Modular structure for additive manufacturing

Abstract

A print engine of an additive manufacturing system includes a print station configured to hold a removable cartridge. A laser engine including a frame can be positioned to hold at least one removable field replaceable unit including at least some laser optics or patterning optics. An optical alignment system can be attached to at least one of the print station or the laser engine to align the field replaceable unit relative to the removable cartridge.

Description

[0001] Related Applications

[0002] This disclosure is part of a non-provisional patent application claiming priority to U.S. Patent Application No. 63 / 030,757, filed May 27, 2020, which is incorporated by reference in its entirety. TECHNICAL FIELD

[0003] The present disclosure relates generally to systems and methods for high yield additive manufacturing. In one embodiment, high speed manufacturing is supported by using a removable print cartridge and a removable laser print engine.

[0004] BACKGROUND

[0005] Traditional part machining often relies on removing material by drilling, cutting, or grinding to form a part. In contrast, additive manufacturing (also known as 3D printing) generally involves successively adding material layer by layer to build a part. Starting from a 3D computer model, an additive manufacturing system can be used to form complex parts from a variety of materials.

[0006] One additive manufacturing technique, known as powder bed fusion (PBF), uses one or more focused energy sources, such as a laser or electron beam, to draw a pattern in a thin layer of powder by melting the powder and binding it to the underlying layer to gradually form a 3D printed part. The powder can be plastic, metal, glass, ceramic, crystal, other meltable materials, or a combination of meltable and non-meltable materials (i.e., plastic and wood or metal and ceramic). This technique is very precise and can often achieve feature sizes as small as 150-300 um. However, industrial additive manufacturing systems can be cumbersome to operate, often requiring workers to wear protective equipment (e.g., respirators, safety glasses, special uniforms) while performing normal daily tasks such as removing 3D printed parts, cleaning the print chamber, or maintaining worn items.

[0007] Some additive manufacturing systems attempt to improve the ease and safety of servicing by sealing the 3D printed item in a box. The box can be removed from the machine after the additive manufacturing system completes printing. Unfortunately, it can be difficult to form a perfect seal between the printer and the sealed box, and as a result some powder always exists outside of the print chamber. This can put the operator at risk of inhalation hazards.

[0008] The additive manufacturing system can also require significant time to remove the 3D-printed item, clean, and service the printer before the next 3D print can begin. Even if the 3D-printed item is sealed in a box, the print chamber can still require manual cleaning and any worn items (e.g., spreader blades, etc.) require manual replacement and realignment. Because printing is inherently a dirty process (in this case, dirt refers to soot, unused powder, spatter, etc.), everything inside the print chamber, including the spreader blades, gas flow plumbing, glass windows, spreader drive mechanisms, can be covered in dirt. Since it is important to ensure the purity of the print powder used, it is critical to thoroughly clean the print chamber and gas plumbing before changing materials. This requires a deep clean, often involving disassembling many parts so that the dirt can be removed. This work cannot be done through a glove port and can require the use of a specially trained labor force wearing protective equipment such as respirators.

[0009] Another problem comes from 3D-printed items that require an inert gas environment. Whenever the print chamber is opened to atmospheric air, the print chamber must be evacuated and purged. This process takes a significant amount of time and results in a loss of expensive inert gas. These activities can also take a significant amount of time, reducing the throughput of the additive manufacturing. New 3D prints cannot typically begin until the cleaning and servicing is complete.

[0010] When the 3D-printed item is removed from the print chamber, the additive manufacturing system can also require that the 3D-printed item be removed from the controlled print environment. This can have a detrimental effect on 3D-printed items that require post processing cooling and / or subsequent stress relief, annealing, or heat treatment in a heat treatment furnace. While the additive manufacturing system can pre-heat the print plate and / or maintain the print at a set temperature during printing in the print chamber, temperature control is typically not available outside of the print chamber. Unfortunately, when the 3D-printed item is removed from the print chamber, these 3D-printed items are typically not temperature controlled and, in many systems, are also exposed to uncontrolled air. These factors can affect the material properties of the 3D-printed item. In addition, the 3D-printed items are often too hot to be immediately removed from the print chamber, so they must remain in the print chamber for hours after they have finished printing. This can tie up the print chamber and prevent the system from starting a new print job.

[0011] SUMMARY

[0012] In some embodiments, a print engine of an additive manufacturing system includes a print station configured to hold a removable cartridge. A laser engine including a frame can be positioned to hold at least one removable field replaceable unit including at least some laser optics or patterning optics. An optical alignment system can be attached to at least one of the print station or the laser engine to align the field replaceable unit relative to the removable cartridge.

[0013] In some embodiments, the removable cartridge includes a sealable chamber having a bed and a laser transparent window.

[0014] In some embodiments, the removable cartridge includes a powder hopper positioned within the sealable chamber and a powder spreader positioned within the sealable chamber for dispensing powder from the powder hopper onto the bed.

[0015] In some embodiments, the frame of the laser engine is actively mechanically damped.

[0016] In some embodiments, the laser passes between multiple field replaceable units.

