] Additive manufacturing, also known as layered manufacturing and 3D printing, is a process that joins materials to create objects, as opposed to subtractive manufacturing. Additive manufacturing has a wide range of applications, from rapid prototyping to the manufacture of end-use products. At a basic level, additive manufacturing technology is based on the concept of building materials layer by layer in a cross-sectional manner to form 3D objects. What additive manufacturing techniques have in common is the use of 3D modeling software (computer-aided design or CAD), machinery, and layered materials. Once a CAD model is generated, the machinery reads data from the CAD file and uses consecutive layers of the desired layered material to create the 3D object.

[0003] One category of additive manufacturing is powder bed additive manufacturing. Powder bed additive manufacturing uses a powder bed to bond powder layers in additive steps, thereby creating a 3D object. In powder bed additive manufacturing, powder layers in the powder bed are bonded to the underlying layers of the object to add new layers to the object. New powder layers are deposited on top of previously formed layers in the powder bed and on the object, and similarly, new powder layers are bonded to the object. This deposition and bonding process is repeated multiple times to create multiple layers on the object, ultimately forming the object.

[0004] Additive manufacturing offers several advantages over conventional manufacturing techniques. Unlike conventional manufacturing, additive manufacturing provides increased design freedom and is not limited by geometric constraints. Compared to conventional manufacturing, additive manufacturing can also simplify and reduce the costs associated with manufacturing objects. However, additive manufacturing also has some drawbacks. For example, in powder bed additive manufacturing, a large amount of powder in the powder bed is not used to form the object. This unused powder is either wasteful material or must be collected and recycled. Additionally, conventional powder bed additive manufacturing techniques may not be suitable for manufacturing objects with compositional gradients. Therefore, those skilled in the art continue research and development efforts to provide improved additive manufacturing techniques, such as powder bed additive manufacturing. Summary of the Invention

[0005] The following is a non-exhaustive list of examples of the subject matter disclosed herein, which may or may not be protected.

[0006] In one instance, the disclosed method for additively manufacturing an object includes the steps of: (1) selectively depositing build powder inside a build contour of the object to form build powder segments of a powder layer; and (2) selectively depositing support powder outside the build contour to form support powder segments of a powder layer. According to this method, the build powder comprises a build powder composition, the support powder comprises a support powder composition, and the build powder composition and the support powder composition are different.

[0007] In one example, the disclosed method for additively manufacturing an object includes the following steps: (1) selectively depositing build powder inside a build contour of the object to form build powder segments of a powder layer; (2) selectively altering the build powder composition of the build powder to achieve a powder gradient within the build powder segments of the powder layer; and (3) selectively depositing support powder outside the build contour to form support powder segments of the powder layer. According to this method, the build powder includes a build powder composition, the support powder includes a support powder composition, and the build powder composition and the support powder composition are different.

[0008] In one example, the disclosed additive manufacturing system includes a powder deposition apparatus configured to selectively deposit build powder inside a build profile to form build powder segments of a powder layer, and to selectively deposit support powder outside the build profile to form support powder segments of the powder layer. The build powder comprises a build powder composition. The support powder comprises a support powder composition. The build powder composition and the support powder composition are different.

[0009] Other examples of the disclosed systems and methods will become apparent from the following detailed description, the accompanying drawings, and the appended claims. Attached Figure Description

[0010] Figure 1 This is a flowchart illustrating an example of a method for additive manufacturing objects;

[0011] Figure 2 This is a schematic diagram of an example of an additive manufacturing system, in which the powder layer is formed by build powder and support powder;

[0012] Figure 3 This is a schematic diagram of an example of an additive manufacturing system, in which object layers are formed from build powder;

[0013] Figure 4 This is a schematic diagram of an example of an additive manufacturing system, in which the second powder layer is formed by the building powder and support powder on the underlying powder layer and the object layer;

[0014] Figure 5 This is a schematic diagram of an example of an additive manufacturing system, in which an object is fully formed;

[0015] Figure 6 This is a schematic diagram of an instance that constructs the outline;

[0016] Figure 7 This is a schematic diagram of an example of a powder layer;

[0017] Figure 8 This is a schematic diagram of an example of a powder layer supporting a powder segment formed before the powder segment is constructed;

[0018] Figure 9 This is a schematic diagram of an example of a powder layer forming a powder segment before a supporting powder segment of a powder layer;

[0019] Figure 10 This is a schematic diagram illustrating an example of an object layer formed by melting and constructing powder;

[0020] Figure 11 This is a schematic diagram of an example of an object layer formed by bonding powder.

[0021] Figure 12 This is a schematic diagram of an example of a second powder layer formed on the underlying powder layer and the object layer;

[0022] Figure 13 This is a schematic diagram of an example of a second object layer formed on top of the object layer below;

[0023] Figure 14 This is a schematic diagram of an example of a powder jetting device in an additive manufacturing system;

[0024] Figure 15 This is a schematic diagram of an example of a powder jetting device in an additive manufacturing system;

[0025] Figure 16 This is a schematic diagram of an example of a recoater for an additive manufacturing system;

[0026] Figure 17 This is a schematic diagram illustrating an example of a powder gradient formed in the powder segment of a powder layer construction.

[0027] Figure 18 This is a schematic diagram of an example of a powder jetting device in an additive manufacturing system;

[0028] Figure 19 This is a schematic diagram of an example of a second powder layer formed on the underlying powder layer, object layer, and support layer;

[0029] Figure 20 This is a schematic diagram of an example of a second object layer formed on the underlying object layer and the support layer;

[0030] Figure 21 This is a schematic diagram of an example of a second powder layer formed on the underlying powder layer, the object layer, and the intermediate support powder layer;

[0031] Figure 22 This is a schematic diagram of an example of a second object layer formed on a lower object layer and an intermediate supporting powder layer;

[0032] Figure 23 This is a schematic diagram of an example of an additive manufacturing system in which a barrier is formed;

[0033] Figure 24 This is a schematic diagram of an example of an additive manufacturing system in which a powder layer is formed within a barrier;

[0034] Figure 25 This is a schematic diagram of an example of a barrier formed by depositing wire;

[0035] Figure 26 This is a schematic diagram of an example of a powder layer formed within a barrier;

[0036] Figure 27 This is a schematic diagram of an example of a barrier formed by bonding and supporting powder;

[0037] Figure 28 This is a schematic diagram of an example of a powder layer formed within a barrier;

[0038] Figure 29 It is a flowchart of aircraft manufacturing and maintenance methods; and

[0039] Figure 30 This is a schematic block diagram of an example of an airplane. Detailed Implementation

[0040] The following detailed description refers to the accompanying drawings, which illustrate specific examples of the subject matter disclosed herein. Other examples with different structures and operations do not depart from the scope of this disclosure. In different drawings, the same reference numerals may denote the same features, elements, or components.

[0041] The following provides illustrative, non-exhaustive examples of the subject matter disclosed herein that may, but are not required to, be claimed. The reference to “example” herein means that one or more features, structures, elements, components, characteristics, and / or operating steps described in connection with an example are included in at least one aspect, implementation, and / or implementation of the subject matter disclosed herein. Therefore, the phrases “one example,” “another example,” “one or more examples,” and similar language throughout this disclosure may, but are not required to, refer to the same example. Furthermore, the subject matter characterizing any example may, but is not required to, include the subject matter characterizing any other example. Moreover, the subject matter characterizing any example may, but is not required to, be combined with the subject matter characterizing any other example.

[0042] In the following description, numerous specific details are set forth to provide a full understanding of the disclosed concepts, which can be practiced without some or all of these details. In other instances, details of known apparatuses and / or processes have been omitted to avoid unnecessarily obscuring this disclosure. While some concepts will be described in conjunction with specific examples, it will be understood that these examples are not intended to be limiting.

[0043] Overall reference Figures 1 to 28 By way of example, this disclosure relates to a method 1000 for additively manufacturing an object 100 and an additive manufacturing system 200 for additively manufacturing the object 100. According to one or more examples, method 1000 utilizes additive manufacturing system 200. In particular, method 1000 and additive manufacturing system 200 are embodiments of a powder bed additive manufacturing process for manufacturing object 100.

[0044] Object 100 refers to an object manufactured using additive manufacturing system 200 and method 1000, and includes any article, part, component or other three-dimensional structure manufactured by powder bed additive manufacturing process.

[0045] refer to Figures 2 to 5 According to additive manufacturing system 200 and method 1000, in one or more instances, powder layer 106 is formed on powder bed 144. Figure 2 In ), a portion of powder layer 106 is bonded to form object layer 134 of object 100. Figure 3 The second powder layer 126 is formed in the powder bed 144 and above the previously formed powder layer 106 and object layer 134. Figure 4 A portion of the second powder layer 126 is bonded to the object layer 134 beneath the second powder layer 126 to add a new object layer to the object 100. This forming and bonding process is repeated multiple times to form multiple object layers and ultimately produce the object 100. Figure 5 ).

[0046] This disclosure recognizes that the powder used to manufacture an object via powder bed additive manufacturing can be an expensive material, and it is desirable to reduce such powder waste. This disclosure also recognizes that a portion of the powder forming the outer contour of the object is not bonded to form a cross-sectional layer, and serves the purpose of supporting a portion of the powder used to form the cross-sectional layer of the object. This disclosure further recognizes that recovering unused portions of the powder (the portions of the powder that were not bonded during object formation) can be difficult or troublesome. Therefore, one or more embodiments of additive manufacturing system 200 and method 1000 provide techniques for selectively depositing different types of powder to form powder layers, resulting in a reduction in wasted powder used to manufacture object 100, a reduction in cost, a reduction in cycle time, and an increase in process efficiency.

[0047] refer to Figure 1 Method 1000 includes the step of selectively depositing build powder 102 within a build profile 112 of an object 100 to form a build powder segment 108 of a powder layer 106 (box 1002). The build powder 102 includes any powder material suitable for layer-by-layer bonding to manufacture the object 100. Examples of build powder 102 include, but are not limited to, metal powders, metal alloy powders, ceramic powders, polymer powders, etc.

[0048] Method 1000 further includes the step of selectively depositing support powder 104 on the exterior of build profile 112 to form support powder segments 110 of powder layer 106 (block 1004). Support powder 104 includes any powder material suitable for supporting build powder 102 without bonding to build powder 102. Examples of support powder 104 include, but are not limited to, metal powders, metal alloy powders, ceramic powders, polymer powders, etc.

[0049] The building powder 102 comprises a building powder composition, and the supporting powder 104 comprises a supporting powder composition. The building powder composition and the supporting powder composition are different. In other words, the building powder 102 and the supporting powder 104 are different types of powder layered materials. Using different types of powder materials within the powder layer 106 of the powder bed 144 allows different powder materials to be used for different purposes. According to method 1000 and additive manufacturing system 200, the building powder 102 is used to form the object layer 134, and the supporting powder 104 is used to provide a foundation against which the building powder 102 is supported during the formation of the object layer 134.

[0050] The composition of the building powder 102 is selected based on various factors, such as, but not limited to, the desired material composition of the object 100, the desired structural characteristics of the object 100, the desired functional characteristics of the object 100, and the type of bonding process used to bond the building powder 102 to manufacture the object 100. The composition of the support powder 104 is selected based on various factors, such as, but not limited to, recyclability, cost, and the type of bonding process used to bond the building powder 102 to manufacture the object 100.

[0051] In one or more instances, the type of powder material used to construct powder 102 may also be based on other factors, such as, but not limited to, the isotropy of the powder material and the resulting part (e.g., object 100) produced using the constructing powder 102; the surface roughness of the resulting part as shown in the printing; the ability of the powder material to bond with different materials; the ability to be exposed to various chemicals, fuels and cleaning agents; whether the powder material must be stored and / or handled in an inert environment; and other factors.

[0052] In one or more instances, the type of powder material used to support powder 104 may also be based on other factors, such as, but not limited to, the ability to detach or dissolve the material; the ability of the support formed on the supporting powder 104 to maintain its shape, temperature, stiffness; and other factors.

[0053] refer to Figures 2 to 5 and Figure 9 The additive manufacturing system 200 includes a powder deposition apparatus 202. The powder deposition apparatus 202 is configured to selectively deposit build powder 102 inside a build contour 112 to form build powder segments 108 of a powder layer 106. The powder deposition apparatus 202 is also configured to selectively deposit support powder 104 outside the build contour 112 to form support powder segments 110 of the powder layer 106.

[0054] In one or more instances, additive manufacturing system 200 includes a build chamber 260 and a build platform 262 within the build chamber 260. For illustrative purposes, in Figures 2 to 5 The front wall (or front track) of the build chamber 260 is omitted. A build platform 262 is provided to support the powder bed 144 and the object 100 manufactured via powder bed additive manufacturing. Figure 5 The build chamber 260 provides a peripheral boundary for the build platform 262. In one or more instances, the build chamber 260 provides a peripheral boundary for the powder bed 144. In one or more instances, a seal (not shown) contacts the build platform 262 and the build chamber 260 to ensure that the build powder 102 and the support powder 104 remain in the build chamber 260 during the formation of the object 100.

[0055] Although the illustrative example depicts the building chamber 260 and building platform 262 as square shapes with a transverse cross-section, in other examples, the building chamber 260 and building platform 262 may have any geometry with a closed cross-section, such as circular, elliptical, rectangular, etc.

[0056] like Figure 2 and Figures 6 to 9 As shown, in one or more instances, powder deposition apparatus 202 selectively deposits build powder 102 at a first location inside the build profile 112 on the build platform 262 to form build powder segments 108 of powder layer 106. Powder deposition apparatus 202 selectively deposits support powder 104 at a second location outside the build profile 112 on the build platform 262 to form support powder segments 110 of powder layer 106.

[0057] In one or more instances, method 1000 and additive manufacturing system 200 convert a three-dimensional (3D) model into two-dimensional (2D) layers. Method 1000 and additive manufacturing system 200 utilize computer numerical control (CNC) to accumulate processes to selectively deposit build-up powder 102 at a first location and selectively deposit support powder 104 at a second location, based on the pre-programmed construction shape of each 2D layer and the pre-programmed toolpath (e.g., G-code) of powder deposition equipment 202. The first location within the build-up profile 112 corresponds to the construction shape of the 2D layers of the 3D model.

[0058] refer to Figure 6 The construction profile 112 marks the boundary of the region formed by the construction powder 102 or refers to the boundary between the construction powder segment 108 and the support powder segment 110 of the powder layer 106. The construction profile 112 can have any two-dimensional geometry. Typically, the two-dimensional geometry of the construction profile 112 is approximately equal to or equal to the object profile 146 of the relevant cross-sectional layer of the object 100 (e.g., object layer 134). Figure 4 , Figure 10 and Figure 11 The object profile 146 can have any two-dimensional geometry and forms the outer boundary of the relevant cross-sectional layer of the object 100 (e.g., object layer 134). In other words, the profile 112 is constructed to correspond to the near-net shape of the relevant cross-sectional layer of the object 100.

[0059] refer to Figure 1 In one or more instances, according to method 1000, the step of selectively depositing support powder 104 (block 1004) precedes the step of selectively depositing build powder 102 (block 1002). Therefore, in one or more instances, the powder deposition apparatus 202 is configured to selectively deposit support powder 104 before selectively depositing build powder 102, as... Figure 7 and Figure 8 As shown. In these examples, the supporting powder boundary 114 of the supporting powder segment 110 of powder layer 106 forms the build profile 112, and the build powder boundary 116 of the build powder segment 108 of powder layer 106 is adjacent to the supporting powder boundary 114 of the supporting powder segment 110 of powder layer 106.

[0060] refer to Figure 1 In one or more instances, according to method 1000, the step of selectively depositing build powder 102 (block 1002) precedes the step of selectively depositing support powder 104 (block 1004). Therefore, in one or more instances, the powder deposition apparatus 202 is configured to selectively deposit build powder 102 before selectively depositing support powder 104, as... Figure 7 and Figure 9As shown. In these examples, the build powder boundary 116 of the build powder segment 108 of the powder layer 106 forms the build profile 112, and the support powder boundary 114 of the support powder segment 110 of the powder layer 106 is adjacent to the build powder boundary 116 of the build powder segment 108 of the powder layer 106.

