Additive manufacturing systems and methods including rotary adhesive jet printheads

Abstract

This invention relates to an additive manufacturing system and method including a rotating adhesive jet printhead. The method and system for preparing a component by consolidating microparticles include: a build platform configured to receive microparticles; a microparticle dispenser configured to deposit microparticles onto the build platform; and at least one printhead including at least one nozzle. The at least one printhead is configured to dispense adhesive through the at least one nozzle onto the microparticles, causing at least a portion of the microparticles to consolidate and form a component. The method and system further include at least one actuator assembly configured to rotate the build platform and at least one of the at least one printhead about a rotation axis extending through the build platform and to move the build platform and at least one of the at least one printhead along a build direction perpendicular to the build platform as part of a helical build process for the component.

Description

Technical Field

[0001] The subject matter described in this article generally relates to additive manufacturing systems, and more particularly to additive manufacturing systems that include an adhesive jet printhead that rotates relative to the build platform. Background Technology

[0002] At least some known additive manufacturing systems involve consolidating microparticles to prepare components. Such techniques facilitate the production of complex components from microparticle materials at reduced costs and with improved manufacturing efficiency. At least some known additive manufacturing systems use one or more adhesive jet printheads to dispense adhesive onto the microparticles to prepare components. Additionally, in at least some additive manufacturing systems, one or more actuators are used to move a build platform during component preparation. However, the size of the prepared components is limited by the construction of the adhesive jet printhead, actuators, and build platform.

[0003] Additionally, in at least some known additive manufacturing systems, a recoater is used to distribute microparticles onto a build platform. For example, in some embodiments, the recoater moves microparticles from a container to the build platform and across the platform. The recoater and the adhesive jet printhead operate at separate times because the adhesive jet printhead cannot bind the microparticles together while the recoater is dispersing them. As a result, the time required to prepare the component is extended to accommodate the sequential operation of the recoater and the adhesive jet printhead.

[0004] Therefore, there is a need for improved additive manufacturing systems that include adhesive jet printheads that allow for the production of components of any size in a reduced time. Summary of the Invention

[0005] In one aspect, an additive manufacturing system is provided. The additive manufacturing system includes: a build platform configured to receive microparticles; and a microparticle dispenser configured to deposit microparticles onto the build platform. The additive manufacturing system further includes at least one printhead, the at least one printhead including at least one nozzle. The at least one printhead is configured to dispense an adhesive through the at least one nozzle onto the microparticles to at least partially solidify the microparticles and form a component. The additive manufacturing system further includes at least one arm extending at least partially across the build platform and configured to support the at least one printhead. The additive manufacturing system also includes at least one actuator assembly configured to rotate the build platform and at least one of the at least one printhead about a rotation axis extending through the build platform and to move the build platform and at least one of the at least one printhead along a build direction perpendicular to the build platform as part of a helical build process for a component.

[0006] In another aspect, a method for fabricating a component using an additive manufacturing system is provided. The method includes: depositing microparticles onto a build platform; and rotating at least one recoater blade relative to the build platform about a rotation axis extending through the build platform. The method further includes: using the at least one recoater blade to contact the microparticles on the build platform to distribute the microparticles across the build platform. The method further includes: rotating at least one printhead relative to the build platform about a rotation axis. The at least one printhead includes at least one nozzle. The method further includes: dispensing an adhesive onto the microparticles through the at least one nozzle to at least partially solidify the microparticles.

[0007] In another aspect, an additive manufacturing system is provided. The additive manufacturing system includes: a build platform configured to receive microparticles; a microparticle dispenser configured to deposit microparticles onto the build platform; and at least one printhead including at least one nozzle. The at least one printhead is configured to dispense adhesive through the at least one nozzle onto the microparticles to cause at least a portion of the microparticles to solidify and form a component. The additive manufacturing system also includes at least one actuator assembly configured to rotate the at least one printhead relative to the build platform about a rotation axis extending through the center of the build platform, and to move the at least one printhead along a build direction perpendicular to the build platform as the at least one printhead rotates. Attached Figure Description

[0008] These and other features, aspects, and advantages of this disclosure will become better understood when the following detailed description is read with reference to the accompanying drawings, in which the same characters throughout the drawings denote the same parts, wherein:

[0009] Figure 1 This is a perspective view of an exemplary additive manufacturing system including at least one rotating adhesive jet printhead;

[0010] Figure 2 yes Figure 1 An enlarged perspective view of a portion of the additive manufacturing system shown;

[0011] Figure 3 yes Figure 1 and Figure 2 A block diagram of the additive manufacturing system shown;

[0012] Figure 4 This is a schematic plan view of an embodiment of an additive manufacturing system including a supply system and at least one rotating adhesive jet printhead;

[0013] Figure 5 yes Figure 4 A schematic side view of the additive manufacturing system shown;

[0014] Figure 6This is a perspective view of an embodiment of an additive manufacturing system including a rotating adhesive jet printhead and multiple articulated arms;

[0015] Figure 7 This is a flowchart of an exemplary method for fabricating components using an additive manufacturing system that includes a rotating adhesive jet printhead;

[0016] Figure 8 This is a schematic perspective view of a mold assembled from mold parts prepared using an additive manufacturing system that includes a rotating adhesive jet printhead;

[0017] Figure 9 Is using Figure 8 A flowchart illustrating an exemplary method for casting components using a mold shown;

[0018] Figure 10 This is a perspective view of an exemplary embodiment of a particle supply and dispenser system for an additive manufacturing system including a rotating adhesive jet printhead;

[0019] Figure 11 yes Figure 10 An enlarged perspective view of a portion of the particle supply and dispenser system shown;

[0020] Figure 12 This is a perspective view of an exemplary embodiment of a recoater assembly for an additive manufacturing system including a rotary adhesive jet printhead;

[0021] Figure 13 yes Figure 12 An enlarged perspective view of a portion of the recoating assembly shown; and

[0022] Figure 14 This is a schematic side view of an additive manufacturing system including a rotary feed system.

[0023] Unless otherwise indicated, the accompanying drawings provided herein are intended to illustrate features of embodiments of the present disclosure. These features are considered applicable to a wide variety of systems that include one or more embodiments of the present disclosure. Accordingly, the drawings are not intended to include all conventional features known to those skilled in the art for practicing the embodiments disclosed herein. Detailed Implementation

[0024] In the following description and claims, references should be limited to a number of terms that have the following meanings.

[0025] Unless the context clearly specifies otherwise, the singular forms “a,” “a,” and “the” include a plural number of referenced objects.