[0017] In some embodiments, the connection to the facility station is used to provide gases, fluids, electrical, control, and database systems to the at least one removable field replaceable unit and the removable cartridge.

[0018] In some embodiments, a print cartridge transporter unit can be used to move the removable cartridge.

[0019] In some embodiments, a field replaceable unit transporter unit can be provided.

[0020] In some embodiments, the laser engine can direct a two-dimensional patterned laser beam into the removable cartridge.

[0021] In some embodiments, the removable field replaceable units can direct laser beams between each other.

[0022] An additive manufacturing printing method includes positioning a removable cartridge in a print station. A laser beam can be directed from a laser engine into the removable cartridge, the laser engine including a frame holding at least one removable field replaceable unit including at least some laser optics or patterning optics. The field replaceable unit can be aligned relative to the removable cartridge using an optical alignment system attached to at least one of the print station or the laser engine.

[0023] In some embodiments, a print engine of an additive manufacturing system includes a print station configured to hold a removable cartridge. A laser engine includes a frame to hold a plurality of removable field replaceable units. Each field replaceable unit can have at least some laser optics or patterning optics to direct a laser beam to a removable cartridge in the print station.

[0024] In some embodiments, a print engine of an additive manufacturing system includes a print station configured to hold a removable cartridge. A laser engine includes a frame to hold a plurality of removable field replaceable units. Each field replaceable unit can have at least some laser optics or patterning optics to direct a laser beam to a removable cartridge in the print station, wherein the laser beam passes through a plurality of field replaceable units before being directed into the removable cartridge. BRIEF DESCRIPTION OF DRAWINGS

[0026] Non-limiting and non-exhaustive embodiments of the present disclosure are described with reference to the following figures, wherein like reference numerals refer to like parts throughout the various figures unless otherwise specified.

[0027] Figure 1A A print cartridge for an additive manufacturing system is illustrated in partial cross-section;

[0028] Figure 1B A transporter for a print cartridge is illustrated;

[0029] Figure 1B (i) an autonomously driven transporter is illustrated;

[0030] Figure 1C Installation of a print cartridge in a print module of an additive manufacturing system is illustrated;

[0031] Figure 1D A print cartridge interface is illustrated;

[0032] Figure 1E A print storage module is illustrated;

[0033] Figure 1F Use of an auxiliary print module is illustrated;

[0034] Figure 1G An eight system work cell factory layout is illustrated;

[0035] Figure 1G (i) an eight system work cell factory layout is illustrated; Figure 1G (ii) and Figure 1G (iii) use of a large print cartridge and various transport mechanisms for a large print cartridge are illustrated;

[0036] Figure 1HAlternative embodiments of print cartridges are illustrated that are capable of interacting with an X-Y stage that can traverse the entire area of a print plate in the print cartridge;

[0037] Figure 1I Alternative embodiments of print cartridges are illustrated that are capable of interacting with an X-Y stage that can traverse the entire area of a print plate in the print cartridge;

[0038] Figure 1J Alternative embodiments of print cartridges are illustrated that are capable of interacting with an X-Y stage that can traverse the entire area of a print plate in the print cartridge;

[0039] Figure 1K Alternative embodiments of print cartridges are illustrated that are capable of interacting with an X-Y stage that can traverse the entire area of a print plate in the print cartridge;

[0040] Figure 1L Alternative embodiments of print cartridges are illustrated that are capable of interacting with an X-Y stage that can traverse the entire area of a print plate in the print cartridge;

[0041] Figure 1M Alternative embodiments of print cartridges are illustrated that are capable of interacting with an X-Y stage that can traverse the entire area of a print plate in the print cartridge;

[0042] Figure 1N Alternative embodiments of print cartridges are illustrated that are capable of interacting with an X-Y stage that can traverse the entire area of a print plate in the print cartridge; Figure 1M Alternative embodiments of print cartridges are illustrated that are capable of interacting with an X-Y stage that can traverse the entire area of a print plate in the print cartridge;

[0043] Figure 1O Alternative embodiments of print cartridges are illustrated that are capable of interacting with an X-Y stage that can traverse the entire area of a print plate in the print cartridge;

[0044] Figure 1P Alternative embodiments of print cartridges are illustrated that are capable of interacting with an X-Y stage that can traverse the entire area of a print plate in the print cartridge;

[0045] Figure 1Q Alternative embodiments of print cartridges are illustrated that are capable of interacting with an X-Y stage that can traverse the entire area of a print plate in the print cartridge;

[0046] Figure 1Q Alternative embodiments of print cartridges are illustrated that are capable of interacting with an X-Y stage that can traverse the entire area of a print plate in the print cartridge;

[0047] Figure 1R Alternative embodiments of print cartridges are illustrated that are capable of interacting with an X-Y stage that can traverse the entire area of a print plate in the print cartridge;

[0048] Figure 1S Alternative embodiments of print cartridges are illustrated that are capable of interacting with an X-Y stage that can traverse the entire area of a print plate in the print cartridge;

[0049] Figure 1T Alternative embodiments of print cartridges are illustrated that are capable of interacting with an X-Y stage that can traverse the entire area of a print plate in the print cartridge;

[0050] Figure 2 Alternative embodiments of print cartridges are illustrated that are capable of interacting with an X-Y stage that can traverse the entire area of a print plate in the print cartridge;

[0051] Figure 3 Alternative embodiments of print cartridges are illustrated that are capable of interacting with an X-Y stage that can traverse the entire area of a print plate in the print cartridge;

[0052] Figure 4 The diagram illustrates the operation of a box-based additive manufacturing system capable of providing one-dimensional or two-dimensional beams to a box.