[0061] In other instances, the steps of selectively depositing build powder 102 (box 1002) and selectively depositing support powder 104 (box 1004) occur simultaneously. Therefore, in one or more instances, the powder deposition apparatus 202 is configured to selectively deposit build powder 102 while selectively depositing support powder 104.

[0062] By selectively depositing build powder 102 at a first location inside build contour 112, build powder 102 is positioned where object layer 134 (the cross-sectional layer of object 100) needs to be formed. Similarly, by selectively depositing support powder 104 at a second location outside build contour 112, support powder 104 is positioned where support for build powder 102 is needed when forming object layer 134 of object 100.

[0063] In one or more instances, object 100 is composed of aerospace materials, such as metal alloys or fiber-reinforced resin materials. Therefore, the build powder composition of build powder 102 includes the same aerospace materials in powder form, which may be relatively scarce and / or expensive. Support powder 104 is composed of materials in powder form that are more abundant and / or cheaper. According to additive manufacturing system 200 and method 1000, the amount of build powder 102 used to form powder layer 106 is limited to the amount required to form object layer 134 (e.g., a cross-sectional layer of object 100), which reduces the amount of waste of build powder 102. Support powder 104 can be readily recycled because it will not be used to form objects in subsequent uses. In cases where support powder 104 cannot be recycled, the costs associated with the amount of waste of support powder 104 are significantly lower than the costs associated with the amount of waste of build powder 102.

[0064] refer to Figure 1 In one or more instances, method 1000 includes the step of bonding the building powder segment 108 of the powder layer 106 with the building powder 102 to form the object layer 134 (block 1006). Thus, as Figures 2 to 5 , Figure 10 and Figure 11 As shown, in one or more instances, the additive manufacturing system 200 includes a powder bonding apparatus 212. The powder bonding apparatus 212 is configured to bond the build powder 102 of the build powder segment 108 of the powder layer 106 to form an object layer 134.

[0065] refer to Figure 1 In one or more instances, according to method 1000, the step of bonding the building powder 102 of the building powder segment 108 to the powder layer 106 (block 1006) includes, for example, melting the building powder 102 of the building powder segment 108 using an energy beam 218 to form the object layer 134. Therefore, as Figure 10 As shown, in one or more instances, the powder bonding apparatus 212 includes a directional energy device 252. The directional energy device 252 is configured to generate an energy beam 218 and direct the energy beam 218 toward the build powder 102. The energy beam 218 is adapted to melt the build powder 102 of the build powder segment 108 of the powder layer 106 to form a solid cross-sectional layer (e.g., object layer 134) of the object 100.

[0066] Examples of methods 1000 and additive manufacturing systems 200 for melting build-up powder 102 using a directed energy device 252 include direct metal laser sintering (DMLS), direct metal laser melting (DMLF), selective laser sintering (SLS), selective laser melting (SLF), and electron beam melting (EBM). In these processes, the directed energy device 252 (e.g., a laser beam generator or an electron beam generator) is used to apply an energy beam 218 (e.g., a laser beam or an electron beam) that melts or sintersulates the build-up powder 102 into a solid layer of material. The type of melting process, the type of directed energy device 252 used, and / or the type of energy beam 218 used to melt the build-up powder 102 can depend on various factors, such as, but not limited to, the composition of the build-up powder 102, the object 100 being manufactured, etc.

[0067] In one or more instances, the different powder materials or different powder compositions used to construct powder 102 may have processing parameters. In one or more instances, the controller 250 ( Figures 2 to 5The system is configured to implement or otherwise execute an iterative process in program instructions (e.g., code) that control the power of energy beam 218, directional energy device 252, and other build parameters, and is configured to vary processing parameters based on the characteristics, quantity, and primary melting point of the powder components used to build powder 102. As will be described in more detail herein, in one or more instances, the build powder composition of the build powder 102 can vary within a given one of the plurality of powder layers, for example, to create a powder gradient within the powder layer. For example, the build powder 102 forming the build powder segment 108 of powder layer 106 may include various percentages of first and second components. When more (e.g., a larger percentage) of the first component is present in the build powder 102, the power required to melt the build powder 102, and therefore the temperature, can be lower than when more (e.g., a larger percentage) of the second component is present. Thus, in one or more instances, a composition ratio that binds (e.g., melts and bonds) the components may require more power and higher temperatures to build different segments of the cross-sectional layers (e.g., object layer 134) of object 100 compared to different composition ratios of the components. In one or more instances, as the composition of the building powder 102 changes, the parameters are iteratively processed by the controller 250 and a lookup table of values, at which the parameters need to be at a specific known composition level.

[0068] refer to Figure 1 In one or more instances, according to method 1000, the step (block 1006) of bonding the building powder 102 of the building powder segment 108 to the building powder layer 106 includes, for example, bonding the building powder 102 of the building powder segment 108 to the building powder 102 using an adhesive 220. Therefore, as Figure 11 As shown, in one or more instances, the powder bonding apparatus 212 includes an adhesive delivery device 254. The adhesive delivery device 254 is configured to deposit adhesive 220 onto the build powder 102. The adhesive 220 is adapted to bond the build powder 102 of the build powder segments 108 of the powder layer 106 to form a solid cross-sectional layer (e.g., object layer 134) of the object 100.

[0069] Examples of the method 1000 and additive manufacturing system 200 for bonding build-up powder 102 using adhesive delivery device 254 include adhesive jetting. In this process, adhesive delivery device 254 (e.g., an inkjet printhead) is used to apply adhesive 220 (e.g., a binder) to bond the build-up powder 102 to a layer of solid material. After the object 100 is fully formed, the object is encapsulated in support powder 104 and allowed to cure and gain strength. In one or more instances, post-processing steps may be required. For example, the object 100 may need to undergo heat treatment to improve mechanical properties and / or reduce porosity.

[0070] refer to Figures 2 to 5 In one or more instances, the build platform 262 is movable relative to the powder deposition apparatus 202 and the powder bonding apparatus 212. In one or more instances, when forming a continuous layer of object 100, the build platform 262 moves vertically (e.g., lowers) relative to the powder deposition apparatus 202 and the powder bonding apparatus 212 within the build chamber 260. In one or more instances, the build platform 262 moves horizontally relative to the powder deposition apparatus 202 during the formation of powder layer 106 and / or horizontally relative to the powder bonding apparatus 212 during the formation of object layer 134. In one or more instances, the build platform 262 rotates about a vertical axis relative to the powder deposition apparatus 202 during the formation of powder layer 106 and / or rotates about a vertical axis relative to the powder bonding apparatus 212 during the formation of object layer 134.

[0071] In one or more instances, the additive manufacturing system 200 includes a build platform actuator 280 coupled to a build platform 262 and configured to drive movement of the build platform 262. In one or more instances, the build platform actuator 280 includes a linear actuator or takes the form of a linear actuator. In one or more instances, the build platform actuator 280 includes a turntable coupled to the build platform 262.

[0072] In one or more instances, the powder deposition apparatus 202 is movable relative to the build platform 262. In one or more instances, the powder deposition apparatus 202 moves vertically (e.g., elevates) relative to the build platform 262 when forming a continuous layer of object 100. In one or more instances, the powder deposition apparatus 202 moves horizontally relative to the build platform 262 as powder layer 106 is formed. In one or more instances, the powder deposition apparatus 202 has multiple degrees of freedom to accommodate multi-axis motion for depositing build powder 102 and support powder 104 at any location on the build platform 262.

[0073] In one or more instances, the additive manufacturing system 200 includes a powder deposition actuator 282 coupled to and configured to drive movement of the powder deposition apparatus 202. In one or more instances, the powder deposition actuator 282 includes a linear actuator, a robotic actuator arm (e.g., a six-axis robotic actuator arm), or takes the form of a linear actuator, a robotic actuator arm (e.g., a six-axis robotic actuator arm), or the like.

[0074] In one or more instances, the powder bonding device 212 is movable relative to the build platform 262. In one or more instances, the powder bonding device 212 moves vertically (e.g., rises) relative to the build platform 262 when forming a continuous layer of object 100. In one or more instances, the powder bonding device 212 moves horizontally relative to the build platform 262 as object layer 134 is formed. In one or more instances, the powder bonding device 202 has multiple degrees of freedom to accommodate multi-axis motion for bonding build powder 102 at any location on the build platform 262.

[0075] In one or more instances, the additive manufacturing system 200 includes a powder bonding actuator 284 coupled to and configured to drive movement of the powder bonding apparatus 212. In one or more instances, the powder bonding actuator 284 includes a linear actuator, a robotic arm (e.g., a six-axis robotic arm), or takes the form of a linear actuator, a robotic arm (e.g., a six-axis robotic arm), or the like.

[0076] Still referencing Figures 2 to 5 In one or more instances, the additive manufacturing system 200 includes a controller 250. The controller 250 communicates with operating components of the additive manufacturing system 200 via one or more communication lines, such as wired and / or wireless communication. In one or more instances, the controller 250 is configured to generate command signals to control the operation of the powder deposition apparatus 202 and the powder bonding apparatus 212. For example, the controller 250 selectively controls the operation of the powder deposition apparatus 202 and the powder bonding apparatus 212 according to a predetermined plan (e.g., G-code) stored in the controller 250 to continuously deposit and bond build powder 102.

[0077] In one or more instances, the controller 250 is configured to selectively control the movement of the powder deposition apparatus 202 according to a build powder deposition pattern stored in the controller 250, to selectively deposit build powder 102 at a first location inside the build profile 112 and to selectively deposit support powder 104 at a second location outside the build profile 112. In one or more instances, the controller 250 is also configured to selectively adjust the composition ratio of a plurality of build powder components forming the build powder 102 distributed at different locations along the build powder deposition pattern.

[0078] In one or more instances, the additive manufacturing system 200 includes a power supply 310. The power supply 310 is configured to provide power to components of the additive manufacturing system 200 as needed. In one or more instances, the power supply 310 may be a single power supply, or it may include multiple power supplies working together to provide the necessary power output. Alternatively, the multiple power supplies may operate independently and can individually supply power to specific components of the additive manufacturing system 200. The power supply 310 may be an AC or DC power supply, or a combination of AC and DC may be utilized.

[0079] In one or more instances, controller 250 is configured to generate command signals to control the operation of powder deposition apparatus 202 and powder bonding apparatus 212. For example... Figure 2 and Figures 7 to 9 As shown, under the guidance of controller 250, powder deposition apparatus 202 moves laterally above build platform 262, thereby distributing build powder 102 and support powder 104 to form powder layer 106 according to a three-dimensional computer model of object 100 stored in memory in controller 250. Figure 3 , Figure 10 and Figure 11 As shown, after the powder layer 106 is deposited on the build platform 262, the powder bonding device 212 is activated and, under the guidance of the controller 250, moves laterally above the build platform 262 to bond selected areas of the build powder 102, thereby forming an object layer 134 on the build platform 262. After the object layer 134 is formed, the support powder 104 remains filling the area around the object layer 134.

[0080] In one or more instances, under the guidance of controller 250, platform 262 is built by indexing down one layer of thickness. For example... Figure 4 and Figure 12 As shown, under the guidance of controller 250, powder deposition apparatus 202 moves laterally above build platform 262, thereby distributing build powder 102 and support powder 104 to form a second powder layer 126 according to a 3D computer model of object 100 stored in memory in controller 250. Figure 13 As shown, after the second powder layer 126 is deposited on the build platform 262, the powder bonding device 212 is activated and, under the guidance of the controller 250, laterally moves above the build platform 262 to bond selected areas of the build powder 102, thereby forming a second object layer 148 on the build platform 262 and attaching the second object layer 148 to the previously formed underlying object layer 134. After the second object layer 148 is formed, the support powder 104 remains filled around the object layer 134 and the second object layer 148. This process is repeated under the guidance of the controller 250 until the object 100 is completed, as shown. Figure 5 As shown.

[0081] refer to Figure 1 In one or more instances, according to method 1000, the step of selectively depositing the build-up powder 102 (box 1002) includes the step of selectively discharging the build-up powder 102 using a powder injector 204. Therefore, as... Figures 2 to 5 As shown, in one or more instances, the powder deposition apparatus 202 includes a powder injector 204. The powder injector 204 is configured to selectively deposit build-up powder 102 to form build-up powder segments 108 of the powder layer 106.

[0082] In one or more instances, the powder deposition actuator 282 is coupled to the powder ejector 204 and configured to drive movement of the powder ejector 204 relative to the build platform 262. In one or more instances, the position and movement of the powder ejector 204 relative to the build platform 262 are controlled via the powder deposition actuator 282 under the guidance of the controller 250. In one or more instances, the powder deposition actuator 282 moves the powder ejector 204 to each of a first position on the build platform 262 for depositing build powder 102.

[0083] refer to Figure 14 In one or more embodiments, the powder injector 204 includes a build powder feeder 222 and a nozzle 208. The nozzle 208 is in volume communication with the build powder feeder 222, such that build powder 102 is transferred from the build powder feeder 222 to the nozzle 208. In one or more embodiments, the nozzle 208 is connected to the build powder feeder 222 via a feed line 264 such as a conduit, pipe, etc.

[0084] In one or more instances, the build powder feeder 222 is gravity-fed, causing the build powder 102 to be distributed by gravity. In one or more instances, the build powder feeder 222 is driven to distribute the build powder 102 by the force of a propellant or by the force of an actuator.

[0085] The build powder feeder 222 is configured to hold the build powder 102 and selectively dispense the build powder 102 to the nozzle 208. In one or more instances, the build powder feeder 222 includes a build powder hopper 268 and a build powder conditioner 270. The build powder hopper 268 includes any suitable structure configured to store and dispense the build powder 102. The build powder conditioner 270 is configured to selectively dispense the build powder 102 from the build powder hopper 268 to the nozzle 208, for example, via a feed line 264.

[0086] The build powder regulator 270 includes any type of regulator suitable for selectively controlling the flow of build powder 102 dispensed from the build powder hopper 268. In one or more instances, the build powder regulator 270 is configured to selectively control the amount of build powder 102 dispensed from the build powder hopper 268. Therefore, the build powder regulator 270 is capable of supplying build powder 102 to the nozzle 208 based on system requirements.

[0087] In one or more instances, the build powder regulator 270 includes a build powder valve 274. The build powder valve 274 is configured to regulate the flow of build powder 102 from the build powder hopper 268. The build powder valve 274 is configured to selectively open or selectively close. In one or more instances, the build powder valve 274 is a butterfly valve.

[0088] In one or more instances, the build powder regulator 270 includes a build powder mass sensor 276. The build powder mass sensor 276 is configured to measure the mass of build powder 102 passing through the build powder regulator 270. In one or more instances, the build powder mass sensor 276 provides online measurement, enabling accurate measurement of the amount of build powder 102 passing through the build powder valve 274.

[0089] In one or more instances, the amount of build powder 102 supplied via build powder regulator 270 can be adjusted as needed. In one or more instances, control of build powder regulator 270 is performed manually. In one or more instances, control is performed, for example, via controller 250. Figures 2 to 5 The received control signal automatically executes the control of the powder conditioner 270.

[0090] In one or more instances, the build powder regulator 270 is actively controlled under the guidance of the controller 250 to selectively dispense a predetermined amount of build powder 102 according to a predetermined plan stored in the controller 250. In one or more instances, the build powder valve 274 is an electronic valve that communicates with and is controlled by the controller 250. In one or more instances, the build powder quality sensor 276 communicates with the controller 250.

[0091] The amount of build powder 102 dispensed from the build powder feeder 222 is determined based on a number of known parameters and values. In one or more instances, the amount of build powder 102 dispensed from the build powder feeder 222 is based on the volume of build powder 102 required to form the build powder segment 108 of the powder layer 106 and the density of the build powder 102.