[0026] "Optional" or "optionally" means that the event or situation described below may or may not occur, and this description includes instances where the event occurs and instances where the event does not occur.

[0027] As used herein and throughout the specification and claims, approximate language may be applied to modify any quantitative expression that may be varied without altering its essential function. Therefore, a value modified by one or more terms such as “approximately,” “substantially,” and “approximately” will not be limited to the specified precise value. In at least some instances, approximate language may correspond to the precision of the instrument used to measure the value. Scope limitations may be combined and / or interchanged herein and throughout the specification and claims, unless otherwise indicated by context or language; such scopes are identified and include all subscopes contained therein.

[0028] Additive manufacturing processes and systems include, but are not limited to, in-container photopolymerization, powder bed fusion, binder jetting, material jetting, sheet lamination, material extrusion, directional energy deposition, and hybrid systems. These processes and systems include, but are not limited to, SLA (stereolithography), DLP (digital light processing), 3SP (scanning, spin and selective photopolymerization), CLIP (continuous liquid interface production), SLS (selective laser sintering), DMLS (direct metal laser sintering), SLM (selective laser melting), EBM (electron beam melting), SHS (selective thermal sintering), MJF (multi-jet fusion), 3D printing, Voxeljet, Polyjet, SCP (smooth curvature printing), MJM (multi-jet modeling ProJet), LOM (laminated object fabrication), SDL (selective deposition lamination), UAM (ultrasonic additive manufacturing), FFF (fusion filament preparation), FDM (fusion deposition modeling), LMD (laser metal deposition), LENS (laser engineered net-shape forming), DMD (direct metal deposition), hybrid systems, and combinations of these processes and systems. These processes and systems may employ, for example, but not limited to, all forms of electromagnetic radiation, heating, sintering, melting, curing, bonding, consolidation, stamping, embedding, and combinations thereof.

[0029] Additive manufacturing processes and systems employ materials including, but not limited to, polymers, plastics, metals, ceramics, sand, glass, waxes, fibers, biological materials, composites, and mixtures of these materials. These materials may be used in these processes and systems in a variety of forms as appropriate for a given material and process or system (including, for example, but not limited to, as liquids, solids, powders, sheets, foils, tapes, filaments, pellets, liquids, slurries, wires, atomizations, pastes, and combinations of these forms).

[0030] The systems and methods described herein include an additive manufacturing system comprising a rotating adhesive jet printhead. The adhesive jet printhead is configured to rotate relative to a build platform and dispense adhesive onto microparticles to cause the microparticles to agglomerate. During operation of the adhesive jet printhead, a microparticle dispenser and a recoater assembly are configured to dispense and disperse microparticles onto the build platform to provide a continuous fabrication process. Additionally, the additive manufacturing system includes a support structure that supports the adhesive jet printhead, microparticle dispenser, and recoater assembly. Actuators are configured to rotate and lift the adhesive jet printhead, microparticle dispenser, and recoater assembly relative to the build platform as the additive manufacturing system fabricates a component on the build platform. As a result, the additive manufacturing system is capable of fabricating objects of any geometric complexity within the dimensions of the printing system. Furthermore, the additive manufacturing system can provide a multi-helix fabrication process that can fabricate objects in a shorter time than at least some known additive manufacturing systems. Moreover, the additive manufacturing system can be transported to a remote location and assembled because the support structure, adhesive jet printhead, microparticle dispenser, recoater assembly, and actuators are modular components.

[0031] Figure 1 This is a perspective view of an exemplary additive manufacturing system 100 including at least one rotating adhesive jet printhead 102. Figure 2 This is an enlarged perspective view of a part of the additive manufacturing system 100. Figure 3 This is a block diagram of additive manufacturing system 100. The coordinate system of additive manufacturing system 100 includes the X-axis, Y-axis, and Z-axis. Additive manufacturing system 100 constructs objects, for example, for casting component 518 (in... Figure 8 The mold 500 (shown in) Figure 8 (As shown in the figure). In an exemplary embodiment, the additive manufacturing system 100 includes at least one adhesive jet printhead 102 for consolidating microparticles. The additive manufacturing system 100 is configured to prepare an object or component using an additive manufacturing process by depositing adhesive from the adhesive jet printhead 102 onto the microparticles. For example, each adhesive jet printhead 102 includes a plurality of outlets or nozzles 108 and is configured to dispense adhesive onto the microparticles through the nozzles 108. Alternatively, the additive manufacturing system 100 may include any consolidation means for facilitating the consolidation of materials using any of the processes and systems described herein.

[0032] In an exemplary embodiment, the additive manufacturing system 100 further includes at least one recoater assembly 110 and at least one particle dispenser 112. Each recoater assembly 110 and particle dispenser 112 is associated with a corresponding rotary adhesive jet printhead 102. In an exemplary embodiment, the additive manufacturing system 100 includes three recoater assemblies 110, three particle dispensers 112, and three adhesive jet printheads 102. In alternative embodiments, the additive manufacturing system 100 includes any adhesive jet printhead 102, recoater assembly 110, and / or particle dispenser 112 that enables the additive manufacturing system 100 to operate as described herein. For example, in some embodiments, a single recoater assembly 110 and / or particle dispenser 112 is associated with a plurality of adhesive jet printheads 102. In other embodiments, the additive manufacturing system 100 includes a single adhesive jet printhead 102.

[0033] Furthermore, in an exemplary embodiment, the adhesive jet printhead 102, the recoater assembly 110, and the particle dispenser 112 are coupled to and supported by a support structure 114. The support structure 114 includes at least one arm 116 that extends at least partially across the build platform 104 and is configured to support at least one adhesive jet printhead 102. In an exemplary embodiment, the support structure 114 includes a central support 118 and three arms 116 equally spaced around the central support 118. The arms 116 extend radially outward from the central support 118. The recoater assembly 110 and the particle dispenser 112 are coupled to the arms 116 and positioned adjacent to the associated adhesive jet printhead 102 located on the arm 116. In an exemplary embodiment, each arm 116 supports one adhesive jet printhead 102, one recoater assembly 110, and one particle dispenser 112. In alternative embodiments, the support structure 114 includes any arm 116 that enables the additive manufacturing system 100 to operate as described herein. For example, in some embodiments, the support structure 114 includes an arm that supports the recoater assembly 110 and / or the particle dispenser 112 and is distinct from the arm 116 that supports the adhesive jet printhead 102.