[0053] Detailed description

[0054] In the following description, reference is made to the accompanying drawings, which form part of the description and illustrate, by way of illustration, specific exemplary embodiments in which the present disclosure may be practiced. These embodiments have been described in sufficient detail to enable those skilled in the art to practice the concepts disclosed herein, and it should be understood that modifications may be made to various disclosed embodiments, and other embodiments may be utilized, without departing from the scope of the present disclosure. Therefore, the following detailed description should not be construed as limiting.

[0055] Figure 1A A partial cross-sectional illustration shows a 3D printing cartridge 1A for an additive manufacturing system. The 3D printing cartridge (hereinafter referred to as the "cartridge") isolates all "dirty" printing functions from the rest of the system and the operator's environment and is designed for replacement or removal. "Dirty" refers to any situation where powder is present, processed for printing, or soot is generated. Whenever the cartridge 1A is connected to a mating device such as a station (printer, de-dust collector, or storage station) described later, the mating device can supply the services required to operate the cartridge as needed based on the station it is mating with (e.g., a printer station allows full control of the cartridge, while a storage station may only provide heating, power and gas recovery, and the use of cameras and lights). The cartridge 1A is designed to be sealed when disconnected from the mating station.

[0056] The cartridge 1A is constructed around the bed or substrate 24A. New powder for a new print is stored in a powder hopper 2A, which can have the capacity to store all the powder required for full-volume printing. The new powder is metered onto the substrate 24A through a powder gate 23A. The powder is swept across the plate by a powder distributor 4A using a powder dispensing blade. A powder distributor drive 5A moves the powder distributor back and forth across the print plate 12A.

[0057] Window 3A seals the top of cartridge 1A, preventing powder or gas leakage and allowing a laser beam (not shown) to pass through the window to weld powder. Window 3A allows access to the cartridge for loading print plates, unloading prints, cleaning and maintaining cartridge components (seals, dispenser scrapers, etc.). The interior of cartridge 1A can be illuminated and imaged by a camera and light 22A. The camera and light can be located inside or outside the sealed chamber, or both, and can be positioned to take photographs and / or focus on scenes inside the cartridge, particularly on the print plates. The camera and light can also be mounted on a motion platform, allowing the user to pan or zoom the item of interest during printing. The camera can be used in conjunction with auxiliary print diagnostic devices (such as pyrometers, motion detectors, photodiodes, thermal cameras, or other sensors) to automatically detect events and pan / zoom the camera to focus on the location of interest. In some embodiments, the operator can view the camera image in an electronic or virtual window, rather than directly through a physical port or window in the cartridge.

[0058] Inert gas can be supplied to the cartridge through gas supply conduit 6A, allowing printing to take place in any atmosphere most favorable for each print. Inert gas is removed through gas return conduit 7A. The gas passes through a HEPA filter 8A to remove impurities (soot, suspended nanoparticles of powder, etc.). The gas then travels to a gas recovery unit (not shown) mounted on the mating device. When the cartridge is disconnected from the mating device, gas supply port 9A and gas return port 10A are sealed to maintain the atmosphere within the cartridge. The gas is subsequently purified by removing oxygen, moisture, etc., by other equipment.

[0059] After each layer is printed, the Z-axis lowers the print plate, allowing a new powder layer to be spread and subsequently printed. In this design, the Z-axis frame 11A holds the Z-axis components. The print plate (also known as the build plate) 12A is where the powder is soldered during printing. The print plate heater 13A contains a heating mechanism for the print plate 12A (if needed) and also insulates and / or cools the sealing plate 14A. The sealing plate 14A carries a seal 15A that confines the powder to the Z-axis frame 11A. The Z-axis base plate 16A closes the lower end of the Z-axis frame 11A and features the ability to accommodate any powder that may slip across the seal 15A. The plunger 17A has an interface that allows it to be remotely, automatically, and precisely engaged with the Z-axis drive. The plunger seal 18A mates with the base plate 16A and further seals the housing 1A to prevent powder and / or gas leakage.

[0060] Interface board 19A contains all the inputs and outputs of the box (compressed air, power, input and output signals, gas, cooling water, etc.). Interface board 19A is designed to make all these connections when the box is connected to mating equipment. The interface may also include a mechanism for electronically identifying each box when it mates with the mating equipment. Roller 20A allows box 1A to roll onto mating rails of the mating equipment. Forklift tube 21A allows the box to be picked up and moved by a forklift or other transport system.