[0092] In one or more instances, the amount of build powder 102 dispensed from build powder feeder 222 is based on a selected area to be covered by build powder 102 (e.g., a selected location in the first position), the layer thickness (T) of powder layer 106, the average particle size of build powder 102, and the average particle density of build powder 102. Based on these parameters, the mass of build powder 102 required to form build powder segment 108 or a selected portion of build powder segment 108 at a given location in the first position can be determined. Once a predetermined mass of build powder 102 has been dispensed from build powder hopper 268 as measured by build powder mass sensor 276, build powder valve 274 is selectively closed under the guidance of controller 250.

[0093] In one or more embodiments, the powder injector 204 includes an emission regulator 286. The emission regulator 286 is configured to selectively deliver build powder 102 to or through nozzle 208. In one or more embodiments, the emission regulator 286 is configured to selectively control the rate at which build powder 102 is delivered through nozzle 208. Therefore, the emission regulator 286 is capable of delivering build powder 102 through nozzle 208 based on system requirements.

[0094] In one or more embodiments, the discharge regulator 286 includes a discharge valve 288. The discharge valve 288 is configured to regulate the flow of build powder 102 to or through nozzle 208. The discharge valve 288 is configured to selectively open, selectively close, or selectively partially open. In one or more embodiments, the discharge valve 288 is a butterfly valve. In one or more embodiments, the discharge valve 288 is integrated into nozzle 208.

[0095] In one or more instances, the discharge regulator 286 includes a mass flow sensor 278. The mass flow sensor 278 is configured to measure the mass flow rate of the build powder 102 through the discharge regulator 286. In one or more instances, the mass flow sensor 278 provides online measurement, enabling accurate measurement of the flow rate of the build powder 102 through the discharge valve 288.

[0096] In one or more instances, the flow rate of the build powder 102 can be adjusted as needed. In one or more instances, control of the emission regulator 286 is performed manually. In one or more instances, control of the emission regulator 286 is performed automatically, for example via controller 250. Figures 2 to 5 ) The received control signals.

[0097] In one or more instances, the discharge regulator 286 is actively controlled by the controller 250 to selectively dispense the build powder 102 at a predetermined flow rate according to a predetermined plan stored in the controller 250. In one or more instances, the discharge valve 288 is an electronic valve that communicates with and is controlled by the controller 250. In one or more instances, the mass flow sensor 278 communicates with the controller 250.

[0098] The flow rate of the build powder 102 delivered through and thus discharged from the nozzle 208 is determined based on several known parameters and values. In one or more instances, the flow rate of the build powder 102 discharged from the nozzle 208 is based on the volume of build powder 102 required to form the build powder segment 108 of the powder layer 106, the density of the build powder 102, the size of the nozzle 208, and the duration.

[0099] In one or more instances, the flow rate of the build powder 102 discharged from nozzle 208 is based on a selected area to be covered by the build powder 102 (e.g., at a selected location in a first position), the layer thickness (T) of the powder layer 106, the average particle size of the build powder 102, the average particle density of the build powder 102, the volume of the outlet orifice of nozzle 208, and the time required to form the build powder segment 108. Based on these parameters, the mass flow rate of the build powder 102 required to form the build powder segment 108 or a selected portion of the build powder segment 108 at a given location in the first position can be determined. During the discharge of the build powder 102 from nozzle 208, controller 250 monitors the mass flow rate of the build powder 102 as measured by mass flow sensor 278. When the measured mass flow rate of the building powder 102 deviates from the predetermined mass flow rate of the building powder 102, the discharge valve 288 selectively opens or selectively closes under the guidance of the controller 250, for example, to adjust the volume of the outlet orifice of the nozzle 208 so that the measured mass flow rate of the building powder 102 is equal to or within the predetermined mass flow rate of the building powder 102.

[0100] In one or more instances, nozzle 208 is configured to selectively discharge build-up powder 102 and guide the build-up powder 102 toward build platform 262. In one or more instances, the position and movement of nozzle 208 relative to build platform 262 are guided by controller 250 via powder deposition actuator 282. Figures 2 to 5The powder deposition actuator 282 controls the process. In one or more instances, the powder deposition actuator 282 moves the nozzle 208 to each of the first positions on the build platform 262 and to a selected (e.g., desired) distance between the nozzle 208 and the build platform 262 for discharging build powder 102. In one or more instances, the nozzle 208 is held at a selected location in the first position and at the selected distance for a predetermined time under the guidance of the controller 250 for discharging build powder 102, thereby forming a build powder segment 108 of the powder layer 106 or a selected portion of the build powder segment 108 at the selected location in the first position.

[0101] refer to Figure 1 In one or more instances, according to method 1000, the step of selectively depositing support powder 104 (block 1004) includes the step of selectively discharging support powder 104 using a powder injector 204. Therefore, as... Figures 2 to 5 As shown, in one or more instances, the powder injector 204 is configured to selectively deposit support powder 104 to form support powder segments 110 of the powder layer 106. In one or more instances, the powder deposition actuator 282 moves the powder injector 204 to each of the second positions on the build platform 262 for discharging support powder 104.

[0102] refer to Figure 15 In one or more embodiments, the powder injector 204 includes a support powder feeder 224. In one or more embodiments, a nozzle 208 is in volume communication with the support powder feeder 224, such that support powder 104 is transferred from the support powder feeder 224 to the nozzle 208. In one or more embodiments, the nozzle 208 is coupled to the support powder feeder 224 via a feed line 264 and configured to selectively discharge support powder 104.

[0103] In one or more instances, the support powder feeder 224 is gravity-fed, such that the support powder 104 is distributed by gravity. In one or more instances, the support powder feeder 224 is driven to feed, such that the support powder 104 is distributed by the force of a propellant or by the force of an actuator.

[0104] The support powder feeder 224 is configured to hold the support powder 104 and selectively dispense the support powder 104 into the nozzle 208. In one or more embodiments, the support powder feeder 224 includes a support powder hopper 296 and a support powder conditioner 298. The support powder hopper 296 includes any suitable structure configured to store and dispense the support powder 104. The support powder conditioner 298 is configured to selectively dispense the support powder 104 from the support powder hopper 296 into the nozzle 208, for example, via a feed line 264.

[0105] The support powder regulator 298 includes any type of regulator suitable for selectively controlling the flow of support powder 104 dispensed from the support powder hopper 296. In one or more instances, the support powder regulator 298 is configured to selectively control the amount of support powder 104 dispensed from the support powder hopper 296. Therefore, the support powder regulator 298 is capable of supplying support powder 104 to the nozzle 208 based on system requirements.

[0106] In one or more embodiments, the support powder regulator 298 includes a support powder valve 300. The support powder valve 300 is configured to regulate the flow of support powder 104 from the support powder hopper 296. The support powder valve 300 is configured to selectively open or selectively close. In one or more embodiments, the support powder valve 300 is a butterfly valve.

[0107] In one or more embodiments, the support powder conditioner 298 includes a support powder mass sensor 302. The support powder mass sensor 302 is configured to measure the mass of support powder 104 passing through the support powder conditioner 298. In one or more embodiments, the support powder mass sensor 302 provides online measurement, enabling accurate measurement of the amount of support powder 104 passing through the support powder valve 300.

[0108] In one or more instances, the amount of support powder 104 via support powder regulator 298 can be adjusted as needed. In one or more instances, control of support powder regulator 298 is performed manually. In one or more instances, control of support powder regulator 298 is performed automatically, for example via controller 250. Figures 2 to 5 ) The received control signals.

[0109] In one or more instances, the support powder regulator 298 is actively controlled under the guidance of the controller 250 to selectively dispense a predetermined amount of support powder 104 according to a predetermined plan stored in the controller 250. In one or more instances, the support powder valve 300 is an electronic valve that communicates with and is controlled by the controller 250. In one or more instances, the support powder quality sensor 302 communicates with the controller 250.

[0110] The amount of support powder 104 dispensed from support powder feeder 224 is determined based on a number of known parameters and values. In one or more instances, the amount of support powder 104 dispensed from support powder feeder 224 is based on the volume of support powder 104 required to form the support powder segment 110 of powder layer 106 and the density of support powder 104.

[0111] In one or more instances, the amount of support powder 104 dispensed from support powder feeder 224 is based on a selected area to be covered by support powder 104 (e.g., a selected location in the second position), the layer thickness (T) of powder layer 106, the average particle size of support powder 104, and the average particle density of support powder 104. Based on these parameters, the mass of support powder 104 required to form support powder segment 110 or a selected portion of support powder segment 110 at a given location in the second position can be determined. Once a predetermined mass of support powder 104 has been dispensed from support powder hopper 296 as measured by support powder mass sensor 302, support powder valve 300 is selectively closed under the guidance of controller 250.

[0112] In one or more embodiments, the emission regulator 286 is configured to selectively deliver the support powder 104 to or through the nozzle 208. In one or more embodiments, the emission regulator 286 is configured to selectively control the rate at which the support powder 104 is delivered through the nozzle 208. Thus, the emission regulator 286 is capable of delivering the support powder 104 through the nozzle 208 based on system requirements.

[0113] In one or more embodiments, the discharge valve 288 is configured to regulate the flow of the support powder 104 to or through the nozzle 208. In one or more embodiments, the mass flow sensor 278 is configured to measure the mass flow rate of the support powder 104 through the discharge regulator 286. In one or more embodiments, the mass flow sensor 278 provides online measurement, allowing for accurate measurement of the flow rate of the support powder 104 through the discharge valve 288. In one or more embodiments, the flow rate of the support powder 104 can be adjusted as needed.

[0114] In one or more instances, the discharge regulator 286 is actively controlled by the controller 250 to selectively distribute the support powder 104 at a predetermined flow rate according to a predetermined plan stored in the controller 250. The flow rate of the support powder 104 delivered through and thus discharged from the nozzle 208 is determined based on a number of known parameters and values. In one or more instances, the flow rate of the support powder 104 discharged from the nozzle 208 is based on the volume of support powder 104 required to form the support powder segment 110 of the powder layer 106, the density of the support powder 104, the size of the nozzle 208, and the duration.

[0115] In one or more instances, the flow rate of the support powder 104 discharged from nozzle 208 is based on a selected area to be covered by the support powder 104 (e.g., at a selected location in the second position), the layer thickness (T) of the powder layer 106, the average particle size of the support powder 104, the average particle density of the support powder 104, the volume of the outlet orifice of nozzle 208, and the time required to form the support powder segment 110. Based on these parameters, the mass flow rate of the support powder 104 required to form the support powder segment 110 or a selected portion of the support powder segment 110 at a given location in the second position can be determined. During the discharge of the support powder 104 from nozzle 208, controller 250 monitors the mass flow rate of the support powder 104 as measured by mass flow sensor 278. When the measured mass flow rate of the supporting powder 104 deviates from the predetermined mass flow rate of the supporting powder 104, the discharge valve 288 selectively partially opens or selectively partially closes under the guidance of the controller 250, for example, to adjust the volume of the outlet orifice of the nozzle 208 so that the measured mass flow rate of the supporting powder 104 is equal to or within a predetermined tolerance of the predetermined mass flow rate of the supporting powder 104.

[0116] In one or more instances, nozzle 208 is configured to selectively discharge support powder 104 and guide the support powder 104 toward build platform 262. In one or more instances, the position and movement of nozzle 208 relative to build platform 262 are guided by controller 250 via powder deposition actuator 282. Figures 2 to 5 The control is as follows: In one or more instances, the powder deposition actuator 282 moves the nozzle 208 to each of the second positions on the build platform 262, and to a selected (e.g., desired) distance between the nozzle 208 and the build platform 262 for discharging support powder 104. In one or more instances, the nozzle 208, under the guidance of the controller 250, is held at a selected location in the second position and at the selected distance for a predetermined time for discharging support powder 104, thereby forming a support powder segment 110 of the powder layer 106 or a selected portion of the support powder segment 110 at the selected location in the second position.

[0117] Nozzle 208 is any suitable powder delivery nozzle configured to discharge solid powder material. In one or more instances, nozzle 208 is a single-orifice nozzle. Nozzle 208 is configured to provide accurate and precise placement of build powder 102 at a first location inside build profile 112. In one or more instances, nozzle 208 is configured to provide accurate and precise placement of support powder 104 at a second location outside build profile 112.

[0118] Build powder 102 is discharged from nozzle 208 at a suitable velocity to allow for accurate and precise placement of build powder 102, thereby forming build powder segment 108 of powder layer 106. Support powder 104 is discharged from nozzle 208 at a suitable velocity to allow for accurate and precise placement of support powder 104, thereby forming support powder segment 110 of powder layer 106. In one or more embodiments, nozzle 208 is gravity-fed, such that build powder 102 or support powder 104 is discharged from nozzle 208 by gravity. In one or more embodiments, nozzle 208 is driven-fed, such that build powder 102 or support powder 104 is discharged from nozzle 208 by the force of a propellant or by the force of an actuator.

[0119] In one or more embodiments, the powder injector 204 includes a tank 290. The tank 290 includes any suitable structure configured to contain a gaseous propellant 294. The gaseous propellant 294 is a pressurized gas used as a propellant via a feed line 264 for discharging build powder 102 or supporting powder 104 from the nozzle 208. In one or more embodiments, the powder injector 204 includes a propellant regulator 292. The propellant regulator 292 is configured to supply the gaseous propellant 294 from the tank 290 via the feed line 264 to the nozzle 208.

[0120] The propellant regulator 292 includes any pressure or flow regulator that controls the output pressure or flow rate of a fluid to a desired value. As an example, the propellant regulator 292 includes a valve. In one or more instances, the output pressure or flow rate of the propellant regulator 292 may be adjusted based on a command signal received from the controller 250.

[0121] In one or more instances, the gaseous propellant 294 is any gaseous propellant suitable for propelling solid powder materials (e.g., building powder 102 and supporting powder 104). As an example, the gaseous propellant is an inert gas propellant. By selecting a gaseous propellant as an inert gas propellant, chemical reactions between the powder material and the gaseous propellant can be minimized or avoided. As an example, the gaseous propellant is at least one of argon, helium, and nitrogen.

[0122] In an illustrative example, powder injector 204 uses a nozzle (e.g., nozzle 208) and a regulator (e.g., discharge regulator 286) associated with and shared by both build powder feeder 222 and support powder feeder 224 to selectively deposit build powder 102 and support powder 104. However, in other examples, powder injector 204 may include more than one nozzle and / or more than one regulator, wherein each nozzle and regulator is associated with or dedicated to one of the build powder feeder 222 or support powder feeder 224 to selectively deposit build powder 102 and support powder 104.

[0123] Therefore, the use of powder injector 204 provides accurate and precise placement of build powder 102 at a first location to form a build powder segment 108 of powder layer 106, and provides accurate and precise placement of support powder 104 at a second location to form a support powder segment 110 of powder layer 106 with uniform result. In one or more instances, this placement eliminates the need for auxiliary steps, such as spreading or distributing build powder 102 or support powder 104 across build platform 262, such as by powder spreading devices (e.g., wipers or rollers), which improves processing efficiency.

[0124] refer to Figure 1 In one or more instances, according to method 1000, the step of selectively depositing support powder 104 (box 1004) includes the step of selectively discharging support powder 104 using a recoater 206. Therefore, as... Figures 2 to 5 As shown, in one or more instances, the powder deposition apparatus 202 includes a recoater 206. The recoater 206 is configured to selectively deposit support powder 104 to form support powder segments 110 of the powder layer 106.

[0125] The recoater 206 is capable of selectively depositing support powder 104 at a second location outside the build profile 112 at a faster deposition rate than the powder injector 204. Therefore, using the recoater 206 to deposit support powder 104 reduces the processing time per layer. Increasing the deposition rate of support powder 104 is particularly advantageous for applications where the majority of each powder layer is formed by support powder 104.

[0126] In one or more instances, the step of selectively depositing support powder 104 (box 1004) includes the steps of selectively dispensing support powder 104 using a recoater 206 to form a first portion of support powder segment 110 of powder layer 106 and selectively dispensing support powder 104 using a powder ejector 204 to form a second portion of support powder segment 110 of powder layer 106. For example, the recoater 206 may deposit support powder 104 on a relatively large area farther from build contour 112, and the powder ejector 204 may deposit support powder 104 on a relatively small area closer to build contour 112, where finer control over powder deposition is beneficial.