[0034] Furthermore, in an exemplary embodiment, the support structure 114 further includes a track 120 and a plurality of struts 122 that support the track 120 at an adjustable height above the build platform 104. The track 120 extends circumferentially around the build platform 104 and is configured to support the arm 116 as it rotates about the axis of rotation 124. Additionally, the struts 122 may be positioned to adjust the height of the support structure 114 relative to the build platform 104 during operation of the additive manufacturing system 100. For example, the angle of each strut 122 relative to the axis of rotation 124 may be adjustable to change the height of the support structure 114, and thus change the distance between the build platform 104 and the adhesive jet printhead 102, the recoater assembly 110, and the particle dispenser 112. In some embodiments, vertical actuators may be used to extend / retract the length of each strut 122. In alternative embodiments, the additive manufacturing system 100 includes any support structure 114 that enables the additive manufacturing system 100 to operate as described herein.

[0035] During operation of the additive manufacturing system 100, microparticles are supplied by a microparticle dispenser 112 and uniformly distributed onto the build platform 104 using a recoater assembly 110. The recoater assembly 110 is configured to control the height of the microparticles relative to the height of the previous rotation of the helix and to facilitate the removal of excess microparticle material. An adhesive jet printhead 102 consolidates a first portion of the microparticles to form a cross-sectional layer of the component. The recoater assembly 110 and the adhesive jet printhead 102 can operate simultaneously to distribute and consolidate the microparticles because the recoater assembly 110 is positioned in front of and rotates in coordination with the corresponding adhesive jet printhead 102. During selective consolidation of the microparticle layer, as the microparticles are distributed onto the build platform 104 and portions of the component, a support structure 114 rises to elevate the adhesive jet printhead 102, the recoater assembly 110, and the microparticle dispenser 112 to allow continuous consolidation of the microparticles via the adhesive jet printhead 102. This process continues until the component is completely constructed from the consolidated portion of the microparticles.

[0036] Furthermore, in an exemplary embodiment, at least a portion of the support structure 114 is movable via an actuator system 126. In an exemplary embodiment, the actuator system 126 includes a first actuator assembly 128 and a second actuator assembly 130. The first actuator assembly 128 is configured to rotate an arm 116 of the support structure 114 about a rotation axis 124, and the second actuator assembly 130 is configured to move the arm 116 along the Z-direction (i.e., orthogonal to the top surface of the build platform 104) (also referred to as the build direction). In some embodiments, the actuator system 126 is configured to move at least one adhesive jet printhead 102 radially relative to the rotation axis 124. For example, in some embodiments, the adhesive jet printhead 102 may be moved along the length of the arm 116 during operation of the additive manufacturing system 100. The respective actuator assemblies 128, 130 include, for example, but not limited to, one or more linear motors, one or more hydraulic pistons and / or pneumatic pistons, one or more screw drive mechanisms, rotary stages, and / or conveyor systems. In alternative embodiments, the additive manufacturing system 100 includes any actuator system 126 that enables the additive manufacturing system 100 to operate as described herein. For example, in some embodiments, the actuator system 126 is configured to rotate the build platform 104 about a rotation axis 124 and / or move the build platform 104 in a build direction.

[0037] Additionally, in an exemplary embodiment, the particle dispenser 112 is positioned to deposit particles in front of the recoater assembly 110. In an alternative embodiment, particles are deposited onto the build platform 104 in any manner that enables the additive manufacturing system 100 to operate as described herein.

[0038] Furthermore, in an exemplary embodiment, at least one recoater blade 132 of the recoater assembly 110 is positioned to contact particles located in front of a corresponding adhesive jet printhead 102 and to distribute the particles across the build platform 104. For example, the recoater blade 132 may extend at least partially along the radius of the build platform 104. In an exemplary embodiment, the recoater blade 132 rotates relative to the build platform 104 together with the adhesive jet printhead 102. As a result, during operation of the additive manufacturing system 100, the recoater blade 132 contacts the particles and guides the particles across the build platform 104 along the length of the recoater blade 132. Additionally, the recoater assembly 110 maintains a uniform thickness of the respective layers of particles located on the build platform 104 over a previously consolidated layer. In some embodiments, the respective layers have a thickness ranging from about 10 micrometers to about 2000 micrometers. In an alternative embodiment, the recoater assembly 110 includes any recoater blade 132 that enables the additive manufacturing system 100 to operate as described herein.

[0039] Furthermore, in an exemplary embodiment, the additive manufacturing system 100 further includes a wall 134 extending around a build platform 104 to define a build container. In an exemplary embodiment, the build platform 104 is generally circular. The wall 134 is generally cylindrical and completely surrounds the particles located on the build platform 104. In alternative embodiments, the build platform 104 and / or the wall 134 may be any shape that facilitates the operation of the additive manufacturing system 100 as described herein. In further embodiments, the wall 134 may surround a portion of the particles and / or may be coupled to any other wall or component that facilitates the operation of the additive manufacturing system 100 as described herein. Additionally, in some embodiments, the additive manufacturing system 100 includes an inner particle receiving wall (not shown) to reduce the amount of particles required to assemble components. The inner particle receiving wall may be cylindrical. In embodiments including an inner particle receiving wall, particles may be distributed and consolidated adjacent to the inner particle receiving wall to form a shape with a cavity, such as a pipe shape, near the central region of the build platform 104.

[0040] Furthermore, in an exemplary embodiment, the adhesive jet printhead 102 is configured to agglomerate microparticles on different regions of the build platform 104, and to agglomerate different portions of the microparticles simultaneously. Because multiple adhesive jet printheads 102 are used to agglomerate the microparticles, the support structure 114 and the adhesive jet printheads 102 are able to rotate at increased speeds during component fabrication. In an alternative embodiment, the additive manufacturing system 100 includes any number of adhesive jet printheads 102, including a single adhesive jet printhead 102.

[0041] Furthermore, in an exemplary embodiment, the additive manufacturing system 100 includes a computer control system or controller 136. The controller 136 includes a processor 138, a memory 140, and a user interface 142, which includes an input device 144 and a display 146. The controller 136 controls the operation of the adhesive jet printhead 102 to facilitate the guiding of adhesive onto the surface of the microparticles of the build layer to form layers of the component. For example, the controller 136 controls the amount of adhesive dispensed through the respective nozzles or orifices 108 of the adhesive jet printhead 102.