[0061] In another embodiment, the interface board can be configured to work with various types or models of printers.

[0062] In one embodiment, the drive components (such as motors, actuators, etc.) can be positioned within the mating station, and a linkage mechanism can be used to transmit power from the external drive components to the driven components inside the cartridge. This reduces the cost and complexity of each cartridge. For example, the powder dispensing drive 5A can be coupled to a linkage mechanism that automatically engages when the cartridge is connected to the print station / print engine via a gear system, belt system (as shown in 5A), magnetic restraint, electrical, magnetic, inductive, hydraulic, or other similar type of signal or energy transmission. Similarly, gas and fluid exchange between the cartridge and any compatible mating station can have an external powder pump, fluid pump, and / or gas pump that hooks into the cartridge at an interface panel 19A or other convenient location that allows the transfer of powder (to the hopper 2A), fluid, or gas without overloading the cartridge with an internal service motor / pump. The internal impeller (for transferring powder and fluid) can be powered by an external motor via the aforementioned linkage mechanism.

[0063] The power coupling via interface panel 19A can be electrical, inductive, or optical, with the latter two allowing for simultaneous power and communication transfer. Furthermore, diagnostic information from various sensors integrated into the box can be obtained via electrical or optical methods.

[0064] In one embodiment, cartridge 1A may include electronic identification (such as electronically readable memory 25A) or other electronically readable markings (such as attached text, QR codes, or barcodes). Memory 25A can provide electronic information about the cartridge or cartridge components that can be used to identify their brand, model, type, powder type, or any other defining details about the unit, its sub-components, or their intended use. This information can be used to inform the print engine about the material to be printed, the desired atmosphere (pressure and temperature), or other print-related aspects, so that the print engine can adjust as needed to adapt to the print cartridge or sub-assembly. The resulting changes may involve behaviors such as: automatic exchange of internal lens assemblies, adjustment of the z-height / final optical projection of the lens assemblies, adjustment of laser parameters (such as power per unit area, pulse shape, pulse duration, pulse repetition rate, wavelength, spatial pulse shape, tile size, spatial energy distribution within the tile), modification of data diagnostics, data feedback algorithms, print process feedback algorithms, or changes to algorithms on how tiles are placed during the print process. Electronic information from the electronic memory 25A associated with the print cartridge can be read by any station to collect data on how much printing has occurred and other key metrics (such as the number of distributor cycles, z-axis adjustment, temperature cycles, pressure cycles, or other attributes experienced by the cartridge or sub-cartridge along the way). This information can also be stored in a central database via any station, a subsystem, a factory automation system, the cartridge itself, a cartridge transport system, or other mating / interface devices.

[0065] Figure 1B An embodiment of the additive manufacturing system 1B, including a cartridge 2B, is illustrated. As shown, the cartridge 2B is transported to the printing station 11B on a custom transport fixture 4B carried by a transporter (here indicated by a forklift 3B). The transporter can engage with the cartridge such that all or some of the cartridge's services and functions are operational, or the cartridge can be partially or completely disconnected from services and inoperable while being carried by the transporter. As will be described in more detail later, the printing engine 11B is a system module comprising the printing station and the laser engine station. The cartridge 2B is ready for printing when it has been prepared in another mating device (such as a preparation service station (not shown)) (i.e., filled with new powder, installed with a new print plate, all cartridge components inspected, updated and aligned, filled with appropriate gas, with a preheated print plate, etc.).

[0066] The transporter 3B aligns the transport fixing device 4B with the mating guide rail 5B. Once aligned, the capturing mechanism 6B pulls the print cartridge 2B into the print station 11B. The print cartridge 2B is aligned and locked in place within the print station 11B. When the cartridge 2B is pulled into place, its interface plate (similar to the one about...) Figure 1AThe described interface board 9B is aligned with the print station interface board 9B. When cartridge 2B is locked in place, the interface board fully engages and services (compressed air, power, input and output signals, gas, cooling water, etc.) are supplied to print cartridge 2B. Locking in place may alternatively or additionally involve the use of permanent magnets or electromagnets, pins, clamps, hooks, cables, ramps, air bearings, linear sliders, linkages, or robot end effectors. Furthermore, hardware keying can be used as an additional safety measure to prevent unauthorized use, such as when active metals are loaded into the cartridge and it is necessary to ensure that the atmosphere in the print station is suitable to prevent explosions. Additional or alternative keying, such as electronic, optical, and software keying, can be used as overlay safety measures and to prevent unauthorized use of the FRU independent of the approved station.

[0067] Once engaged, the Z-axis piston 7B rises to touch the Z-axis plunger (similar to the...). Figure 1A (As described). Once the Z-axis piston 7B and the Z-axis plunger make contact, the automatic clamp 8B connects them. The Z-axis of the cartridge is now fully controllable by the print station 11B. The built-in optical diagnostic device (camera / sensor) and illumination in the cartridge are now powered by the print station 11B, and diagnostic images / data can be displayed on the virtual window 10B, and / or anywhere else the print station is directed to send images / data.