[0127] In one or more instances, a powder deposition actuator 282 is coupled to a recoater 206 and configured to drive movement of the recoater 206 relative to a build platform 262. The position and movement of the recoater 206 relative to the build platform 262 are controlled via the powder deposition actuator 282 under the guidance of a controller 250. In one or more instances, the powder deposition actuator 282 causes the recoater 206 to move linearly across the build platform 262 to discharge support powder 104 at each of two positions on the build platform 262.

[0128] refer to Figure 16 In one or more embodiments, the recoater 206 includes a support powder feeder 224 and a roller 210. The support powder feeder 224 is configured to selectively distribute support powder 104 to the roller 210. In one or more embodiments, the flow of support powder 104 from the support powder feeder 224 to the roller 210 is controlled by a support powder regulator 298 in a manner similar to that described above.

[0129] Roller 210 is configured to collect support powder 104 from support powder feeder 224 and selectively discharge support powder 104 at a second location outside build profile 112 on build platform 262 to form support powder segment 110 of powder layer 106. In one or more embodiments, roller 210 has a surface 306 with a cylindrical shape and is configured to rotate about a cylindrical axis while discharging support powder 104.

[0130] In one or more instances, the support powder 104 is selectively held onto the surface 306 of the roller 210 using adhesive forces distributed on the surface 306. The support powder 104 is selectively separated from the surface 306 by releasing the adhesion. As the roller 210 traverses the build platform 262, the separated particles of the support powder 104 are selectively deposited at a second location outside the build profile 112 on the build platform 262 to form the support powder segment 110 of the powder layer 106.

[0131] In one or more instances, the recoater 206 includes an adhesion mechanism 304. In one or more instances, the adhesion mechanism 304 is located in or as part of the roller 210. The adhesion mechanism 304 is configured to generate an adhesion force having a component perpendicular to the surface 306, under the guidance of the controller 250. The support powder feeder 224 deposits support powder 104 onto the surface 306 of the roller 210. The adhesion force acts in a radially inward direction to retain the support powder 104 on the surface 306.

[0132] In one or more embodiments, the adhesion mechanism 304 is also configured to selectively detach or release the adhesion force under the guidance of the controller 250, causing the support powder 104 to separate from the surface 306. Alternatively or additionally, in one or more embodiments, the recoater 206 includes an ejection mechanism 308. In one or more embodiments, the ejection mechanism 308 is located in or part of the roller 210. The ejection mechanism 308 is configured to generate an ejection force having a component perpendicular to the surface 306 and acting in a radially outward direction under the guidance of the controller 250. This ejection force overcomes and partially disrupts the adhesion force between the surface 306 and the support powder 104, causing the support powder 104 to selectively separate from the surface 306.

[0133] In one or more instances, the adhesion mechanism 304 is configured to selectively attach the support powder 104 to selected portions of the surface 306 of the roller 210 as the support powder 104 is deposited on the surface 306 under the guidance of the controller 250. These selected portions of the surface 306 correspond to some of the second locations on the build platform 262 traversed by the roller 210. Thus, as the roller 210 traverses the build platform 262, the entirety of the support powder 104 on the surface 306 is separated from the surface 306 by at least one of removing adhesive force or generating ejection force.

[0134] Alternatively, in one or more instances, the adhesion mechanism 304 is configured to attach the support powder 104 to the entire surface 306 of the roller as the support powder 104 is deposited on the surface 306. The adhesion mechanism 304 and / or the ejection mechanism 308 are configured to selectively separate the support powder 104 from selected portions of the surface 306 corresponding to some of the second locations on the build platform 262 as the roller 210 traverses the build platform 262. Thus, as the roller 210 traverses the build platform 262, selected portions of the support powder 104 located on the surface 306 are separated from the surface 306 by removing the adhesive force or generating an ejection force.

[0135] In one or more instances, the adhesive force used by the adhesion mechanism 304 to selectively activate and optionally selectively deactivate to attach the support powder 104 to the surface 306 of the roller 210 is at least one of magnetic force, electrostatic force, van der Waals force, negative pressure from a vacuum, positive pressure from an airflow, etc. Similarly, these same forces can be used as ejection forces, selectively activated and selectively deactivated by the ejection mechanism 308, to detach the support powder 104 from the surface 306 of the roller 210. As described above, these forces can be localized, corresponding only to certain portions of the surface 306 of the roller 210, or they can be distributed, corresponding to the entire surface 306 of the roller 210.

[0136] refer to Figure 1In one or more instances, method 1000 includes the step of selectively controlling the composition of the build powder 102 (block 1008). Thus, in one or more instances, powder injector 204 is configured to selectively control the composition of the build powder 102.

[0137] In one or more instances, according to method 1000, the steps of selectively controlling the build powder composition of build powder 102 (block 1008) and selectively depositing build powder 102 (block 1002) occur simultaneously. For example, the build powder feeder 222 is configured, under the guidance of controller 250, to selectively control the build powder composition of the build powder 102 dispensed to nozzle 208 as the build powder 102 is discharged from nozzle 208. Thus, as the powder injector 204 moves relative to the build platform 262, the build powder composition of the build powder 102 can be controlled in real time to deposit the build powder 102 at a first location within the build profile 112, thereby forming the build powder segment 108 of the powder layer 106. This real-time control of the build powder composition of the build powder 102 improves processing efficiency and reduces cycle time.

[0138] This disclosure recognizes the advantage of providing an object having a compositional gradient in one or more axial directions. This disclosure also recognizes that it may be difficult to form an object with a compositional gradient using conventional manufacturing techniques. One or more instances of additive manufacturing system 200 and method 1000 provide techniques for selectively depositing powder gradients in one or more powder layers, resulting in an object 100 having a compositional gradient that can be customized based on desired physical, chemical, electrical, thermal, and / or magnetic properties within the object 100.

[0139] refer to Figure 1 In one or more instances, the step of selectively controlling the composition of the build powder 102 (block 1008) includes selectively changing the composition of the build powder 102 to achieve a powder gradient 152 within the build powder segment 108 of the powder layer 106. Figure 17 The steps of constructing powder 102 include, in one or more instances, constructing powder 102 by mixing a first component 122 of the powder and a second component 124 of the powder. Figure 18 According to method 1000, the step of selectively controlling the composition of the building powder 102 (block 1008) includes the step of selectively controlling the composition ratio of the first component 122 and the second component 124 of the building powder in the building powder segment 108 of the powder layer 106.

[0140] Figure 17An example of a composition ratio of the percentage of the first component 122 of the building powder 102 to the percentage of the second component 124 of the building powder forming a powder gradient 152 in a building powder segment 108 of an example of powder layer 106 is shown. In the illustrative example of powder gradient 152, a first portion of the building powder segment 108 of powder layer 106 includes building powder 102 having a first building powder composition, for example, it includes 100% of the second component 124 of the building powder and 0% of the first component 122 of the building powder. A second portion of the building powder segment 108 includes building powder 102 having a second building powder composition, for example, it includes 0% of the second component 124 of the building powder and 100% of the first component 122 of the building powder. The gradient portion of the building powder segment 108 between the first and second segments forms a composition gradient region that transitions between the first and second building powder compositions in an axial direction.

[0141] The distribution of the first component 122 and the second component 124 of the building powder is not limited to the example shown. In other examples, the powder gradient 152 may have any other compositional distribution in one or more axial directions. Thus, the object layer 134 formed by bonding the building powder 102 of the building powder segment 108 of the powder layer 106 having the powder gradient 152 includes a compositional gradient corresponding to the powder gradient 152 in one or more axial directions. Furthermore, in various examples, the powder gradient 152 is formed by a compositional ratio of any number (e.g., two or more) of the building powder components.

[0142] This illustrative example depicts one of a plurality of consecutive powder layers joined together to form a plurality of object layers of object 100. In one or more examples, the powder gradient 152 of each of the plurality of powder layers is identical, such that the composition of object 100 is substantially the same across its entire thickness. In these examples, object 100 may have a composition gradient along the X-axis and / or the Y-axis. In one or more examples, the powder gradient 152 of one or more of the plurality of powder layers is different, such that the composition of object 100 varies across its entire thickness. In these examples, object 100 may have a composition gradient along the X-axis and / or the Y-axis and Z-axis.

[0143] In one or more instances, each powder layer's building powder segment 108 consists of only one building powder composition; however, the building powder composition varies between successive powder layers. In these instances, the object 100 may have a compositional gradient along the Z-axis.

[0144] refer to Figure 18In one or more instances, the powder injector 204 is configured to selectively alter the build powder composition of the build powder 102 to achieve a powder gradient 152 within the build powder segment 108 of the powder layer 106. In one or more instances, the build powder feeder 222 includes a first build powder component feeder 226 and a second build powder component feeder 228. The first build powder component feeder 226 is configured to selectively dispense a first build powder component 122. The second build powder component feeder 228 is configured to selectively dispense a second build powder component 124.

[0145] The build powder feeder 222 also includes a mixer 230. The mixer 230 is in volume communication with the build powder first component feeder 226 and the build powder second component feeder 228, such that build powder first component 122 and build powder second component 124 are transferred to the mixer 230. In one or more embodiments, the mixer 230 is coupled to the build powder first component feeder 226 and the build powder second component feeder 228 via a feed line 264. The mixer 230 is configured to mix the build powder first component 122 and the build powder second component 124 together to form build powder 102 having a predetermined build powder composition. The mixer 230 is also configured to contain the build powder 102 and selectively dispense the build powder 102 to the nozzle 208.

[0146] In one or more instances, according to method 1000, the step of selectively controlling the composition ratio of the first component 122 of the building powder and the second component 124 of the building powder (block 1008) includes the steps of selectively distributing a first mass of the first component 122 of the building powder and selectively distributing a second mass of the second component 124 of the building powder. Selectively distributing predetermined masses of each of the first component 122 of the building powder and the second component 124 of the building powder provides building powder 102 having a predetermined (e.g., desired) building powder composition.

[0147] In one or more instances, the first component powder feeder 226 and the second component powder feeder 228 are gravity-fed, such that the first component powder 122 and the second component powder 124 are distributed by gravity. In one or more instances, the first component powder feeder 226 and the second component powder feeder 228 are driven to feed, such that the first component powder 122 and the second component powder 124 are distributed by the force of a propellant or by the force of an actuator.

[0148] The build powder first component feeder 226 is configured to hold the build powder first component 122 and selectively dispense the build powder first component 122 to the mixer 230. In one or more instances, the build powder first component feeder 226 includes a build powder first component hopper 312 and a build powder first component regulator 232. The build powder first component hopper 312 includes any suitable structure configured to store and dispense the build powder first component 122. The build powder first component regulator 232 is configured to selectively dispense the build powder first component 122 from the build powder first component hopper 312 to the mixer 230, for example, via a feed line 264.

[0149] The build powder first component regulator 232 includes any type of regulator suitable for selectively controlling the flow of build powder first component 122 dispensed from the build powder first component hopper 312. In one or more instances, the build powder first component regulator 232 is configured to selectively control the amount of build powder first component 122 dispensed from the build powder first component hopper 312. Therefore, the build powder first component regulator 232 is capable of supplying build powder first component 122 to the mixer 230 based on system requirements.

[0150] In one or more instances, the build powder first component regulator 232 includes a build powder first component valve 236. The build powder first component valve 236 is configured to regulate the flow of build powder first component 122 from the build powder first component hopper 312. The build powder first component valve 236 is configured to selectively open or selectively close. In one or more instances, the build powder first component valve 236 is a butterfly valve.

[0151] In one or more instances, the build powder first component regulator 232 includes a build powder first component mass sensor 238. The build powder first component mass sensor 238 is configured to measure a first mass of build powder first component 122 passing through the build powder first component regulator 232. In one or more instances, the build powder first component mass sensor 238 provides online measurement, enabling accurate measurement of the amount of build powder first component 122 passing through the build powder first component valve 236.

[0152] In one or more instances, the amount of the first component of the building powder 122 can be adjusted as needed via the first component regulator 232. In one or more instances, control of the first component regulator 232 is performed manually. In one or more instances, control of the first component regulator 232 is performed automatically, for example via a controller 250. Figures 2 to 5 ) The received control signals.

[0153] In one or more instances, the build powder first component regulator 232 is actively controlled under the guidance of controller 250 to selectively dispense a predetermined amount of build powder first component 122 according to a predetermined plan stored in controller 250. In one or more instances, the build powder first component valve 236 is an electronic valve that communicates with and is controlled by controller 250. In one or more instances, the build powder first component mass sensor 238 communicates with controller 250.

[0154] The amount of first component of the build powder 122 dispensed from the first component of the build powder feeder 226 is determined based on a number of known parameters and values. In one or more instances, the amount of first component of the build powder 122 dispensed from the first component of the build powder feeder 226 is based on the volume of the first component of the build powder 122 required to form the build powder segment 108 of the powder layer 106 and the density of the first component of the build powder 122.

[0155] In one or more instances, the amount of first component of the building powder 122 dispensed from the first component of the building powder feeder 226 is based on a selected area to be covered by the building powder 102 (e.g., a selected location in a first position), the layer thickness (T) of the powder layer 106, the average particle size of the first component of the building powder 122, the average particle density of the first component of the building powder 122, and the percentage composition of the first component of the building powder 122 in the building powder 102. Based on these parameters, a first mass of the first component of the building powder 122 required to form a selected portion of the building powder segment 108 or the building powder segment 108 at a given location in the first position can be determined. Once a predetermined first mass of the first component of the building powder 122 has been dispensed from the first component of the building powder hopper 312 as measured by the first component of the building powder mass sensor 238, the first component of the building powder valve 236 is selectively closed under the guidance of the controller 250.

[0156] The second component of the building powder feeder 228 is configured to hold the second component of the building powder 124 and selectively dispense the second component of the building powder 124 to the mixer 230. In one or more instances, the second component of the building powder feeder 228 includes a second component of the building powder hopper 314 and a second component of the building powder regulator 234. The second component of the building powder hopper 314 includes any suitable structure configured to store and dispense the second component of the building powder 124. The second component of the building powder regulator 234 is configured to selectively dispense the second component of the building powder 124 from the second component of the building powder hopper 314 to the mixer 230, for example, via a feed line 264.

[0157] The second component of the building powder regulator 234 includes any type of regulator suitable for selectively controlling the flow of the second component of the building powder 124 dispensed from the second component of the building powder hopper 314. In one or more instances, the second component of the building powder regulator 234 is configured to selectively control the amount of the second component of the building powder 124 dispensed from the second component of the building powder hopper 314. Therefore, the second component of the building powder regulator 234 is capable of supplying the second component of the building powder 124 to the mixer 230 based on system requirements.

[0158] In one or more instances, the construct powder second component regulator 234 includes a construct powder second component valve 244. The construct powder second component valve 244 is configured to regulate the flow of construct powder second component 124 from the construct powder second component hopper 314. The construct powder second component valve 244 is configured to selectively open or selectively close. In one or more instances, the construct powder second component valve 244 is a butterfly valve.

[0159] In one or more instances, the build powder second component regulator 234 includes a build powder second component mass sensor 246. The build powder second component mass sensor 246 is configured to measure a second mass of the build powder second component 124 passing through the build powder second component regulator 234. In one or more instances, the build powder second component mass sensor 246 provides online measurement, enabling accurate measurement of the amount of build powder second component 124 passing through the build powder second component valve 244.

[0160] In one or more instances, the amount of the second component of the building powder 124 can be adjusted as needed via the second component regulator 234. In one or more instances, control of the second component regulator 234 is performed manually. In one or more instances, control of the second component regulator 234 is performed automatically, for example via a controller 250. Figures 2 to 5 ) The received control signals.