[0042] In an exemplary embodiment, the additive manufacturing system 100 is operated to fabricate a component based on a computer-modeled representation of its 3D geometry. The computer-modeled representation may be generated in a computer-aided design (CAD) or similar file. The CAD file of the component is converted into a format including multiple build parameters for one or more helical layers of the component. For example, the build layers of the component include microparticles that will be solidified by the additive manufacturing system 100. In an exemplary embodiment, the component is modeled with a desired orientation relative to the origin of the coordinate system used in the additive manufacturing system 100. The geometry of the component is cut into one or more helical layers. An inkjet firing sequence is generated across the geometry of the respective layers. Build parameters are applied for each firing sequence to fabricate that layer of the component from the microparticles. Once this process is complete, a computer-generated build file including all layers(one or more) is generated. The build file is loaded into a controller 136 of the additive manufacturing system 100 to control the system during the fabrication of each layer.

[0043] After the build file is loaded into controller 136, additive manufacturing system 100 is operated to generate components by implementing additive manufacturing processes (such as adhesive jet printing methods). The exemplary additive manufacturing process does not use a pre-existing article as a precursor to the final component; instead, the process produces components from raw materials (such as microparticles) in a constructible form. For example, but not limited to, molds can be additively manufactured using sand, which is then bonded using an adhesive. Additive manufacturing system 100 enables the fabrication of components using a wide range of materials, including but not limited to metals, ceramics, glass, and polymers.

[0044] Furthermore, in an exemplary embodiment, during operation of the additive manufacturing system, the controller 136 is capable of controlling the position of the support structure 114 to adjust the height of the adhesive jet printhead 102. For example, Figure 1 The support structure 114 is shown in its initial position, wherein the adhesive jet printhead 102 is positioned adjacent to the build platform 104. Figure 2 A support structure is shown in an elevated position, with the adhesive jet printhead 102 positioned at a distance from the build platform 104. In an exemplary embodiment, the support structure 114 is moved vertically by adjusting the position or length of the strut 122 using an actuator system 126. In an alternative embodiment, the support structure 114 is moved in any manner that enables the additive manufacturing system 100 to operate as described herein.

[0045] In some embodiments, the controller 136 controls the rotational speed and / or vertical travel speed of the adhesive jet printhead 102, the particle dispenser 112, and / or the recoater blade 132 based on operating parameters of the additive manufacturing system 100. Operating parameters of the additive manufacturing system 100 include, for example, but not limited to, the configuration of the particle dispenser 112, the configuration of the recoater assembly 110, the number and type of the adhesive jet printhead 102, and the dimensions of the build platform 104.

[0046] Additionally, in an exemplary embodiment, the controller 136 coordinates the rotational speeds of the adhesive jet printhead 102, the recoater blade 132, and / or the particle dispenser 112 to accommodate localized variations in build-up time requirements. For example, the controller 136 identifies layers or segments of layers that require more or less build-up time due to variations in the thickness of corner sectors of the component, and adjusts the rotational rates of the adhesive jet printhead 102, the recoater blade 132, and / or the particle dispenser 112 to maintain the segments within the build-up area for the time required for the adhesive jet printhead 102 to complete the consolidation of each segment.

[0047] Furthermore, in an exemplary embodiment, the additive manufacturing system 100 includes a cleaning assembly 148, which is positioned adjacent to and configured to clean the respective adhesive jet printheads 102. For example, the cleaning assembly 148 is coupled to arm 116 and is capable of cleaning the adhesive jet printheads 102 without disassembling the additive manufacturing system 100.

[0048] Figure 4 This is a schematic plan view of an additive manufacturing system 200, which includes a supply system 204 and at least one rotating adhesive jet printhead 202. The additive manufacturing system 200 includes the adhesive jet printhead 202, the supply system 204, at least one particle dispenser 206, at least one recoater assembly 208, a build platform 210, and a support structure 212. The support structure 212 includes a plurality of arms 214 that support the adhesive jet printhead 202, the particle dispenser 206, and the recoater assembly 208. The adhesive jet printhead 202, the particle dispenser 206, and the recoater assembly 208 rotate relative to the build platform 210 about a rotation axis 216 extending through the build platform 210.

[0049] Figure 5This is a schematic side view of the additive manufacturing system 200. During operation of the additive manufacturing system 200, as the particle dispenser 206 and recoater assembly 208 rotate relative to the build platform 210, the particle dispenser 206 deposits particles 218 onto the build platform 210, and the recoater assembly 208 uniformly distributes the particles 218 onto the build platform 210. The recoater assembly 208 is configured to control the height of the particles 218 relative to the height of the previous rotation of the helix and facilitates the removal of excess particles 218. The adhesive jet printhead 202 selectively agglomerates the particles 218 to form cross-sectional layers of the component. During the selective consolidation of the microparticles 218, as the microparticles 218 are distributed across the build platform 210 and portions of the component, the arm 214 of the support structure 212 rises to elevate the adhesive jet printhead 202, the recoater assembly 208, and the microparticle dispenser 206, allowing for continuous consolidation of the microparticles 218 via the adhesive jet printhead 202. This process continues until the component is completely constructed from the consolidated portions of the microparticles 218.

[0050] Additionally, in an exemplary embodiment, each particulate dispenser 206 includes: a feed hopper or reservoir 220; a conduit 222 connected to an outlet 224 of the feed hopper 220; a discharge hopper or reservoir 226 connected to the conduit 222; and a valve 228 configured to regulate the flow of particulates from the feed hopper 220 and through the conduit 222 to the discharge hopper 226. In an exemplary embodiment, the feed hopper 220 and the conduit 222 are positioned above the discharge hopper 226, and the particulates are supplied to the discharge hopper 226 by gravity. In some embodiments, a sensor (not shown) (such as a scale or proximity switch) provides feedback for use in controlling the particulate dispenser 206. For example, the particulate dispenser 206 may be controlled to provide an appropriate feed rate of particulates 218 to the build platform 210 and to regulate the amount of particulates 218 on the build platform 210.

[0051] Additionally, in an exemplary embodiment, each particle dispenser 206 includes: a trough or conduit 230 extending along a corresponding arm 214; and a conveyor device 232 configured to convey particles 218 through the trough 230. Each trough 230 is in flow communication with a corresponding hopper 226 of the particle dispenser 206 and receives particles from the corresponding hopper 226 of the particle dispenser 206. The conveyor device 232 includes, for example, but not limited to, a belt conveyor, a screw conveyor, and / or any other conveyor device. The conveyor device 232 transports the particles 218 along the length of the trough 230 such that the particles 218 are distributed in a desired manner. For example, in some embodiments, additional particles 218 are distributed at locations spaced apart from the center of the build platform 210 because the relative rotational speed of the particle dispenser 206 is greater at distances spaced from the axis of rotation. The trough 230 includes multiple outlets 234 for allowing particles 218 to exit the trough 230 as the conveyor device 232 transports the particles 218 along the trough 230. The conveyor device 232 also transports excess particles 218 (i.e., particles not distributed through the outlets 234) back towards the discharge hopper 226 along the length of the trough 230. In an alternative embodiment, the additive manufacturing system 200 includes any particle dispenser 206 that enables the particle dispenser 206 to operate as described herein.