[0068] When printing is complete, the conveyor 3B aligns the transport fixture 4B with the print cartridge 2B. The capturing mechanism 6B pushes the print cartridge 2B, causing it to roll outwards and onto the transport fixture 4B. The print cartridge 2B engages with and locks into place on the transport fixture 4B. The conveyor 3B can now deliver the cartridge 2B to another station or another mating device. The printing station 11B is immediately available, allowing another print cartridge to be loaded into place, and the next printing can begin with minimal downtime between prints. Note that this second print cartridge can contain entirely different printable material.

[0069] In this case, the transporter (3B) is a human-driven box transporter; however, in other embodiments, the transporter may be partially or fully automated. In other cases, partially or fully automated transporters may be guided by a telepresence camera (remote operator), by an embedded transponder, by simple or complex algorithms (such as artificial intelligence, neural networks, deep learning networks, neuromorphic processing, or other automated decision-making methods), and assisted by any number of optical or non-optical sensors.

[0070] In other embodiments, the module interface (6B) is at the same height as the box, and the transporter 3B engages with and locks into the box 2B without any height adjustment, thereby eliminating the need for "forklift-style" operation on the transporter 3B.

[0071] Figure 1B (i) illustrates an autonomously propelled transporter 1B(i) carrying a print cartridge. The print cartridge (3B(i)) is loaded onto the autonomously propelled transporter 5B(i). The transporter can be controlled by its own software / instructions / programming to deliver 3B(i) to a destination indicated by instructions located in the cartridge 3B(i), a manufacturing system control program, instructions loaded into the cartridge 3B(i), telemetry control, or any of the communication connection methods mentioned below. The transporter 5B(i) may also include power / communication to allow the cartridge to operate and to allow the control system to monitor diagnostic devices within the cartridge via a communication system on the transporter.

[0072] Figure 1C The illustration shows an embodiment of the additive manufacturing system 1C, with a front view of a print station 11C that holds a print cartridge 2C during printing. The cartridge 2C is aligned and supported by mating guide rails 3C. A Z-axis piston 4C has risen and is connected to the cartridge plunger (similar to the one about...). Figure 1A (As described). The laser beam 5C leaves the print station 11C, passes through the top window 6C of the cartridge, and welds the powder into the printed parts inside the cartridge 2C. A safety shield 7C prevents the laser from escaping from the print station and protects the operator from accidental contact with the print chamber 2C during printing. The operator can check the print by viewing a camera image displayed on a virtual window 8C. Furthermore, any diagnostic data can be displayed on the virtual window 8C, such as images in the visible or invisible wavelength range, optical pyrometric measurements, or information from a laser ultrasound imaging system (LUIS) or a similar high-speed imaging system.

[0073] Figure 1D Example 1D shows a front view of a standard box interface. These interface features 6D can be incorporated into all mating devices, allowing the box to mate with each device in the same way. The box mating guide 6D guides and supports the box. The capturing mechanism 2D pulls the box into the mating device and pushes it back onto the transport fixture (similar to the diagram above). Figure 1B(As described). The dimensions, materials, functions, and locations of these features can be standardized. Standard interfaces provide maximum flexibility for the customer processing box. Communication with any module can be accomplished via the interface panel 3D. In some embodiments, communication can be achieved using low-frequency or high-frequency modes or via a hardware interface; other methods may include RF, Wi-Fi, induction, Ethernet, USB, or Bluetooth. High-frequency methods may include fiber optic, LiFi, or free-space optical links. Hardware interfaces may include SIM, floppy disk, DVD, laser DVD, holographic disc, or volume optical memory structures. Hardware modes can be operator-installed or have a transfer mechanism that allows the box to physically transfer one of its instruction storage modes from itself to a similar receiver interface on the module.

[0074] In other embodiments where the boxes are very large (the size of a cargo container), the boxes will be very heavy. In these embodiments, the boxes are fixed, and stations are transported to the boxes, where... Figure 1D The same interface allows the station to work with the fixed box.

[0075] Figure 1E An exemplary additive manufacturing system 1E is illustrated, including a storage station or storage shelf 11E, which shows three boxes 2E already installed. A transporter 4E is illustrated to transport a fourth box 3E to the shelf 11E for storage. The shelf 11E has an example of four standard print box interfaces, including supports, mating rails 5E, interface plates 6E, and capture mechanisms 7E. The shelf 11E will have a facility station 8E, which houses means for supplying services (compressed air, power, input and output signals, gas, cooling water, etc.) to each box as needed. The facility station 8E can be configurable to allow customers flexibility in using the shelf. The status of each box 2E can be obtained on one or more monitors, which will also serve as virtual windows 9E, allowing the operator to observe the interior of each box.