[0161] In one or more instances, the build powder second component regulator 234 is actively controlled under the guidance of controller 250 to selectively dispense a predetermined amount of build powder second component 124 according to a predetermined plan stored in controller 250. In one or more instances, the build powder second component valve 244 is an electronic valve that communicates with and is controlled by controller 250. In one or more instances, the build powder second component mass sensor 246 communicates with controller 250.

[0162] The amount of second component of the building powder 124 dispensed from the second component of the building powder feeder 228 is determined based on a number of known parameters and values. In one or more instances, the amount of second component of the building powder 124 dispensed from the second component of the building powder feeder 228 is based on the volume of the second component of the building powder 124 required to form the building powder segment 108 of the powder layer 106 and the density of the second component of the building powder 124.

[0163] In one or more instances, the amount of second component of the building powder 124 dispensed from the second component of the building powder feeder 228 is based on a selected area to be covered by the building powder 102 (e.g., a selected location in the first position), the layer thickness (T) of the powder layer 106, the average particle size of the second component of the building powder 124, the average particle density of the second component of the building powder 124, and the percentage composition of the second component of the building powder 124 in the building powder 102. Based on these parameters, a second mass of the second component of the building powder 124 required to form a segment 108 or a selected portion of a segment 108 at a given location in the first position can be determined. Once a predetermined second mass of the second component of the building powder 124 is dispensed from the second component of the building powder hopper 314 as measured by the second component of the building powder mass sensor 246, the second component of the building powder valve 244 is selectively closed under the guidance of the controller 250.

[0164] In one or more instances, the step of selectively controlling the composition ratio of the first component 122 and the second component 124 of the building powder (block 1008) further includes monitoring the quality of the building powder 102 formed from the first component 122 and the second component 124 of the building powder with the predetermined and selectively controlled composition ratio. Monitoring the quality of the building powder 102 formed from the first component 122 and the second component 124 of the building powder serves as a quality control measurement, which verifies whether the actual building powder composition of the building powder 102 is equal to or within the expected (e.g., predetermined) building powder composition of the building powder 102.

[0165] like Figure 18 As shown, in one or more embodiments, the build powder feeder 222 includes a mixer regulator 316. The mixer regulator 316 is configured to selectively distribute build powder 102 to nozzle 208. In one or more embodiments, the mixer regulator 316 includes a mixer valve 318. The mixer valve 318 is configured to regulate the flow of build powder 102 to nozzle 208. The mixer valve 318 is configured to selectively open or selectively close. In one or more embodiments, the mixer valve 318 is a butterfly valve. In one or more embodiments, the mixer valve 318 is an electronic valve that communicates with and is controlled by a controller 250.

[0166] In one or more instances, the mixer regulator 316 includes a mixer mass sensor 320. The mixer mass sensor 320 is configured to measure the mass of the build powder 102 passing through the mixer regulator 316. In one or more instances, the mixer mass sensor 320 provides online measurement, allowing for accurate measurement of the mass of the build powder 102 passing through the mixer valve 318. In one or more instances, the mixer mass sensor 320 communicates with the controller 250.

[0167] In one or more instances, the mass of the build powder 102 formed from the first component of the build powder 122 and the second component of the build powder 124, as measured by the mixer mass sensor 320, is provided to the controller 250. Figures 2 to 5 The controller monitors the quality of the build powder 102 dispensed from the mixer 230. When the measured quality of the build powder 102 having the actual build powder composition deviates from the desired (e.g., predetermined) quality of the build powder 102 having a predetermined build powder composition, a selected one of the build powder first component regulator 232 or the build powder second component regulator 234 selectively dispenses an additional quality of one of the build powder first component 122 or the build powder second component 124 under the guidance of the controller 250 to adjust the build powder composition of the build powder 102 such that the measured quality of the build powder 102 is equal to or within the acceptable tolerance of the desired quality of the build powder 102.

[0168] In one or more instances, the step of selectively controlling the composition ratio of the first component 122 and the second component 124 of the building powder (block 1008) further includes the step of selectively controlling a first mass flow rate of the first component 122 of the building powder and a second mass flow rate of the second component 124 of the building powder. Selectively dispensing each of the first component 122 and the second component 124 of the building powder at a predetermined mass flow rate provides building powder 102 having a predetermined (e.g., desired) building powder composition, and serves as another quality control measure to ensure that the actual building powder composition of building powder 102 is equal to the desired (e.g., predetermined) building powder composition of building powder 102 or within its permissible tolerances.

[0169] like Figure 18 As shown, in one or more embodiments, the build powder first component regulator 232 includes a build powder first component mass flow sensor 240. The build powder first component mass flow sensor 240 is configured to measure a first mass flow rate of the build powder first component 122 through the build powder first component regulator 232. In one or more embodiments, the build powder first component mass flow sensor 240 provides online measurement, enabling accurate measurement of the first mass flow rate of the build powder first component 122 through the build powder first component valve 236.

[0170] The first mass flow rate of the first component of the build powder 122, which is conveyed by the first component of the build powder regulator 232 and thus distributed from the first component of the build powder feeder 226, is determined based on a number of known parameters and values. In one or more instances, the first mass flow rate of the first component of the build powder 122 distributed from the first component of the build powder feeder 226 is based on the first mass of the first component of the build powder 122, the volume of the first component of the build powder 122 required to form the build powder segment 108 of the powder layer 106, the density of the first component of the build powder 122, the size of the first component of the build powder valve 236, and the duration.

[0171] In one or more instances, the first mass flow rate of the first component of the build powder 122 dispensed from the first component of the build powder feeder 226 is based on the first mass of the first component of the build powder 122 required for the desired build powder composition of the build powder 102, the selected area to be covered by the build powder 102 (e.g., at a selected location in the first position), the layer thickness (T) of the powder layer 106, the average particle size of the first component of the build powder 122, the average particle density of the first component of the build powder 122, the volume of the outlet orifice of the first component of the build powder valve 236, and the time required to dispense the first mass of the first component of the build powder 122. Based on these parameters, the first mass flow rate of the first component of the build powder 122 required to achieve the desired build powder composition of the build powder 102 to form a build powder segment 108 or a selected portion of the build powder segment 108 at a given location in the first position can be determined. During the discharge of the first component of the build powder 122 from the first component of the build powder regulator 232, the controller 250 monitors the mass flow rate of the first component of the build powder 122, as measured by the first component of the build powder mass flow sensor 240. When the measured mass flow rate of the first component of the building powder 122 deviates from the predetermined mass flow rate of the first component of the building powder 122, the first component of the building powder valve 236 is selectively partially opened or selectively partially closed under the guidance of the controller 250, for example, to adjust the volume of the outlet orifice of the first component of the building powder valve 236 so that the measured mass flow rate of the first component of the building powder 122 is equal to or within the predetermined mass flow rate of the first component of the building powder 122.

[0172] In one or more instances, the build powder second component regulator 234 includes a build powder second component mass flow sensor 248. The build powder second component mass flow sensor 248 is configured to measure a second mass flow rate of the build powder first component 122 through the build powder second component regulator 234. In one or more instances, the build powder second component mass flow sensor 248 provides online measurement, enabling accurate measurement of the second mass flow rate of the build powder second component 124 through the build powder second component valve 244.

[0173] The second mass flow rate of the second component of the build powder 124, delivered by the second component of the build powder regulator 234 and thus distributed from the second component of the build powder feeder 228, is determined based on a number of known parameters and values. In one or more instances, the second mass flow rate of the second component of the build powder 124 distributed from the second component of the build powder feeder 228 is based on the second mass of the second component of the build powder 124, the volume of the second component of the build powder 124 required to form the build powder segment 108 of the powder layer 106, the density of the second component of the build powder 124, the size of the second component of the build powder valve 244, and the duration.

[0174] In one or more instances, the second mass flow rate of the second component of the building powder 124 dispensed from the second component of the building powder feeder 228 is based on the second mass of the second component of the building powder 124 required for the desired building powder composition of the building powder 102, the selected area to be covered by the building powder 102 (e.g., at a selected location in the first position), the layer thickness (T) of the powder layer 106, the average particle size of the second component of the building powder 124, the average particle density of the second component of the building powder 124, the volume of the outlet orifice of the second component of the building powder valve 244, and the time required to dispense the second mass of the second component of the building powder 124. Based on these parameters, the second mass flow rate of the second component of the building powder 124 required to achieve the desired building powder composition of the building powder 102 to form a segment 108 or a selected portion of the segment 108 at a given location in the first position can be determined. During the discharge of the second component of the building powder 124 from the second component of the building powder regulator 234, the controller 250 monitors the mass flow rate of the second component of the building powder 124, as measured by the second component of the building powder mass flow sensor 248. When the measured mass flow rate of the second component of the building powder 124 deviates from the predetermined mass flow rate of the second component of the building powder 124, the second component of the building powder valve 244 is selectively partially opened or selectively partially closed under the guidance of the controller 250, for example, to adjust the volume of the outlet orifice of the second component of the building powder valve 244 such that the measured mass flow rate of the second component of the building powder 124 is equal to or within the predetermined mass flow rate of the second component of the building powder 124.

[0175] Therefore, the mass flow rates of the first component 122 and the second component 124 of the building powder can be adjusted as needed. In one or more instances, control of the first component regulator 232 and the second component regulator 234 of the building powder is performed manually. In one or more instances, control of the first component regulator 232 and the second component regulator 234 of the building powder is performed automatically, for example via a controller 250. Figures 2 to 5 The controller receives control signals. In one or more instances, the first component regulator 232 and the second component regulator 234 of the build powder are actively controlled by the controller 250 to selectively distribute the first component 122 and the second component 124 of the build powder at a predetermined mass flow rate according to a predetermined plan stored in the controller 250. In one or more instances, the first component valve 236 and the second component valve 244 of the build powder are electronic valves that communicate with and are controlled by the controller 250. In one or more instances, the first component mass flow sensor 240 and the second component mass flow sensor 248 of the build powder communicate with the controller 250.

[0176] As described above, in one or more instances, the emission regulator 286 is configured to selectively control the rate at which the build powder 102, formed from a mixture of build powder first component 122 and build powder second component 124, is delivered through nozzle 208 to form the build powder segment 108 of powder layer 106.

[0177] Therefore, the combination of simultaneously measuring and selectively controlling mass and mass flow rate provides real-time control over the build powder composition of build powder 102 and the deposition of build powder 102 to form build powder segments 108 of powder layer 106. In one or more exemplary embodiments of additive manufacturing system 200 and method 1000, the desired layer thickness (T) of powder layer 106 and the percentage composition of each build powder component (e.g., build powder first component 122 and build powder second component 124) are provided as inputs to controller 250. For a given powder gradient 152, the percentage composition of each build powder component (e.g., first build powder component) at the start of the pre-programmed tool path of powder injector 204 and the percentage composition of each build powder component (e.g., second build powder component) at the end of the pre-programmed tool path of powder injector 204 are provided as inputs to controller 250. Controller 250 is configured to mathematically iterate multiple points between the start and end points to provide the percentage composition of each build powder component through the gradient region during the deposition of build powder 102.

[0178] In one or more instances, the component mass of each build powder component (e.g., the first mass of build powder first component 122 and the second mass of build powder second component 124) is a known value based on its unique material density. In one or more instances, the material densities of the various build powder components are stored in a material lookup table accessible by controller 250. The mass of build powder 102 is measured prior to deposition to determine the average density of the resulting mixture of build powder components (e.g., build powder first component 122 and build powder second component 124). Based on the measured mass of build powder 102, the actual build powder composition of build powder 102 can be electronically adjusted in real time to achieve a desired (e.g., predetermined) build powder composition. The mass per unit volume of each build powder component is a known value based on the average particle size, and the outlet volume at the discharge point (e.g., at discharge regulator 286 or nozzle 208) is also a known value. The mass flow rate of build powder 102 is measured during deposition. When the measured mass flow rate of the build powder 102 is not 1:1 related to the average particle density, the controller 250 uses a feedback loop to iterate the process parameters, so that the controller 250 automatically adjusts the amount of build powder components (e.g., build powder first component 122 and build powder second component 124) to achieve the desired build powder composition.

[0179] Therefore, controller 250 utilizes machine learning or artificial intelligence to actively control the build powder composition of build powder 102 during the deposition of build powder 102 to form build powder segments 108 of powder layer 106. This active control also serves as quality control. By using controller 250, for example, an automated and iterative process is performed to determine optimized build parameters and material composition at any time and / or any point in the construction of each object layer.

[0180] Therefore, in one or more instances, controller 250 is a feedback controller that uses sensor data, such as from various quality sensors and mass flow sensors, along with a feedback control algorithm, to generate multiple commands to control the build powder composition and deposition rate of build powder 102. For example, quality is verified through real-time computational iterations and adjustments in analytical models and equations executed by controller 250, serving as a continuous quality control check for the expected composition of build powder 102.

[0181] The combination of varying parameters creates an iterative multivariable feedback algorithm used by controller 250. As an example, controller 250 may employ one or more of the following relationships during the execution of the feedback control algorithm.

[0182] Mf p =(ρ p *V e ) / t

[0183] M fp It is the mass flow rate of powder particles at the outlet orifice.

[0184] ρ p It is the average density of the powder particles.

[0185] V e It is the volume of powder at the outlet or discharge port.

[0186] t represents time.

[0187] In one example, the mass flow rate of the build powder 102 corresponds to the mass flow rate of the particles of the build powder 102 at the outlet orifice (e.g., the discharge orifice) of the nozzle 208 or the discharge regulator 286. In another example, the mass flow rate of any build powder component corresponds to the mass flow rate of the particles of the build powder component at the outlet orifice (e.g., the discharge orifice) of a build powder component regulator associated with the build powder component.

[0188] In one or more instances, the average density of the particles (ρ) p It is determined based on the percentage composition of the components of the powder that form the powder.

[0189] ρ p =(%Wt) m1 *ρ m1 )+[1-(%Wt m1 )*ρ m2 ]

[0190] %Wt m1 It is the weight percentage of the first component (e.g., the first component 122 of the powder) in the powder-forming process.

[0191] ρ m1 It is the average density of the particles of the first component in the powder-forming structure (e.g., the first component 122 of the powder-forming structure).

[0192] ρ m2 It is the average density of the particles of the second component (e.g., the second component 124 of the powder) in the powder-forming structure.

[0193] The illustrative example depicts a build powder 102 formed from a mixture of two build powder components (e.g., build powder first component 122 and build powder second component 124), thus the powder gradient 152 includes a gradient region that varies the percentage composition of the two build powder components. In other examples, the build powder 102 is formed from two or more build powder components, thus the powder gradient 152 includes a gradient region that varies the percentage composition of the two or more build powder components.

[0194] refer to Figure 18 In one or more instances, the build powder 102 comprises a mixture of a first build powder component 122, a second build powder component 124, and any number of build powder additives 154. Therefore, the powder injector 204 includes any number of build powder additive feeders 322 for conveying the various build powder additives 154 to the mixer 230. Each of these multiple build powder additive feeders 322 includes a build powder additive hopper 324 and a build powder additive regulator 326 that perform the functions described above.

[0195] Therefore, the average particle density (ρ) used in the feedback control algorithm p It is scalable to account for the various building powder additives 154.

[0196] Therefore, for the three building powder components, the average density is calculated using the following formula:

[0197] ρ p =(%Wt) m1 *ρ m1 )+[1-(%Wt m1 +%Wt m3 )*ρ m2 ]+[1-(%Wt m1 +%Wt m2 )*ρ m3 ]

[0198] %Wt m3 It is the weight percentage of a third component (e.g., one of the component powder additives 154) in the powder-forming structure.

[0199] ρ m3 It is the average density of the particles of the third type (e.g., one of the powder additives 154) in the powder-forming components.

[0200] This same measurement procedure can be applied to any composition of the building powder 102, or to any quantity of the building powder components required or desired.

[0201] refer to Figure 1 The operation steps of depositing and bonding powders in method 1000 can be repeated multiple times to form multiple consecutive powder layers, thereby producing multiple consecutive object layers and ultimately forming object 100 (box 1010).