[0052] In an exemplary embodiment, the supply system 204 is configured to deliver microparticles to individual microparticle dispensers 206. The supply system 204 includes a supply reservoir 236 and a microparticle transfer assembly 238 configured to transfer microparticles from the supply reservoir 236 to the individual microparticle dispensers 206. For example, the transfer assembly 238 includes a lift or conveyor device 240 for conveying microparticles 218 to a hopper 220. In an exemplary embodiment, the supply system 204 is stationary relative to the build platform 210. Therefore, the supply system 204 is positioned aligned with each microparticle dispenser 206 at a specific angular location along the rotational path of the microparticle dispensers 206. In some embodiments, the microparticle dispensers 206 pause or stop at designated rotational positions to receive microparticles 218. In another embodiment, the supply system 204 delivers microparticles 218 to the microparticle dispensers 206 as they rotate. In alternative embodiments, the additive manufacturing system 200 includes any supply system 204 that enables the additive manufacturing system 200 to operate as described herein. For example, in some embodiments (such as...), Figure 14 In the embodiment shown, the particle dispenser 206 may be located at the center of the support structure 212, rather than at the outer circumference of the support structure 212.

[0053] Furthermore, in an exemplary embodiment, the additive manufacturing system 200 includes an actuator system 242 configured to rotate the support structure 212 about a rotation axis 216 and to raise the support structure 212 in a direction perpendicular to the build platform 210. For example, the actuator system 242 includes a rotary actuator (not shown) configured to rotate the support structure 212 on a track 244. Additionally, in an exemplary embodiment, the actuator system 242 includes a vertical actuator 246 configured to raise the track 244 relative to the build platform 210, and thus raise the support structure 212 positioned on the track 244 relative to the build platform 210. The vertical actuator 246 includes a hydraulic actuator or any other actuator that enables the actuator system 242 to operate as described herein. In an alternative embodiment, the additive manufacturing system 200 includes any actuator system 242 that enables the additive manufacturing system 200 to operate as described herein.

[0054] Figure 14 This is a schematic side view of additive manufacturing system 248. Additive manufacturing system 248 is similar to additive manufacturing system 200 (in... Figure 4 and Figure 5 (As shown in the figure), the additive manufacturing system 248 includes a particle dispenser 250 positioned at the center of the support structure 212 and aligned with the center of the build platform 210. In an exemplary embodiment, the particle dispenser 250 is mounted to the support structure 212 and rotates together with the support structure 212.

[0055] Additionally, in an exemplary embodiment, the particle dispenser 250 includes: a conduit 252; a central hopper or reservoir 254 coupled to the conduit 252; a trough or conduit 256 extending along each arm 214; and a conveyor device 258 configured to convey particles 218 through each trough 256. Each trough 256 is in flow communication with and receives particles from the central hopper 254 of the particle dispenser 250. In an alternative embodiment, the additive manufacturing system 200 includes any particle dispenser 206 that enables the particle dispenser 206 to operate as described herein.

[0056] In an exemplary embodiment, the supply system 204 is configured to deliver microparticles 218 to the microparticle dispenser 250. Specifically, a microparticle transfer assembly 238 extends from the supply reservoir 236 across the radius of the build platform 210 to a conduit 252 of the microparticle dispenser 250. The conduit 252 is configured to receive microparticles 218 and guide them to a central hopper 254 as the microparticle dispenser 250 rotates relative to the supply system 204. For example, in some embodiments, the conduit 252 includes an inlet for allowing microparticles 218 to enter the conduit 252 from the transfer assembly 238 and an outlet for dispensing microparticles 218 into the central hopper 254. Furthermore, the conduit 252 includes seals or valves, such as bellows seals, for preventing leakage of microparticles 218 from the conduit 252 and / or controlling the flow of microparticles through the dispenser 250. In an alternative embodiment, the additive manufacturing system 248 includes any supply system 204 that enables the additive manufacturing system 200 to operate as described herein. For example, in some embodiments, the supply storage 236 is located at the center of the construction platform 210.

[0057] Figure 6 This is a perspective view of an embodiment of an additive manufacturing system 300, which includes at least one rotating adhesive jet printhead 302 and a plurality of articulated arms. The additive manufacturing system 300 includes a support structure 304, which includes a central support 306 and a plurality of first articulated arms 308 extending radially outward from the central support 306, at least partially. The adhesive jet printhead 302 and a recoater assembly 312 are coupled to the ends of the first articulated arms 308. The first articulated arms 308 are configurable to adjust the position of the adhesive jet printhead 302 and the recoater assembly 312 relative to a build platform 316. Additionally, the first articulated arms 308 are rotatably coupled to the central support 306 such that the adhesive jet printhead 302 and the recoater assembly 312 are rotatable relative to the build platform 316. The recoating assembly 312 is adjacent to the adhesive jet printhead 302 and connected to the first hinge arm 308 such that when the first hinge arm 308 rotates about the central support 306 relative to the build platform 316, the recoating assembly 312 disperses microparticles in front of the adhesive jet printhead 302.

[0058] Furthermore, in an exemplary embodiment, the particle dispenser 314 is coupled to a second hinged arm 318, which allows the particle dispenser 314 to be positioned relative to the build platform 316. The particle dispenser 314 is capable of radial movement relative to the build platform by positioning the second hinged arm 318. In some embodiments, the angular position of the particle dispenser 314 about the center of the build platform 316 is fixed as the adhesive jet printhead 302 and the recoater assembly 312 rotate relative to the build platform 316. Therefore, the particle dispenser 314 is capable of depositing particles for each recoater assembly 312 to spread across the build platform 316 for consolidation of the adhesive jet printhead 302. In alternative embodiments, the additive manufacturing system 300 includes any particle dispenser 314 that enables the additive manufacturing system 300 to operate as described herein. For example, in some embodiments, the additive manufacturing system 300 includes a plurality of particle dispensers 314.