[0076] Shelf 11E provides a storage location for cartridges. Unused or new cartridges filled with new powder and a new print plate can be stored here, ready to be installed in the print engine to begin a new print. Shelf 11E can preheat the print plate and keep the cartridge filled with gas as needed for the print job assigned to the cartridge. Additionally, cartridges containing newly completed prints can be stored on shelf 11E while awaiting post-processing. Prints can be held at any temperature, or allowed to rise or fall with a temperature profile. This allows for annealing or heat treatment of the prints to relieve stress or achieve desired mechanical properties. This simply allows the prints time to cool sufficiently for powder removal. The atmosphere can also be altered, for example, by introducing new gas or a mixture of gases, to achieve desired mechanical properties. In other system embodiments, empty cartridges can simply be stored on storage shelf 11E to keep them out of the way. Cartridges can be stored on shelf 11E in any state, including new and filled with powder, used and depleted of powder, or partially used.

[0077] Built-in diagnostics continuously monitor the printing status of the cartridges. These built-in diagnostics can include part, powder, and ambient temperature, image diagnostics at multiple wavelengths, and other modalities such as vibration and ultrasonic imaging, as well as LUIS volume mapping of the printed parts. Any diagnostic information (images or data) for any cartridge contained in the shelving can be displayed on the virtual window 9E. Furthermore, information for current and past cartridges can be sent to any other virtual window or user interface via the control system.

[0078] Figure 1F An example of a print engine 11F with an auxiliary print station 2F attached is illustrated. Print engine 11F can accept print cartridge 3F. Auxiliary print station 2F can also accept print cartridge 4F. Auxiliary print station 2F uses laser energy generated by print engine 11F to print parts. When cartridge 3F or 4F is installed in its respective print modules 11F and 2F, the print engine can direct laser energy to cartridge 3F or 4F. Processing priority can be set to favor cartridge 3F, so that most laser emissions are directed to cartridge 3F. When laser energy cannot be sent to cartridge 3F (e.g., during powder dispensing or unloading / loading of print cartridges), energy can be directed to cartridge 4F, ensuring maximum utilization of the laser of print engine 11F.

[0079] Figure 1GAn alternative embodiment of the additive manufacturing system 1G is illustrated. Multiple print engines 11G are closely spaced together on the workshop floor. A service aisle 2G allows transport vehicles 3G to transport print cartridges 4G between print engines and powder stations 5G, shelves 6G, and any other mating equipment components. A facility station 7G can be positioned on a mezzanine 8G to save floor space. This printer is particularly well-suited for this type of multi-cell factory layout due to its low cycle time and high print speed. This layout offers cost-effectiveness because mating equipment can be shared among many print stations / engines. In some embodiments, various types of communication between cartridges, print engines, powder stations, and shelves are possible. In other embodiments, identification information on the cartridge can be used to guide the cartridge to automatic, semi-automatic, or manual positioning at the appropriate print engine, powder, or storage module. Types of communication that can be used include low-frequency and high-frequency methods, including RF, Wi-Fi, induction, Ethernet, USB, Bluetooth (low-frequency type), fiber optic, LiFi, and FSO (high-frequency type). Furthermore, this information can be transferred from the cartridge to the mating station using physical media hardware such as SIM, floppy disk, DVD, laser DVD, holographic disc, or volumetric optical media.

[0080] Figure 1G (i) illustrates an embodiment of box 1G(i), where the box is the same size as a cargo container. The box contains, as shown in the diagram... Figure 1A All the listed functional components are housed within the much larger structure 2G(i). In this embodiment, the interface with the laser system of the printing engine passes through a movable window positioned on the top surface of 2G(i) (as shown in 3G(i) (top surface) and 5G(i) (optical interface)). This laser window interface uses... Figure 1I , Figure 1J , Figure 1K , Figure 1M or Figure 1N The interface is constructed using one of the box interface embodiments listed herein, and embodiment 1L, used in several of these embodiments, is used to assist in cleaning the interface laser window. The movement of window 7G(i) on the top surface 3G(i) is represented by direction 9G(i).

[0081] Such as about Figure 1G (i) The movement of the box illustrated can be as follows: Figure 1G (ii) The special crane 11G(ii) shown in the figure, the overhead crane (usually seen in ship ports) or Figure 1G(iii) The guide rail system 13G(iii). The printing system may then include (in the case of the guide rail system 13G(iii)) or may be such that the cartridge 15G(iii) moves on the guide rail 14G(iii) and stops below the dedicated processing station 17G(iii), 19G(iii) or 21G(iii), where all or part of the powder contents of the cartridge are processed. Other processes (23G(iii)) may be performed before or after the processes shown. These processes may be performed sequentially, in parallel, or in any order according to the requirements of processing time and sequence.

[0082] Figure 1H An alternative embodiment of the additive manufacturing system 1H is illustrated. The printing chamber (also referred to as the room) 11H inside the printing module has a fixed window 6H positioned at the top of the chamber. A printhead 5H can be mounted to an XY stage such that the printhead 5H can pass through the entire area of ​​the printing plate 2H. This movement is indicated by arrow 8H. A laser beam 7H is projected from the printhead, passes through the window 6H, and welds powder into the metal parts on the printing plate 2H. The window must be large enough, approximately the same size as the printing plate, so that the laser can be guided to the entire area of ​​the printing plate. A powder hopper 4H and a Z-axis wall 3H are shown for reference.