[0202] In one or more instances, method 1000 includes the step of selectively depositing builder powder 102 within a second builder profile 132 of an object 100 to form a second builder powder segment 128 of a second powder layer 126. Method 1000 also includes the step of selectively depositing support powder 104 outside the second builder profile 132 to form a second support powder segment 130 of the second powder layer 126. Method 1000 further includes the step of bonding the builder powder 102 to the second builder powder segment 128 of the second powder layer 126 to form a second object layer 148.

[0203] refer to Figure 12 and Figure 13 In one or more instances, powder deposition apparatus 202 ( Figures 2 to 5 For example, powder injector 204 ( Figure 14 , Figure 15 and Figure 18 The powder deposition apparatus 202 is configured to selectively deposit buildable powder 102 within a second buildable profile 132 to form a second buildable powder segment 128 of powder layer 106. Figures 2 to 5 For example, powder injector 204 ( Figure 14 , Figure 15 and Figure 18 ) and / or recoater 206 ( Figure 16 The second support powder segment 130 is configured to selectively deposit support powder 104 on the exterior of the second build profile 132 to form the second powder layer 126. In one or more instances, the powder bonding device 212, such as the directional energy device 252, is configured to selectively deposit support powder 104 on the exterior of the second build profile 132 to form the second support powder segment 130 of the second powder layer 126. Figure 10 ) or adhesive delivery device 254 ( Figure 11 The building powder 102 is configured to bond the second building powder segment 128 of the second powder layer 126 to form the second object layer 148.

[0204] In one or more instances, the building powder 102 and the support powder 104 are deposited in substantially the same manner as described above with respect to powder layer 106 to form a second powder layer 126. In one or more instances, the building powder 102 of the second powder layer 126 is bonded in substantially the same manner as described above with respect to object layer 134 to form a second object layer 148.

[0205] In one or more instances, such as Figure 12 and Figure 13As shown, the construction profile 112 of powder layer 106 and the second construction profile 132 of second powder layer 126 are identical. Therefore, the object profile 146 of object layer 134 and the second object profile 150 of second object layer 148 are identical. In these examples, the second object layer 148 is integrally bonded to the previously formed object layer 134 and located below the second object layer 148.

[0206] refer to Figures 19 to 22 In one or more instances, the construction outline 112 and the second construction outline 132 are different. Therefore, the object outline 146 of object layer 134 and the second object outline 150 of object layer 148 are different.

[0207] According to method 1000, in one or more instances, the step of selectively depositing builder powder 102 inside the second builder profile 132 causes a first portion of the second builder powder segment 128 of the second powder layer 126 to lie on the previously formed underlying object layer 134 and a second portion of the second builder powder segment 128 of the second powder layer 126 to lie on the previously formed underlying support powder segment 110 of the powder layer 106. In these instances, the first portion of the second object layer 148 is integrally bonded to the previously formed object layer 134 located below the first portion of the second object layer 148, and the second portion of the second object layer 148 is supported by the support powder segment 110 below the powder layer 106.

[0208] In one or more instances, the supporting powder 104 of the supporting powder segment 110 of powder layer 106 may not adequately support the second portion of the second object layer 148. (See reference) Figure 19 and Figure 20 In one or more instances, method 1000 includes the step of consolidating a portion of the support powder segment 110 of powder layer 106 with support powder 104 to form support layer 136 (block 1012). According to method 1000, in one or more instances, the step of selectively depositing builder powder 102 inside the second builder profile 132 causes a second portion of the second builder powder segment 128 of the second powder layer 126 to lie on the previously formed and underlying support layer 136 and a first portion of the second builder powder segment 128 of the second powder layer 126 to lie on the previously formed and underlying object layer 134. In these instances, a first portion of the second object layer 148 is integrally bonded to the previously formed object layer 134 located below the first portion of the second object layer 148, and the second portion of the second object layer 148 is supported by the underlying support layer 136. Support layer 136 advantageously provides a stable, solid structure capable of adequately supporting the second portion of the second object layer 148.

[0209] In one or more instances, it may be advantageous to prevent a second portion of the second object layer 148 from engaging with the previously formed and underlying support layer 136. (See reference) Figure 21 and Figure 22 In one or more instances, method 1000 includes the step of selectively depositing support powder 104 inside the second build contour 132 to form an intermediate support powder layer 138 on the support layer 136 (block 1014). Thus, the step of selectively depositing support powder 104 inside the second build contour 132 to form the intermediate support powder layer 138 precedes the step of selectively depositing build powder 102 inside the second build contour 132 to form a second build powder segment 128 of the second powder layer 126. According to method 1000, the step of selectively depositing support powder 104 inside the second build contour 132 positions the intermediate support powder layer 138 on the support layer 136. The step of selectively depositing build powder 102 inside the second build contour 132 positions a second portion of the second build powder segment 128 of the second powder layer 126 on the previously formed and underlying intermediate support powder layer 138, and positions a first portion of the second build powder segment 128 of the second powder layer 126 on the previously formed and underlying object layer 134. In these examples, a first portion of the second object layer 148 is integrally bonded to a previously formed object layer 134 located below the first portion of the second object layer 148, and a second portion of the second object layer 148 is supported by a combination of an underlying support layer 136 and an intermediate support powder layer 138. The intermediate support powder layer 138 advantageously prevents the second portion of the second object layer 148 from becoming bonded to the previously formed, underlying support layer 136.

[0210] In one or more instances, the thickness of the intermediate support powder layer 138 is a portion of the thickness of a given powder layer. Thus, the support layer 136 provides structural support for a portion of a continuous, covering object layer, and the intermediate support powder layer 138 provides a buffer between the object layer and the support layer 136 without altering the constructed shape of the object 100.

[0211] According to method 1000, in one or more instances, the step of selectively controlling the composition of the building powder 102 (block 1008) is applied to the second building powder segment 128 forming the second powder layer 126. For example, the step of selectively controlling the composition of the building powder 102 (block 1008) and the step of selectively depositing the building powder 102 occur simultaneously. In one or more instances, the composition of the building powder 102 used to form the second building powder segment 128 of the second powder layer 126 is controlled in substantially the same manner as described above with respect to the building powder segment 108 of the powder layer 106.

[0212] Therefore, in one or more embodiments, the additive manufacturing system 200 and method 1000 are used to form a plurality of powder layers, wherein at least one of the plurality of powder layers has a compositional gradient. In one or more embodiments, the additive manufacturing system 200 and method 1000 are used to form a plurality of cross-sectional object layers of an object 100, wherein at least one of the plurality of object layers has a compositional gradient. In one or more embodiments, the additive manufacturing system 200 and method 1000 are used to manufacture an object 100, wherein the object 100 has a compositional gradient.

[0213] In one or more instances, the composition gradient within a given powder layer and thus the composition gradient within a given object layer and the composition gradient of object 100 are controlled under the guidance of the controller 250 according to a predetermined plan stored in the controller 250.

[0214] refer to Figure 1In one or more instances, method 1000 includes the step of determining characteristic data of object 100 (box 1016). In one or more instances, the characteristic data represents a two-dimensional distribution of at least one desired material property of object 100 corresponding to a two-dimensional cross-sectional layer of object 100. For example, the characteristic data is obtained from a three-dimensional model representing the distribution of at least one desired material property of object 100, and the three-dimensional model is converted into a two-dimensional layer. In one or more instances, the characteristic data represents a three-dimensional distribution of the at least one desired material property of object 100. For example, the characteristic data is obtained from a three-dimensional model representing the distribution of the at least one desired material property of object 100, and the three-dimensional model is converted into multiple two-dimensional layers. In one or more instances, method 1000 includes the step of determining or generating composition data of build powder segments for deposition to form each of multiple powder layers of object 100 (box 1018). In one or more instances, the composition data represents a two-dimensional distribution of the build powder composition of the build powder segments of the powder layers. The two-dimensional distribution of the build powder composition is mapped to the two-dimensional distribution of the at least one material property of object 100. In these examples, the step of selectively controlling the composition ratio of the build powder 102 (block 1008) includes adjusting the composition ratio of multiple build powder components based on a two-dimensional distribution of the build powder composition of the build powder segments of the powder layer. In one or more examples, the composition data represents a three-dimensional distribution of the build powder composition of the build powder segments of the multiple powder layers deposited to form the object 100. The three-dimensional distribution of the build powder composition is mapped to a three-dimensional distribution of the at least one material property of the object 100. In these examples, the step of selectively controlling the composition ratio of the build powder 102 (block 1008) includes adjusting the composition ratio of multiple build powder components based on the three-dimensional distribution of the build powder composition of the build powder segments of the multiple powder layers. The at least one desired material property of the object 100 includes, but is not limited to, desired physical, chemical, electrical, thermal, and / or magnetic properties of a given object layer or within the object 100.

[0215] This disclosure recognizes that, in certain applications of powder bed additive manufacturing, reducing the area of ​​the powder layer or the volume of the powder bed can be advantageous. Therefore, one or more embodiments of additive manufacturing system 200 and method 1000 provide techniques for reducing the area of ​​the powder layer or the volume of the powder bed, resulting in a reduction in the amount of powder required to form the powder layer, lower costs, shorter cycle times, and increased processing efficiency.

[0216] refer to Figure 1In one or more instances, method 1000 includes the step of forming a barrier 142 (block 1020). Barrier 142 is configured to contain a powder layer 106. According to method 1000, in one or more instances, barrier 142 includes a closed cross-section configured to surround a build profile 112 of the powder layer 106. In one or more instances, barrier 142 is located at a position outside (e.g., around) the build profile 112. In one or more instances, barrier 142 forms at least a portion of the build profile 112.

[0217] refer to Figure 23 and Figure 24 In one or more instances, the additive manufacturing system 200 includes a barrier forming apparatus 256. The barrier forming apparatus 256 is configured to form a barrier 142. In one or more instances, the barrier 142 is formed on a build platform 262. A powder layer 106 is formed inside the barrier 142. In other words, the barrier 142 provides a peripheral boundary for the powder layer 106. In one or more instances,

[0218] In one or more instances, the step of forming barrier 142 (box 1020) precedes the steps of selectively depositing constructive powder 102 to form constructive powder segments 108 of powder layer 106 (box 1002) and selectively depositing support powder 104 to form support powder segments 110 of powder layer 106 (box 1004).

[0219] In one or more instances, powder layer 106 is formed by depositing build powder 102 and support powder 104 within a perimeter formed by barrier 142, as described above. In these instances, powder layer 106, consisting of support powder 104 (support powder segment 110) and build powder 102 (build powder segment 108), is located inside and defined by barrier 142. In these instances, support powder segment 110 of powder layer 106 is located between barrier 142 and build profile 112. Therefore, the use of barrier 142 reduces the area of ​​powder layer 106, and more specifically, reduces the area of ​​support powder segment 110 of powder layer 106.

[0220] Alternatively, in one or more instances, the powder layer 106 is formed by depositing only the build-up powder 102 within the perimeter formed by the barrier 142, as described above. In these instances, the powder layer 106, consisting solely of the build-up powder 102, is located within and defined by the barrier 142. Therefore, the use of the barrier 142 reduces the area of ​​the powder layer 106 and allows the entire powder layer 106 to be formed from the build-up powder 102, while reducing the amount of unused build-up powder 102 that might be wasted or require recycling.

[0221] In one or more instances, the barrier forming device 256 is movable relative to the build platform 262. In one or more instances, when forming a continuous layer of object 100, the barrier forming device 256 moves vertically (e.g., elevates) relative to the build platform 262. In one or more instances, when forming barrier 142, the barrier forming device 256 moves horizontally relative to the build platform 262. In one or more instances, the barrier forming device 256 has multiple degrees of freedom to accommodate multi-axis motion for forming barrier 142 at any location on the build platform 262.

[0222] In one or more instances, the additive manufacturing system 200 includes a barrier forming actuator 272 coupled to and configured to drive movement of the barrier forming apparatus 256. In one or more instances, the barrier forming actuator 272 includes a linear actuator, a robotic actuator arm (e.g., a six-axis robotic actuator arm), or takes the form of a linear actuator, a robotic actuator arm (e.g., a six-axis robotic actuator arm), or the like.

[0223] In one or more instances, the step of forming barrier 142 (box 1020) includes the step of selectively depositing wire 140 to form barrier 142. Thus, as... Figure 25 and Figure 26 As shown, in one or more instances, the barrier forming apparatus 256 includes a wire deposition apparatus 258. The wire deposition apparatus 258 is configured to dispense or supply wire 140 onto a growth surface while directing an energy beam onto the growth surface to melt the wire 140 and form a liquid pool. Under the guidance of a controller 250, the wire deposition apparatus 258 moves across the growth surface while supplying wire 140 into the pool to form a barrier 142. The growth surface is the surface of the build platform 262 when forming the barrier 142 associated with the powder layer 106 (e.g., the initial powder layer).

[0224] The wire deposition apparatus 258 includes any suitable high-energy additive manufacturing apparatus having a wire supply. In one or more instances, the wire deposition apparatus 258 includes a feeder configured to dispense wire 140 and a directional energy device (e.g., a laser) configured to generate and emit an energy beam (e.g., a laser beam) to form a molten pool.

[0225] Wire 140 includes any solid wire suitable for being supplied and melted into a molten pool to construct barrier 142 in a layered manner. Examples of wire 140 include, but are not limited to, metal wire, metal alloy wire, polymer wire, etc.

[0226] While forming powder layer 106 within barrier 142, bonding construction powder 102 is used to form object layer 134 as described above. This formation and bonding process is repeated multiple times to form multiple successive barriers (multiple layers of barrier 142), to form multiple successive powder layers, thereby forming multiple successive object layers, and ultimately forming object 100. After each object layer is formed, and before the formation of successive powder layers, a successive layer of barrier 142 is formed on the previously formed and underlying layer of barrier 142. When forming successive layers of barrier 142 associated with successive powder layers, the growth surface is the surface of the previously formed and underlying layer of barrier 142.

[0227] In one or more embodiments, the step of forming barrier 142 (box 1020) includes the step of bonding selected portions of support powder 104 of support powder segment 110 of powder layer 106 to form barrier 142. In one or more embodiments, the step of bonding support powder 104 includes, for example, bonding selected portions of support powder 104 of support powder segment 110 using adhesive 220. Thus, as Figure 27 and Figure 28 As shown, in one or more embodiments, the barrier forming apparatus 256 includes an adhesive delivery device 254. The adhesive delivery device 254 is configured to deposit adhesive 220 onto the support powder 104. The adhesive 220 is adapted to bond selected portions of the support powder 104 of the support powder segment 110 of the powder layer 106 to form a solid layer of barrier 142.

[0228] In one or more instances, for example, a powder deposition apparatus 202 as described above is used to deposit support powder 104 to form at least a portion of support powder segment 110 of powder layer 106. Using an adhesive delivery device 254, selected portions of support powder 104 of support powder segment 110 are bonded via adhesive 220 to form barrier 142. After barrier 142 is formed, for example, a build powder 102 is deposited using a powder deposition apparatus 202 as described above to form build powder segment 108 of powder layer 106. While forming powder layer 106 within barrier 142, build powder 102 is bonded to form object layer 134 as described above. This forming and bonding process is repeated multiple times to form multiple successive barrier layers (layers of multiple barriers 142), thereby forming multiple successive powder layers to form multiple successive object layers, and ultimately forming object 100. After each object layer is formed, and before the formation of successive powder layers, a successive layer of barrier 142 is formed on the previously formed and underlying layer of barrier 142.

[0229] In this disclosure, the operational steps of the method 1000 described for depositing build powder 102 to form a powder layer 106, depositing support powder 104 to form a support powder section 110 of the powder layer 106, and bonding build powder 102 to form an object layer 134, and the components of the additive manufacturing system 200, are equally applicable to the operational steps and components for depositing build powder 102 to form a second build powder section 128, depositing support powder 104 to form a second powder layer 126, and bonding build powder 102 to form a second object layer 148, and equally applicable to forming multiple consecutive powder layers and forming multiple consecutive object layers. Furthermore, without departing from the scope of this disclosure, additional components, such as additional powder feeders, regulators, nozzles, directional energy devices, etc., may be included in the additive manufacturing system 200.