[0059] Figure 7 It uses additive manufacturing system 100 (in) Figure 1-3 (shown in the image), additive manufacturing system 200 (in) Figure 4 and Figure 5 (as shown in the diagram) or additive manufacturing system 300 (in Figure 6 A flowchart of an exemplary method 400 for preparing a component is shown in the figure. (See also:) Figure 1-3 and Figure 7 Method 400 includes depositing microparticles 402 onto a build platform 104. For example, a microparticle dispenser 112 is used to deposit microparticles onto the build platform 104. The microparticle dispenser 112 rotates relative to the build platform 104, and the microparticles are deposited relative to the rotation direction of the microparticle dispenser 112 in front of the recoater blade 132 and the adhesive jet printhead 102. In some embodiments, the microparticle dispenser 112 is supplied from a supply system 204 (in...) Figure 4 and Figure 5 (As shown in the diagram) receiving microparticles. In an alternative embodiment, microparticles are deposited on the build platform 104 in any manner that enables the additive manufacturing system 100 to operate as described herein.

[0060] Additionally, method 400 includes: rotating at least one recoater blade 132 relative to build platform 104 at 404; and using at least one recoater blade 132 to contact 406 particles on build platform 104 such that the particles are distributed across build platform 104. Furthermore, method 400 includes rotating at least one adhesive jet printhead 102 about a rotation axis 124 extending through build platform 104 relative to build platform 104 at 408. For example, in some embodiments, an arm 116 supporting adhesive jet printhead 102 and recoater blade 132 is rotated about rotation axis 124 using actuator system 126. In alternative embodiments, the recoater blade 132 and / or the recoater blade 132 are rotated in any manner that enables additive manufacturing system 100 to operate as described herein.

[0061] Furthermore, method 400 includes dispensing an adhesive through nozzle 108 410 onto the particles to at least partially solidify the particles. In some embodiments, the particles comprise sand, and the adhesive is configured to bond the sand together to form a component, such as a part of a mold.

[0062] Furthermore, method 400 includes moving at least one adhesive jet printhead 102 in a direction perpendicular to the build platform 104 by 412. For example, support structure 114 supports adhesive jet printhead 102, recoater blade 132, and particle dispenser 112, and during operation of additive manufacturing system 100, support structure 114 is rotated and raised by actuator system 126.

[0063] In some embodiments, during component fabrication, the build platform 104 rotates relative to the adhesive jet printhead 102 and / or moves along the build direction. For example, in some embodiments, the build platform 104 rotates relative to the adhesive jet printhead 102. In other embodiments, the build platform 104 descends while the adhesive jet printhead 102 or the build platform 104 rotates.

[0064] In an exemplary embodiment, method 400 allows the adhesive jet printhead 102 and the recoater blade 132 to operate simultaneously and provides a spiral build-up process in which multiple spiral build-up layers are used to fabricate a component. As a result, using additive manufacturing system 100 (in...) Figure 1-3 (shown in the image), additive manufacturing system 200 (in) Figure 4 and Figure 5 (as shown in the diagram) and / or additive manufacturing system 300 (in Figure 6 (As shown in the figure) the time required to prepare components is reduced.

[0065] Figure 8 This is a schematic perspective view of mold 500, which is constructed using additive manufacturing system 100 (in... Figure 1-3 (shown in the image), additive manufacturing system 200 (in) Figure 4 and Figure 5 (as shown in the diagram) and / or additive manufacturing system 300 (in Figure 6 The components are assembled using additive manufacturing systems (as shown in the diagram). For example, additive manufacturing systems 100, 200, and 300 are used to prepare multiple mold portions or layers 502 assembled into mold 500. In an exemplary embodiment, mold 500 is a sand mold, and each mold portion 502 is formed of sand. As a result, mold 500 can have a larger size and lower cost compared to molds formed of other materials.

[0066] Figure 9 It uses mold 500 (in) Figure 8 A flowchart of an exemplary method 504 for casting components is shown in the figure. (See also:) Figure 1 , Figure 4 , Figure 6 , Figure 8 as well as Figure 9 Method 504 includes: preparing a first mold portion 502 506 using an additive manufacturing system 100, 200, 300 including a rotating adhesive jet printhead 102, 202, 302; and preparing a second mold portion 502 508 using an additive manufacturing system 100, 202, 300 including a rotating adhesive jet printhead 102, 202, 302.

[0067] Furthermore, method 504 includes using filler (such as sand) to support the first mold portion 502 and the second mold portion 502. In some embodiments, unconsolidated particles 218 (in Figure 5 The filler sand (which may be cheaper than the fine particles 218) is removed and positioned around the mold portion 502. Additionally, in some embodiments, the individual mold portions 502 are surrounded by a barrel or bottle 512. Furthermore, in some embodiments, one or more chills (not shown) are positioned on, adjacent to, and / or within the mold portion 502 to control the solidification of the component formed using the mold 500. In another embodiment, a coating is applied to at least a portion of the mold portion 502. In alternative embodiments, the mold portion 502 is supported and processed in any manner that enables the mold 500 to function as described herein.

[0068] Additionally, method 504 includes joining the first mold portion 502 and the second mold portion 502 together 514 to assemble the mold 500. In an exemplary embodiment, the mold portions 502 are stacked in a vertical arrangement. In an alternative embodiment, the mold portions 502 are assembled in any manner that enables the mold 500 to function as described herein.

[0069] Furthermore, method 504 optionally includes repeating any of steps 508, 510, and 514 for any number of iterations to assemble mold 500 from any number of mold parts 502.

[0070] Furthermore, method 504 includes using mold 500 to cast component 516 518. For example, in some embodiments, one or more precursor materials in liquid form are used to fill cavities in mold 500, and the material is solidified to form component 518.

[0071] Figure 10 This is a perspective view of an exemplary embodiment of the particulate feeder and dispenser system 600. The particulate feeder and dispenser system 600 can be integrated with the additive manufacturing system 100 (in... Figure 1 and Figure 2 (shown in the image), additive manufacturing system 200 (in) Figure 3 and Figure 4 (as shown in the diagram) and / or additive manufacturing system 300 (in Figure 6 (as shown in the diagram) for use together. In an alternative embodiment, the feed and dispenser system 600 may be used with any additive manufacturing system that enables the feed and dispenser system 600 to function as described herein.