[0083] Figure 1I An alternative embodiment of the additive manufacturing system 1I is illustrated. In this embodiment, chamber 11I includes a window 6I, which is mounted to a bellows 7I such that the window is freely movable in the XY plane (denoted by 10I). After the cartridge is installed in the print station, the window 6I is attached to the print head 5I at position 9I using a clamp, magnet, kinematic mount, or other suitable attachment mechanism (this can be done manually or automatically). The print head 5I is mounted to the XY stage such that the print head 5I can pass through the entire area of ​​the print plate 2I. This movement is indicated by arrow 10I. Because the window 6I and the print head 5I are attached, the window 6I will move with the print head 5I. A laser beam 8I is projected from the print head, passes through the window 6I, and welds powder to the metal parts on the print plate 2I. In this embodiment, the window 6I can be significantly smaller than the print plate 2I because the window 6I will be carried around the entire area of ​​the print plate. A powder hopper 4I and a Z-axis wall 3I are shown for reference.

[0084] Figure 1JAn alternative embodiment of the additive manufacturing system 1J is illustrated. The printing chamber 11J has a window 6J mounted to a bellows 7J, allowing the window to move freely in the XY plane. After the cartridge is installed in the printing station, the window 6J is attached at position 9J to an auxiliary XY stage 10J using a clamp, magnet, kinematic mount, or other suitable attachment mechanism. The auxiliary XY stage 10J is attached to the printing station (alternatively, the auxiliary XY stage can be part of the printing cartridge). The auxiliary XY stage can be much cheaper and lighter than the printhead XY stage because it has a relatively small weight to support and does not need to move as quickly or precisely as the printhead XY stage. The printhead 5J is mounted to the XY stage so that it can move across the entire area of ​​the printing plate 2J. This movement is indicated by arrow 13J. The printing station system controller can guide the auxiliary stage 10J to move in unison with the printhead 5J. A laser beam 8J is projected from the printhead, passes through window 6J, and bonds powder to a metal part on the print plate 2J. In this embodiment, window 6J can be significantly smaller than the print plate because it will follow the movement of the printhead across the entire area of ​​the print plate. The powder hopper 4J and Z-axis wall 3J are shown for reference.

[0085] Figure 1K An alternative embodiment of the additive manufacturing system 1K is illustrated. Aside from the more flexible 9K attachment and the printhead push and moving window 6K, this embodiment is similar to the one described above. Figure 1I The illustrated embodiment shows a mechanism that supports the window 6K against gravity, preventing it from sagging.

[0086] Figure 1L An alternative embodiment of the additive manufacturing system 1L is illustrated. Except that the window 6L is periodically cleaned by a wiper 10L attached to the carriage 9L, this embodiment is similar to... Figure 1HThe illustrated embodiment is similar. The carriage is positioned on guide rail 8L and driven through window 6L. Each pass of the wiper cleans accumulated dirt on the window surface, allowing laser energy 7L to pass through the window unimpeded. In some embodiments, the wiper may be a cloth-like material, either dry or soaked in a solvent, and then quickly wipes against the inner window of the box. In other embodiments, the wiper may be constructed of a bristle brush with soft bristles that will not damage or scratch the window, but are stiff enough to allow any powder to be wiped away. In some embodiments, the wiper may be a gas jet (e.g., an air knife) for non-contact cleaning. In some embodiments, the wiper may be a gas or liquid sprayer or a combination of such a sprayer and a physical wiper. After cleaning the window, the wiper can be cleaned by a gas jet, by wiping the wiper on a specialized or abrasive surface to remove any powder, or by cleaning in a separate cleaning area with a solvent or bath. In some embodiments, the wiper can be replaced when it becomes dirty. In some embodiments, the dirty portion of the wiper can be moved to expose a new portion of the wiper. In some embodiments, the wiper is made of cotton, polyester, wool, carbon fiber strands, Kevlar, fiberglass, aluminized fabric, ceramic fabric, silica fabric, or other suitable materials.

[0087] Figure 1M An alternative embodiment of the additive manufacturing system 1M is illustrated. A printhead 5M can be mounted to an XY stage, allowing it to pass through the entire area of ​​the printing plate 2M. This movement is indicated by arrow 8M. The printing chamber 11M has an opening 16M located at the top of the chamber. This opening can be closed by a sliding door 12M and isolated from the surrounding environment by a seal 13M. The door can be opened or closed by an actuator 14M. The printing station 15M has a fixed window 6M that isolates the printing station from the surrounding environment.

[0088] Figure 1N The illustration shows the "open" position of an alternative embodiment of the additive manufacturing system 1M. The print station 15N expands a seal 17N against the top of the print chamber to isolate the chamber from the surrounding environment. The door 12N can then be opened via an actuator 14N, opening the aperture 16N. A laser beam 7N is projected from the print head, passes through a window 6N, and bonds powder to metal parts on the print plate 2N. The window must be large enough, approximately the same size as the print plate, so that the laser can be directed across the entire area of ​​the print plate. In this embodiment, the window 6N is fixed to the print station 15N, making the print chamber 11N less expensive. A powder hopper 4N and a Z-axis wall 3N are shown for reference.