[0230] As described herein, controller 250 communicates with and / or controls various components of additive manufacturing system 200. In one or more instances, controller 250 is a computing device including a processor and memory. The memory may be a computer-readable storage medium and is configured to store data required for the operation of additive manufacturing system 200. A computer-readable storage medium is any medium that can be used to store information that can subsequently be accessed by a processor. Computer-readable storage media may include computer memory and data storage devices. Computer memory may be fast access memory and may be used to run program instructions executable by a processor. Computer memory may include random access memory (RAM), flash memory, and read-only memory (ROM). Data storage devices may be physical devices and may be used to store any information or computer programs that can be accessed by a processor, such as operating systems, computer programs, program modules, and program data. The data storage device and its associated computer-readable storage medium provide the system with storage for computer-readable instructions, data structures, program modules, and other data. Data storage devices may include magnetic media, such as floppy disks, hard disks, and magnetic tapes; optical media, such as optical discs (CDs), digital video discs (DVDs), and Blu-ray discs; and solid-state storage, such as random access memory (RAM), flash memory, and read-only memory (ROM).

[0231] In one or more instances, the memory includes data packets consisting of data required for the controlled operation of the additive manufacturing system 200. For example, one data packet may contain data required to control the powder deposition apparatus 202, while another data packet may contain data required to control the powder bonding apparatus. The processor communicates with the memory to retrieve the necessary data for controlling the operation of the additive manufacturing system 200.

[0232] In one or more instances, unless otherwise specified, the subject matter of this disclosure is described with reference to symbolic representations of actions and operations performed by one or more computers or computer systems. Therefore, it will be understood that such actions and operations, sometimes referred to as computer-performed, include manipulation by one or more processors of the additive manufacturing system 200 (e.g., controller 250) via electrical signals representing data in a structured form. This manipulation transforms or holds the data at a specific location in the memory of the additive manufacturing system 200, which reconfigures or otherwise alters the operation of the additive manufacturing system 200 in a manner well known to those skilled in the art. The data structure holding the data is the physical location of memory having specific characteristics defined by the data format. However, although one or more instances have been described in the foregoing context, this is not intended to be limiting, as those skilled in the art will understand that some of the actions and operations described herein can also be implemented in hardware, software and / or firmware and / or some combination thereof.

[0233] Now for reference Figure 29 and Figure 30 Examples of method 1000 and additive manufacturing system 200 can be found in, for example... Figure 29 The aircraft manufacturing and maintenance method 1100 shown in the flowchart and as follows Figure 30 The aircraft 1200 is used in the background, which is shown schematically in the middle.

[0234] refer to Figure 30 In one or more instances, aircraft 1200 includes a fuselage 1202, an interior 1206, and multiple advanced systems 1204. Examples of advanced systems 1204 include one or more of a propulsion system 1208, an electrical system 1210, a hydraulic system 1212, and an environmental system 1214. In other instances, aircraft 1200 may include any number of other types of systems, such as communication systems, guidance systems, etc. The object 100 manufactured according to method 1000 and using additive manufacturing system 200 may be a structure, component, sub-component, part, component, or any other part of aircraft 1200, such as part of fuselage 1202 or interior 1206.

[0235] refer to Figure 29 During pre-production, method 1100 includes the specification and design of aircraft 1200 (box 1102) and material procurement (box 1104). During the production of aircraft 1200, the manufacturing of components and sub-components of aircraft 1200 (box 1106) and system integration (box 1108) are carried out. Subsequently, aircraft 1200 is certified and delivered (box 1110) for service (box 1112). Routine maintenance and repair (box 1114) includes modification, reconfiguration, refurbishment, etc., of one or more systems of aircraft 1200.

[0236] Figure 29 Each process of the method 1100 shown may be performed or implemented by a system integrator, a third party, and / or an operator (e.g., a customer). For the purposes of this specification, a system integrator may include, but is not limited to, any number of spacecraft manufacturers and master system subcontractors; a third party may include, but is not limited to, any number of suppliers, subcontractors, and vendors; and an operator may be an airline, leasing company, military entity, service organization, etc.

[0237] Examples of the method 1000 and additive manufacturing system 200 shown and described herein can be found in... Figure 29 The disclosed method 1000 and additive manufacturing system 200 are employed during any one or more stages of the manufacturing and maintenance method 1100 shown in the flowchart. In one example, embodiments of the disclosed method 1000 and additive manufacturing system 200 may form part of component and sub-component manufacturing (box 1106) and / or system integration (box 1108). For example, the assembly of an aircraft 1200 and / or its components using embodiments of the disclosed method 1000 and additive manufacturing system 200 may correspond to component and sub-component manufacturing (box 1106) and may be prepared in a manner similar to that of components or sub-components prepared when the aircraft 1200 is in service (box 1112). Furthermore, embodiments of the disclosed method 1000 and additive manufacturing system 200 may be used during system integration (box 1108) and during certification and delivery (box 1110). Similarly, embodiments of the disclosed method 1000 and additive manufacturing system 200 may be utilized, for example, but not limited to, when the aircraft 1200 is in service (box 1112) and during maintenance and repair (box 1114).

[0238] While examples from aerospace (e.g., aircraft or spacecraft) have been shown, the examples and principles disclosed herein can be applied to other industries, such as the automotive, construction, wind turbine, electronics, and other design and manufacturing sectors. Therefore, in addition to aircraft and spacecraft, the examples and principles disclosed herein can be applied to powder bed additive manufacturing processes used to form objects for use with other vehicles (e.g., land vehicles, marine vehicles, construction vehicles, etc.), machines, and freestanding structures.

[0239] As used herein, a system, device, apparatus, structure, article, element, component, or hardware "configured to" perform a specified function is actually capable of performing the specified function without any changes, rather than merely having the potential to perform the specified function after further modification. In other words, a system, device, apparatus, structure, article, element, component, or hardware "configured to" perform the specified function is specifically selected, created, implemented, utilized, programmed, and / or designed for the purpose of performing the specified function. As used herein, "configured to" refers to an existing characteristic of the system, device, structure, article, element, component, or hardware that enables the system, device, article, component, or hardware to perform the specified function without further modification. For the purposes of this disclosure, a system, device, apparatus, structure, article, element, component, or hardware described as "configured to" perform a particular function may additionally or alternatively be described as "suitable" and / or "operating as" to perform that function.

[0240] Unless otherwise stated, the terms “first,” “second,” “third,” etc., are used herein merely as markers and are not intended to impose any order, position, or hierarchy requirements on the items referred to by these terms. Furthermore, a reference to an item “second,” for example, does not require or exclude the existence of an item, for example, “first” or a lower-numbered item and / or an item, for example, “third” or a higher-numbered item.

[0241] For the purposes of this disclosure, the terms "connection," "link," and similar terms refer to two or more elements that are joined, linked, fastened, attached, connected, communicated, or otherwise associated with each other (e.g., mechanically, electrically, fluidly, optically, electromagnetically). In various instances, elements may be associated directly or indirectly. As an example, element A may be directly associated with element B. As another example, element A may be indirectly associated with element B, for example, via another element C. It should be understood that not all associations between the various elements disclosed need to be represented. Therefore, connections other than those shown in the figures may also exist.

[0242] As used herein, the term "approximately" means or indicates a condition that is close to, but not exactly close to, the condition still performs the desired function or achieves the desired result. As an example, the term "approximately" means a condition within an acceptable predetermined tolerance or precision. For example, the term "approximately" means a condition within 10% of the stated condition. However, the term "approximately" does not preclude a condition that is precisely the stated condition.

[0243] Those skilled in the art will understand that the above-mentioned Figures 2 to 28 and Figure 30 Some of the elements, features and / or components described and shown may be combined in various ways, without including Figures 2 to 28 and Figure 30Other features described and illustrated in the accompanying drawings and / or disclosures, even if such combinations or combinations are not explicitly shown herein. Similarly, additional features, not limited to the presented examples, may be combined with some or all of the features shown and described herein. Unless otherwise expressly stated, the above-mentioned features are not limited to those in the examples presented herein. Figures 2 to 28 and Figure 30 The illustrative examples depicted herein are not intended to imply structural limitations regarding the illustrative examples. Rather, while an illustrative structure is indicated, it should be understood that this structure can be modified as appropriate. Therefore, modifications, additions, and / or omissions can be made to the illustrated structures. Furthermore, those skilled in the art will understand that not only the above-mentioned... Figures 2 to 28 and Figure 30 All elements described and shown herein need to be included in every instance, and not all elements described herein need to be depicted in every illustrative instance.

[0244] In the above-mentioned Figure 1 and Figure 29 In this document, these boxes may represent operations, steps, and / or parts thereof, and the lines connecting the various boxes do not imply any particular order or dependency between the operations or their parts. It will be understood that it is not necessary to represent all dependencies between the various disclosed operations. The above-mentioned... Figure 1 and Figure 29 The accompanying disclosure describing the operations of the methods set forth herein should not be construed as requiring a predetermined order of operations. Rather, while an illustrative order is indicated, it should be understood that the order of operations can be modified as appropriate. Therefore, the operations shown can be modified, added to, and / or omitted, and some operations can be performed in a different order or simultaneously. Furthermore, those skilled in the art will understand that it is not necessary to perform all the described operations.

[0245] Furthermore, references to features, advantages, or similar language used throughout this specification do not imply that all features and advantages that can be implemented with respect to the examples disclosed herein should be any single instance or in any single instance. Rather, language relating to features and advantages should be understood to mean that a specific feature, advantage, or characteristic described in conjunction with an example is included in at least one instance. Therefore, the discussion of features, advantages, and similar language used throughout this disclosure may, but is not required to, refer to the same instances.

[0246] Furthermore, this disclosure includes implementations based on the following examples:

[0247] Example 1. A method (1000) for additively manufacturing an object (100), the method (1000) comprising:

[0248] The build powder (102) is selectively deposited inside the build profile (112) of the object (100) to form build powder segments (108) of the powder layer (106); and

[0249] Support powder (104) is selectively deposited on the outside of the construction profile (112) to form support powder segments (110) of the powder layer (106);

[0250] in:

[0251] The construction of powder (102) includes the composition of the construction powder;

[0252] The support powder (104) comprises a support powder composition; and

[0253] The construction of powder composition and the support of powder composition are different.

[0254] Example 2. According to the method (1000) of Example 1, wherein the selective deposition of support powder (104) precedes the selective deposition of construction powder (102), such that:

[0255] The supporting powder boundary (114) of the supporting powder segment (110) of the powder layer (106) forms the construction profile (112); and

[0256] The powder layer (106) is constructed by the powder segment (108) and the powder boundary (116) is adjacent to the supporting powder segment (110) and the supporting powder boundary (114).

[0257] Example 3. According to the method (1000) of Example 1, wherein the selective deposition of the building powder (102) precedes the selective deposition of the support powder (104), such that:

[0258] The powder layer (106) is constructed by the powder segment (108), and the powder boundary (116) forms the construction profile (112); and

[0259] The supporting powder boundary (114) of the supporting powder segment (110) of the powder layer (106) is adjacent to the building powder boundary (116) of the building powder segment (108) of the powder layer (106).

[0260] Example 4. According to the method (1000) of Example 1, wherein selectively depositing the build powder (102) includes selectively discharging the build powder (102) using a powder injector (204).

[0261] Example 5. According to the method (1000) of Example 4, wherein selectively depositing the support powder (104) includes selectively discharging the support powder (104) using a powder injector (204).

[0262] Example 6. According to the method (1000) of Example 4, wherein selectively depositing the support powder (104) includes selectively discharging the support powder (104) using a recoater (206).

[0263] Example 7. The method (1000) according to Example 1 further includes selectively controlling the composition of the construct powder (102).

[0264] Example 8. According to the method (1000) of Example 7, wherein selective control of the composition of the building powder and selective deposition of the building powder (102) occur simultaneously.

[0265] Example 9. According to the method (1000) of Example 7, wherein selectively controlling the composition of the construction powder (102) includes selectively changing the composition of the construction powder (102) to achieve a powder gradient (152) within the construction powder segment (108) of the powder layer (106).

[0266] Example 10. Based on the method (1000) of Example 7, where:

[0267] The powder (102) comprises a mixture of a first component (122) and a second component (124) of the powder; and

[0268] Selectively controlling the composition of the building powder (102) includes selectively controlling the composition ratio of the first component (122) and the second component (124) of the building powder.

[0269] Example 11. According to the method (1000) of Example 10, wherein selectively controlling the composition ratio of the first component (122) of the building powder and the second component (124) of the building powder includes:

[0270] The first mass of the first component (122) of the powder was measured;

[0271] The second mass of the second component (124) of the powder was measured; and

[0272] The mass of the building powder (102) is measured, which comprises a mixture of a first component (122) and a second component (124) of the building powder.

[0273] Example 12. According to the method (1000) of Example 11, wherein selectively controlling the composition ratio of the first component (122) of the powder and the second component (124) of the powder further includes:

[0274] The first mass flow rate of the first component (122) of the construction powder is selectively controlled; and the second mass flow rate of the second component (124) of the construction powder is selectively controlled.

[0275] Example 13. According to the method (1000) of Example 11, wherein selectively controlling the composition ratio of the first component (122) and the second component (124) of the building powder further includes measuring the mass flow rate of the building powder (102) comprising the mixture of the first component (122) and the second component (124) of the building powder.

[0276] Example 14. According to the method (1000) of Example 1, it further includes the construction powder (102) of the construction powder segment (108) of the bonding powder layer (106) to form the object layer (134).

[0277] Example 15. According to the method (1000) of Example 14, wherein the building powder (102) of the building powder segment (108) of the bonding powder layer (106) includes the building powder (102) of the melting building powder segment (108).

[0278] Example 16. According to the method (1000) of Example 14, wherein the building powder (102) of the building powder segment (108) of the bonding powder layer (106) includes the building powder (102) of the bonding building powder segment (108).

[0279] Example 17. According to the method (1000) of Example 14, it also includes:

[0280] The construct powder (102) is selectively deposited inside the second construct profile (132) of the object (100) to form a second construct powder segment (128) of the second powder layer (126); and

[0281] The support powder (104) is selectively deposited on the outside of the second construction profile (132) to form the second support powder segment (130) of the second powder layer (126).

[0282] Example 18. The method (1000) according to Example 17 further includes a support powder (104) of a portion of the support powder segment (110) of the bonded powder layer (106) to form a support layer (136);

[0283] in:

[0284] The constructed profile (112) and the second constructed profile (132) are different; and

[0285] The build powder (102) is selectively deposited inside the second build profile (132) of the object (100) such that a portion of the second build powder segment (128) of the second powder layer (126) is located on the support layer (136) and another portion of the second build powder segment (128) of the second powder layer (126) is located on the object layer (134).

[0286] Example 19. According to the method (1000) of Example 17, it also includes:

[0287] Support powder (104) of a portion of the support powder segment (110) of the bonded powder layer (106) is used to form a support layer (136); and

[0288] Before selectively depositing the building powder (102) inside the second building profile (132), the support powder (104) is selectively deposited inside the second building profile (132) to form an intermediate support powder layer (138);

[0289] in:

[0290] The support powder (104) is selectively deposited inside the second construction profile (132) of the object (100) such that the intermediate support powder layer (138) is located on the support layer (136); and

[0291] The build powder (102) is selectively deposited inside the second build profile (132) of the object (100) such that a portion of the second build powder segment (128) of the second powder layer (126) is located on the intermediate support powder layer (138) and another portion of the second build powder segment (128) of the second powder layer (126) is located on the object layer (134).

[0292] Example 20. The method (1000) according to Example 17 further includes selectively controlling the composition of the building powder (102).

[0293] Example 21. According to the method (1000) of Example 20, wherein selectively controlling the composition of the build powder (102) includes selectively changing the composition of the build powder to achieve a powder gradient (152) within the build powder segment (108) of the powder layer (106) and within the second build powder segment (128) of the second powder layer (126).