[0072] In an exemplary embodiment, the feed and dispenser system 600 includes a plurality of feed components 602 and a plurality of dispenser components 604. Each dispenser component 604 is coupled to a corresponding feed component 602 and receives microparticles from the corresponding feed component 602. Additionally, each dispenser component 604 extends radially across a build platform 606 and is configured to dispense microparticles onto the build platform 606. Furthermore, the feed and dispenser system 600 includes a recoater component 608 coupled to each dispenser component 604. The recoater component 608 is configured to disperse microparticles across the build platform 606. In some embodiments, at least a portion of the feed and dispenser system 600 is configured to rotate relative to the build platform 606 when the dispenser components 604 dispense microparticles and when the recoater components 608 disperse microparticles across the build platform 606. In an alternative embodiment, the feed and dispenser system 600 includes any dispenser component 604 and / or recoater component 608 that enables the particulate feed and dispenser system 600 to operate as described herein.

[0073] Figure 11This is an enlarged perspective view of a portion of the microparticle supply and dispenser system 600. In an exemplary embodiment, each dispenser assembly 604 includes a conduit 610 that receives and dispenses microparticles from and from a supply assembly 602. A reapplier assembly 608 is coupled to the conduit 610. Each reapplier assembly 608 includes a return conduit 612 and a reapplier blade 614 coupled to the return conduit 612. The return conduit 612 defines a cavity for receiving excess microparticles as the reapplier blade 614 spreads microparticles across a build platform 606. A conveyor device 616 is configured to transport microparticles through the return conduit 612 toward the supply assembly 602. In some embodiments, the conveyor device 616 includes a screw conveyor (not shown) positioned within the return conduit 612 and a motor configured to rotate the screw conveyor. In an alternative embodiment, the supply and dispenser system 600 includes any dispenser assembly 604 that enables the supply and dispenser system 600 to operate as described herein.

[0074] Furthermore, in an exemplary embodiment, each supply component 602 includes: a hopper 618; a conduit 620 connected to an outlet 622 of the hopper 618; a discharge hopper 624 connected to the conduit 620; and a valve 626 configured to regulate the flow of particles from the hopper 618 and through the conduit 620 to the discharge hopper 624. During operation of the particle supply and distributor system 600, particles are guided from the supply component 602 to the conduit 610 of the distributor component 604, and the particles are distributed through the outlet onto the build platform 606. In some embodiments, a conveyor device 616 or a separate conveyor device (not included in the original text) Figure 11 (As shown in the diagram) configured to guide microparticles through conduit 610. For example, a helical conveyor may be positioned in conduit 610 to guide and dispense microparticles along the length of conduit 610. In such embodiments, the distal end of conduit 610 is at least partially open to allow microparticles to exit conduit 610. In some embodiments, a container or collection device is positioned to collect microparticles as they exit conduit 610. In alternative embodiments, the feed and dispenser system 600 includes any feed component 602 that enables the feed and dispenser system 600 to operate as described herein.

[0075] Additionally, in an exemplary embodiment, the recoating blade 614 contacts the microparticles and disperses them across the build platform 606 into a layer of desired thickness. Excess microparticles are received in the conduit 612 and guided toward the supply assembly 602 via the conveyor device 616.

[0076] The microparticle supply and dispenser system 600 is configured to provide for the ejection of adhesive through the printhead 102 (in Figure 1-3 As shown in the figure), adhesive jet printhead 202 (in Figure 4 and Figure 5 (as shown in the image) or adhesive jet printhead 302 (in the image) Figure 6 (as shown in the figure) and solidified into one or more layers of microparticles. In some embodiments, the microparticle supply and dispenser system 600 is coordinated with the adhesive jet printheads 102, 202, 302 and rotates relative to the build platform 606. In other embodiments, at least a portion of the microparticle supply and dispenser system 600 (such as the supply assembly 602) is stationary relative to the build platform 606.

[0077] Figure 12 This is a perspective view of a portion of the recoating unit 700. Figure 13 This is an enlarged perspective view of a portion of the recoater assembly 700. The recoater assembly 700 can be integrated with the additive manufacturing system 100 (in... Figure 1 and Figure 2 (shown in the image), additive manufacturing system 200 (in) Figure 3 and Figure 4 (as shown in the diagram) and / or additive manufacturing system 300 (in Figure 6 (As shown in the figure) for use. In an alternative embodiment, the recoater assembly 700 may be used with any additive manufacturing system that enables the recoater assembly 700 to function as described herein.

[0078] In an exemplary embodiment, the recoater assembly 700 includes a groove 702 extending across a build platform 704. The groove 702 includes a top 706; a bottom 708 opposite to the top 706; and an opposing wall 710 extending between the top 706 and the bottom 708. The top 706 is substantially open. The bottom 708 includes angled walls 712 forming a funnel shape. The bottom 708 defines an outlet 714 adjacent to the build platform 704. Particles received within the groove 702 are formed downwards toward the outlet 714 in a funnel shape and are dispensed from the groove 702 through the outlet 714. In an alternative embodiment, the recoater assembly 700 includes any groove 702 that enables the recoater assembly 700 to operate as described herein.

[0079] Additionally, in an exemplary embodiment, outlet 714 is sized to limit the amount of particles flowing out of trough 702. For example, the width of outlet 714 is smaller than the width of top 706, through which particles can be received into trough 702. Therefore, in an exemplary embodiment, trough 702 is filled with particles when they are supplied to it at a rate greater than the rate at which they leave outlet 714. Particles are supplied to and guided through recoater assembly 700 in any manner that enables recoater assembly 700 to operate as described herein. In some embodiments, recoater assembly 700 includes a valve (not shown) for controlling the flow of particles supplied to trough 702. In another embodiment, recoater assembly 700 includes a conveyor device (not shown) for guiding particles along the length of trough 702 in at least one direction. Figure 12 and Figure 13 (as shown in the image).

[0080] Furthermore, in an exemplary embodiment, the recoater blade 716 is adjacent to the outlet 714 and coupled to the slot 702. The recoater blade 716 is configured to disperse particles across the build platform 704 as the particles exit the slot 702 through the outlet 714. The recoater blade 716 is removably coupled to the slot 702 to allow for removal and replacement of the recoater blade 716. In an alternative embodiment, the recoater assembly 700 includes any recoater blade 716 that enables the recoater assembly 700 to operate as described herein.

[0081] The embodiments described herein include an additive manufacturing system comprising a rotating adhesive jet printhead. The adhesive jet printhead is configured to rotate relative to a build platform and dispense adhesive onto microparticles to cause the microparticles to agglomerate. During operation of the adhesive jet printhead, a microparticle dispenser and a recoater assembly are configured to dispense and disperse microparticles onto the build platform to provide a continuous fabrication process. Additionally, the additive manufacturing system includes a support structure that supports the adhesive jet printhead, microparticle dispenser, and recoater assembly. Actuators are configured to rotate and rise the adhesive jet printhead, microparticle dispenser, and recoater assembly relative to the build platform as the additive manufacturing system fabricates a component on the build platform. As a result, the additive manufacturing system is capable of fabricating objects of any complexity. Furthermore, the additive manufacturing system can provide a multi-spiral fabrication process that can fabricate objects in a shorter time than at least some known additive manufacturing systems. Moreover, the additive manufacturing system can be transported to remote locations and assembled because the support structure, adhesive jet printhead, microparticle dispenser, recoater assembly, and actuators are modular components.

[0082] The exemplary technical effects of the methods, systems, and apparatuses described herein include at least one of the following: a) reducing the time required to fabricate components using an additive manufacturing system; b) providing an additive manufacturing system capable of fabricating components of any complexity; c) providing an additive manufacturing system that allows the consolidation device and recoating assembly to operate simultaneously during component fabrication; d) simplifying the mechanisms required to deposit microparticles onto a build platform; e) reducing the cost of additively manufactured components; and f) providing a modular additive manufacturing system capable of fabricating components in situ.

[0083] Exemplary embodiments of additive manufacturing systems have been described in detail above. Additive manufacturing systems and methods of using and manufacturing such systems are not limited to the specific embodiments described herein; rather, components of the system and / or steps of the method may be used independently of and separately from other components and / or steps described herein. For example, the method may also be used in combination with other additive manufacturing systems and is not limited to practice using only the additive manufacturing systems and methods described herein. Rather, it may be implemented in combination with many other additive manufacturing systems and utilize exemplary embodiments.

[0084] Although specific features of various embodiments of this disclosure may be shown in some of the accompanying drawings but not in others, this is merely for convenience. According to the principles of this disclosure, any feature in the drawings may be referenced and / or claimed in combination with any feature in any other drawing.

[0085] This written description uses examples to disclose embodiments (including best modes) and also enables any person skilled in the art to practice the embodiments (including making and using any apparatus or system and performing any incorporated methods). The patentability scope of this disclosure is defined by the claims and may include other examples that would occur to a person skilled in the art. Such other examples are intended to be within the scope of the claims if they have structural elements that are not different from the literal language of the claims, or if they include equivalent structural elements that are not substantially different from the literal language of the claims.

Claims

1. An additive manufacturing system (100, 200, 248, 300), comprising: A platform (104, 210, 316, 606, 704) is constructed to receive particles (218); A particle dispenser (250) configured to deposit the particles (218) onto the construction platform (104, 210, 316, 606, 704); At least one printhead (102, 202, 302) includes at least one nozzle (108), the at least one printhead (102, 202, 302) being configured to dispense adhesive through the at least one nozzle (108) onto the microparticles (218) to at least partially solidify the microparticles (218) and form a component (518); At least one arm (116, 214) extends at least partially across the build platform (104, 210, 316, 606, 704) and is configured to support the at least one printhead (102, 202, 302). At least one actuator assembly (128, 130) is configured to rotate at least one of the at least one printhead and the build platform (104, 210, 316, 606, 704) about a rotation axis (124, 216) extending through the build platform (104, 210, 316, 606, 704) and move at least one of the at least one printhead and the build platform (104, 210, 316, 606, 704) in a build direction perpendicular to the build platform (104, 210, 316, 606, 704) as part of a helical build process for the component (518); At least one recoater blade (132, 614, 716) is positioned adjacent to the build platform (104, 210, 316, 606, 704) and configured to contact the particles (218) deposited on the build platform (104, 210, 316, 606, 704) and to distribute the particles (218) across the build platform (104, 210, 316, 606, 704), wherein the at least one recoater blade (132, 614, 716) is coupled to the at least one arm (116, 214), and wherein the at least one actuator assembly (128, 130) is further configured to cause the at least one arm (116, 214) and the at least one recoater blade (132, 614, 716) to be connected. 614, 716) rotate relative to the construction platform (104, 210, 316, 606, 704); The at least one arm (116, 214) includes a first arm (116, 214) that supports the at least one printhead and the at least one recoater blade (132, 614, 716). The at least one actuator assembly (128, 130) is configured to rotate the at least one arm (116, 214) and the at least one printhead about the axis of rotation (124, 216) and to move the at least one printhead (102, 202, 302) along the construction direction; Furthermore, the additive manufacturing system includes at least one support (122) coupled to the at least one arm (116, 214), and wherein the at least one actuator assembly (128, 130) is configured to adjust the position of the at least one support (122) to move the at least one printhead (102, 202, 302) along the build direction.

2. The additive manufacturing system (100, 200, 248, 300) according to claim 1, characterized in that, The printheads (102, 202, 302) are first printheads (102, 202, 302), and the additive manufacturing system (100, 200, 248, 300) further includes a second printhead (102, 202, 302). The at least one actuator assembly (128, 130) is configured to rotate the second printhead about the axis of rotation (124, 216) relative to the build platform (104, 210, 316, 606, 704).

3. The additive manufacturing system (100, 200, 248, 300) according to any one of claims 1-2, characterized in that, The building platform (104, 210, 316, 606, 704) is circular, and the additive manufacturing system (100, 200, 248, 300) further includes a cylindrical wall (134) extending around the building platform (104, 210, 316, 606, 704) to define a building container, and the axis of rotation (124, 216) extends through the center of the building platform (104, 210, 316, 606, 704).

4. The additive manufacturing system (100, 200, 248, 300) according to any one of claims 1-2, characterized in that, The device further includes a cleaning component (148) which is positioned adjacent to the at least one printhead (102, 202, 302) and configured to clean the at least one printhead.

5. The additive manufacturing system (100, 200, 248, 300) according to any one of claims 1-2, characterized in that, The particle dispenser (250) is adjacent to and coupled to the at least one arm (116, 214) of the at least one printhead, and is configured to deposit the particles (218) onto the build platform (104, 210, 316, 606, 704) as the at least one printhead rotates, the particle dispenser (250) distributing the particles (218) in front of the at least one printhead in the direction of rotation of the at least one printhead.

6. The additive manufacturing system (100, 200, 248, 300) according to claim 5, characterized in that, It further includes a particle reservoir (220, 226, 254) and a particle transfer assembly (238) configured to transfer particles (218) from the particle reservoir (220, 226, 254) to the particle dispenser (250) during rotation of the at least one printhead (102, 202, 302).

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