[0294] Example 22. According to the method (1000) of Example 20, where:

[0295] The powder (102) comprises a mixture of a first component (122) and a second component (124) of the powder; and

[0296] Selectively controlling the composition of the building powder (102) includes selectively controlling the composition ratio of the first component (122) and the second component (124) of the building powder.

[0297] Example 23. According to the method (1000) of Example 22, wherein selectively controlling the composition ratio of the first component (122) of the building powder and the second component (124) of the building powder includes:

[0298] The first mass of the first component (122) of the powder was measured;

[0299] The second mass of the second component (124) of the powder was measured; and

[0300] The mass of the building powder (102) is measured, the building powder comprising a mixture of a first component (122) and a second component (124) of the building powder.

[0301] Example 24. According to the method (1000) of Example 23, wherein selectively controlling the composition ratio of the first component (122) of the powder and the second component (124) of the powder further includes:

[0302] Selectively control the first mass flow rate of the first component (122) of the powder; and

[0303] The second mass flow rate of the second component (124) of the powder can be selectively controlled.

[0304] Example 25. According to the method (1000) of Example 23, wherein selectively controlling the composition ratio of the first component (122) and the second component (124) of the building powder further includes measuring the mass flow rate of the building powder (102) comprising the mixture of the first component (122) and the second component (124) of the building powder.

[0305] Example 26. The method (1000) according to Example 1 further includes forming a barrier (142) having a closed cross-section, wherein the powder layer (106) is defined by the barrier (142).

[0306] Example 27. According to the method (1000) of Example 26, wherein forming a barrier (142) includes selectively depositing wire (140).

[0307] Example 28. According to the method (1000) of Example 26, wherein a barrier (142) of support powder (104) forms a portion of the support powder segment (110) of the bonding powder layer (106).

[0308] Example 29. A method (1000) for additively manufacturing an object (100), the method (1000) comprising:

[0309] The build powder (102) is selectively deposited inside the build profile (112) of the object (100) to form a build powder segment (108) of the powder layer (106), the build powder (102) comprising a build powder composition;

[0310] Selectively alter the composition of the building powder (102) to achieve a powder gradient (152) within the building powder segment (108) of the powder layer (106); and

[0311] Support powder (104) is selectively deposited on the exterior of the construction profile (112) to form support powder segments (110) of the powder layer (106), the support powder (104) comprising a support powder composition.

[0312] The composition of the building powder and the composition of the supporting powder are different.

[0313] Example 30. Based on the method (1000) of Example 29, where:

[0314] Selectively depositing the building powder (102) includes selectively discharging the building powder (102) using a powder injector (204); and

[0315] Selectively depositing support powder (104) includes selectively discharging support powder (104) using a powder injector (204).

[0316] Example 31. Based on the method (1000) of Example 29, where:

[0317] Selectively depositing the building powder (102) includes selectively discharging the building powder (102) using a powder injector (204); and

[0318] Selective deposition of support powder (104) includes selectively discharging support powder (104) using a recoater (206).

[0319] Example 32. The method (1000) according to Example 29 further includes forming a barrier (142) around the construction profile (112), wherein a powder layer (106) is formed inside the barrier (142).

[0320] Example 33. An additive manufacturing system (200), comprising:

[0321] The powder deposition equipment (202) is configured as follows:

[0322] The construct powder (102) is selectively deposited inside the construct profile (112) to form construct powder segments (108) of the powder layer (106); and

[0323] Support powder (104) is selectively deposited on the outside of the construction profile (112) to form support powder segments (110) of the powder layer (106); and wherein:

[0324] The construction of powder (102) includes the composition of the construction powder;

[0325] The support powder (104) comprises a support powder composition; and

[0326] The construction of powder composition and the support of powder composition are different.

[0327] Example 34. An additive manufacturing system (200) according to Example 33, wherein the powder deposition apparatus (202) is configured to selectively deposit support powder (104) prior to selectively depositing build powder (102), such that:

[0328] The supporting powder boundary (114) of the supporting powder segment (110) of the powder layer (106) forms the construction profile (112); and

[0329] The powder layer (106) is constructed by the powder segment (108) and the powder boundary (116) is adjacent to the supporting powder segment (110) and the supporting powder boundary (114).

[0330] Example 35. An additive manufacturing system (200) according to Example 33, wherein the powder deposition apparatus (202) is configured to selectively deposit build powder (102) prior to selectively depositing support powder (104), such that:

[0331] The powder layer (106) is constructed by the powder segment (108), and the powder boundary (116) forms the construction profile (112); and

[0332] The supporting powder boundary (114) of the supporting powder segment (110) of the powder layer (106) is adjacent to the building powder boundary (116) of the building powder segment (108) of the powder layer (106).

[0333] Example 36. Based on the additive manufacturing system (200) of Example 33, wherein:

[0334] The powder deposition apparatus (202) includes a powder injector (204) configured to selectively deposit building powder (102); and

[0335] The powder injector (204) includes:

[0336] A build powder feeder (222) is configured to selectively dispense build powder (102);

[0337] as well as

[0338] The nozzle (208) is connected to the build powder feeder (222) and configured to selectively discharge build powder (102).

[0339] Example 37. Based on the additive manufacturing system (200) of Example 36, wherein:

[0340] The powder injector (204) is configured to selectively deposit support powder (104) and also includes a support powder feeder (224) configured to selectively dispense the support powder (104); and

[0341] The nozzle (208) is connected to the support powder feeder (224) and configured to selectively discharge support powder (104).

[0342] Example 38. Based on the additive manufacturing system (200) of Example 36, wherein:

[0343] The powder deposition apparatus (202) includes a recoater (206) configured to selectively deposit support powder (104); and

[0344] The recoating device (206) includes:

[0345] A support powder feeder (224) is configured to selectively dispense support powder (104);

[0346] as well as

[0347] Roller (210) is configured to collect support powder (104) from support powder feeder (224).

[0348] And selectively discharge the support powder (104).

[0349] Example 39. An additive manufacturing system (200) according to Example 36, wherein the powder injector (204) is configured to selectively control the composition of the build powder (102).

[0350] Example 40. An additive manufacturing system (200) according to Example 36, wherein a powder injector (204) is configured to selectively change the build powder composition of the build powder (102) to achieve a powder gradient (152) within the build powder segment (108) of the powder layer (106).

[0351] Example 41. Based on the additive manufacturing system (200) of Example 40, where:

[0352] The powder (102) comprises a mixture of a first component (122) and a second component (124) of the powder;

[0353] Constructing the powder feeder (222) includes:

[0354] A first component powder feeder (226) is configured to selectively dispense the first component powder (122);

[0355] A second component powder feeder (228) is configured to selectively dispense the second component powder (124); and

[0356] A mixer (230) is connected to a first component feeder (226) and a second component feeder (228) of the building powder, and is configured as follows:

[0357] The first component feeder (226) and the second component feeder (228) of the building powder are mixed together;

[0358] Contains building powder (102); and

[0359] The building powder (102) is selectively dispensed into the nozzle (208).

[0360] Example 42. Based on the additive manufacturing system (200) of Example 41, wherein:

[0361] The construct powder first component feeder (226) includes a construct powder first component regulator (232) configured to selectively control the composition percentage of the construct powder first component feeder (226) in the construct powder (102) contained in the mixer (230); and

[0362] The second component feeder (228) includes a second component regulator (234) configured to selectively control the percentage of the second component of the building powder (102) contained in the mixer (230).

[0363] The mixer (230) includes a mixer regulator (316) configured to selectively control the mass flow rate of the build powder (102) dispensed to the nozzle (208).

[0364] Example 43. Based on the additive manufacturing system (200) of Example 42, wherein:

[0365] The construction powder first component regulator (232) includes a construction powder first component mass sensor (238) configured to measure a first mass of the construction powder first component (122);

[0366] The second component regulator (234) for constructing powder includes a second component mass sensor (246) for constructing powder, which is configured to measure the second mass of the second component ...

[0367] The mixer regulator (316) includes a mixer mass sensor (320) configured to measure the mass of the build powder (102).

[0368] Example 44. Based on the additive manufacturing system (200) of Example 43, where:

[0369] The first component regulator (232) for the construction powder also includes a first component mass flow sensor (240) for the construction powder, configured to measure a first mass flow rate of the first component (122) of the construction powder; and

[0370] The second component of the construction powder regulator (234) also includes a second component of the construction powder mass flow sensor (248) configured to measure the second mass flow rate of the second component of the construction powder (124).

[0371] Example 45. The additive manufacturing system (200) according to Example 41 also includes an emission regulator (286) configured to measure and selectively control the mass flow rate of the build powder (102) emitted from the nozzle (208).

[0372] Example 46. The additive manufacturing system (200) according to Example 41 also includes a controller (250) configured as follows:

[0373] The movement of the powder injector (204) is selectively controlled according to the constructed powder deposition pattern; and

[0374] The composition ratio of the first component (122) and the second component (124) of the building powder in the building powder (102) dispensed from the mixer (230) at different locations along the building powder deposition pattern is selectively adjusted.

[0375] Example 47. The additive manufacturing system (200) according to Example 33 also includes a powder bonding device (212) configured to bond the building powder (102) of the building powder segment (108) of the powder layer (106).

[0376] Example 48. An additive manufacturing system (200) according to Example 47, wherein the powder bonding device (212) is configured to bond a portion of the support powder segment (110) of the powder layer (106) to the support powder (104).

[0377] Example 49. An additive manufacturing system (200) according to Example 47, wherein the powder bonding apparatus (212) includes a directional energy device (252) configured to generate an energy beam (218) of the build powder (102) suitable for melting the build powder segment (108) of the powder layer (106).

[0378] Example 50. An additive manufacturing system (200) according to Example 47, wherein the powder bonding apparatus (212) includes an adhesive delivery device (254) configured to deposit an adhesive (256) of the build powder (102) of the build powder segment (108) suitable for bonding the powder layer (106).

[0379] Example 51. The additive manufacturing system (200) according to Example 47 further includes a wire deposition apparatus (258) configured to dispense wire (140) to form a barrier (142), wherein the powder deposition apparatus (202) is configured to selectively deposit support powder (104) and build powder (102) within the barrier (142).

[0380] Example 52. Based on the additive manufacturing system (200) of Example 47, wherein:

[0381] The powder bonding apparatus (212) includes an adhesive delivery device (254) configured to selectively deposit adhesive (220), the adhesive being adapted to bond a portion of the support powder (104) of the support powder segment (110) of the powder layer (106) to form a barrier (142); and

[0382] The powder deposition apparatus (202) is configured to selectively deposit the build powder (102) within the barrier (142).

[0383] The features, advantages, and characteristics described in one instance can be combined in any suitable manner in one or more other instances. Those skilled in the art will recognize that the instances described herein can be practiced without the presence of one or more specific features or advantages in a particular instance. In other cases, additional features and advantages that may not be present in all instances may be recognized in certain instances. Furthermore, while various instances of method 1000 and additive manufacturing system 200 have been shown and described, modifications will occur to those skilled in the art upon reading the specification. This application includes such modifications and is defined only by the scope of the claims.

Claims

1. A method (1000) for additively manufacturing an object (100), the method (1000) comprising: The build powder (102) is selectively deposited inside the build profile (112) of the object (100) to form the build powder segment (108) of the powder layer (106). Support powder (104) is selectively deposited on the outside of the build profile (112) to form support powder segments (110) of the powder layer (106). in: The building powder (102) comprises a building powder composition, which is a mixture of a first building powder component (122) and a second building powder component (124); The supporting powder (104) comprises a supporting powder composition; and The composition of the building powder and the composition of the supporting powder are different; and Selectively controlling the composition of the construct powder (102) includes selectively controlling the composition ratio of the first component (122) and the second component (124) of the construct powder; Selectively controlling the composition of the building powder (102) includes selectively changing the composition of the building powder (102) to achieve a powder gradient (152) within the building powder segment (108) of the powder layer (106). In this process, selective control of the composition of the construct powder and selective deposition of the construct powder (102) occur simultaneously; and The selective control of the composition ratio of the first component (122) and the second component (124) of the constructing powder includes: Measure the first mass of the first component (122) of the constructed powder; The second mass of the second component (124) of the constructed powder was measured; and The mass of the building powder (102) is measured, the building powder comprising a mixture of the first component (122) and the second component (124) of the building powder.

2. The method (1000) according to claim 1, wherein, The support powder (104) is selectively deposited prior to the selective deposition of the construct powder (102), such that: The supporting powder boundary (114) of the supporting powder segment (110) of the powder layer (106) forms the construction profile (112); and The building powder boundary (116) of the building powder segment (108) of the powder layer (106) is adjacent to the supporting powder boundary (114) of the supporting powder segment (110) of the powder layer (106).

3. The method (1000) according to claim 1, wherein, The construct powder (102) is selectively deposited prior to the support powder (104), such that: The construction powder boundary (116) of the construction powder segment (108) of the powder layer (106) forms the construction profile (112); and The supporting powder boundary (114) of the supporting powder segment (110) of the powder layer (106) is adjacent to the building powder boundary (116) of the building powder segment (108) of the powder layer (106).

4. The method (1000) according to claim 1, wherein, Selectively controlling the composition ratio of the first component (122) and the second component (124) of the constructive powder further includes: Selectively control the first mass flow rate of the first component (122) of the constructing powder; and The second mass flow rate of the second component (124) of the construct powder is selectively controlled.

5. An additive manufacturing system (200), the additive manufacturing system (200) comprising: Powder deposition apparatus (202), wherein the powder deposition apparatus (202) is configured as follows: The construct powder (102) is selectively deposited inside the construct profile (112) to form construct powder segments (108) of the powder layer (106); and Support powder (104) is selectively deposited outside the build contour (112) to form support powder segments (110) of the powder layer (106); and wherein: The constructing powder (102) comprises a constructing powder composition; The supporting powder (104) comprises a supporting powder composition; and The composition of the building powder and the composition of the supporting powder are different; The powder deposition apparatus (202) includes a powder ejector (204) configured to selectively deposit the build powder (102), selectively control the build powder composition of the build powder (102), and selectively change the build powder composition of the build powder (102) to achieve a powder gradient (152) within the build powder segment (108) of the powder layer (106), wherein selectively controlling the build powder composition and selectively depositing the build powder (102) occur simultaneously; and The powder injector (204) includes: A build powder feeder (222) is configured to selectively dispense the build powder (102); and A nozzle (208) is connected to the build powder feeder (222) and configured to selectively discharge the build powder (102). The building powder (102) comprises a mixture of a first component (122) and a second component (124) of the building powder; The construction of the powder feeder (222) includes: A first component feeder (226) for constructing powder is configured to selectively dispense the first component of the constructing powder (122). A second component feeder (228) for constructing powder is configured to selectively dispense the second component of the constructing powder (124); and A mixer (230) is connected to the first component feeder (226) and the second component feeder (228) of the building powder, and is configured as follows: The first component feeder (226) and the second component feeder (228) of the building powder are mixed together; Contains the construct powder (102); and The building powder (102) is selectively dispensed into the nozzle (208). The first component feeder (226) of the building powder includes a first component regulator (232) of the building powder, the first component regulator (232) of the building powder being configured to selectively control the percentage of the composition of the first component feeder (226) of the building powder (102) contained in the mixer (230); and The second component feeder (228) of the building powder includes a second component regulator (234) configured to selectively control the composition percentage of the second component feeder (228) in the building powder (102) contained in the mixer (230); and The mixer (230) includes a mixer regulator (316) configured to selectively control the mass flow rate of the building powder (102) dispensed to the nozzle (208).

6. The additive manufacturing system (200) according to claim 5, wherein, The powder deposition apparatus (202) is configured to selectively deposit the support powder (104) prior to selectively depositing the build powder (102), such that: The supporting powder boundary (114) of the supporting powder segment (110) of the powder layer (106) forms the construction profile (112); and The building powder boundary (116) of the building powder segment (108) of the powder layer (106) is adjacent to the supporting powder boundary (114) of the supporting powder segment (110) of the powder layer (106).

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