[0089] Figure 1OThe illustration shows an additive manufacturing system 10, which includes a printing facility control system and a database 20 connected to various stations within the printing facility. The control system and database 20 communicate with cartridges 30, printing stations 40, shelves 50, toner removal stations 60, conveyors (cartridge movement system) 70, and facility stations 80. Each of these components can provide status updates and be reconfigured in real time to optimize facility operation.

[0090] Figure 1PThe illustration depicts an additive manufacturing system 1P, which includes various other possible stations that may be part of the additive manufacturing system 1P. In some embodiments, a cartridge is loaded into the station. An example of a station is a cartridge-equipped printing station, where energy (laser or electron beam) is delivered from a laser engine (station) to enable the printing station to print parts. Typically, the laser engine is used only in conjunction with the printing station to turn the combination into a printing engine. These stations can be arranged and connected to each other to form a manufacturing system. The manufacturing system may contain a number of cartridge-equipped stations, as well as support stations captured in a frame arrangement, the cartridge-equipped stations and support stations being coordinated by a control system that receives printing instructions from the user to complete the print order / job. These additional functional stations can mitigate messy processes to reduce human exposure during the manufacture of 3D parts. As mentioned earlier, 3D printing itself is messy, as are the pre- and post-processing of cartridges, the post-processing of powder, and the post-processing of printed parts. Furthermore, cartridge system interfaces are used to interact with various diagnostic systems. The control system and database 2P will communicate with the cartridge independently, or when the cartridge is connected to any of the listed stations 40P, or when the cartridge is manipulated by the transporter 5P. The listed stations are not an exhaustive list, but do include the print engine 41P (consisting of the print station 42P and the laser engine 43P), the storage (shelf) station 44P, the facility station 56P, and the powder preparation / de-powdering station 45P. The powder preparation station can be a single station for preparing the cartridge, which involves removing powder from the cartridge after printing. These two functions (cartridge preparation and powder removal) can be performed in one station or two separate stations; in the case of two separate stations, the preparation station may be referred to as "prep," and the other as "de-powdering." Other stations may include a surface coating station 46P, a heat treatment station 47P, a CNC / machining station 48P, a surface finishing station 49P, a preparation service station, a deburring station, a powder re-sieving station 52P, a powder surface treatment / coating station 53P, a LUIS diagnostic station 54P, other volume and surface diagnostic stations 55P, and other processing stations 56P. The laser engine 43P works in conjunction with and interacts with the printing station 42P (to form the printing engine 41P), with the surface coating station 46P, and with the LUIS diagnostic station 54P, and may also interact with the heat treatment station 47P and the surface finishing station 49P.

[0091] Printing station 42P, surface coating station 46P, heat treatment station 47P, CNC / machining station 48P, surface finishing station 49P, and deburring station 51P perform post-processing on the printed parts. Surface coating station 46P, in conjunction with laser engine 43P, manipulates the printed parts to add functional layers to selected surfaces, such as drill bits, airfoil surfaces, turbine blades, or medical implants. Heat treatment station 47P, in conjunction with laser engine 43P, can perform surface annealing and hardening, or heat treatment station 47P can use other conventional methods such as standard heat sources or directional energy non-laser sources for this form of post-processing. CNC / machining station 48P performs standard subtractive manufacturing on the printed parts to obtain the final drawing and form. Surface finishing station 49P can interact with laser engine 43P to perform surface smoothing via mass transport / surface tension or laser peening / hardening. Surface finishing station 49P can also be performed using more conventional subtractive methods (which does not require connecting 49P to 43P). The deburring station 51P will use traditional subtractive machining methods to improve the surface finish of the printed parts. The LUIS diagnostic station 54P will connect to the laser engine 43P (equipped with a dedicated FRU for LUIS) to perform volumetric scanning of the printed parts to ensure print accuracy, density, and defect statistics. Furthermore, LUIS and other volumetric diagnostics (54P and 55P, respectively) can be used in conjunction with the storage station and laser engine to determine the functionality of the printed parts under environmental conditions (such as high or low temperatures, high pressure or partial vacuum, or other environmental or operational extremes) to ensure that the printed parts can withstand static operational performance requirements.

[0092] The preparation service station 50P is used for maintenance boxes and can be used in conjunction with the powder station 45P and the facility station 56P. In the preparation station, consumables (such as...) are stored... Figure 1A The scraper 4A, construction plate 12A, and HEPA filter 8A are replaced to minimize human interaction with the contaminated environment. Gases and fluids are removed for post-treatment via facility station 56P. Used powder is removed and transferred to powder re-screening station 52P for powder recycling.

[0093] Powder processing / coating stations process powders for chemical action or emissivity enhancement, which will depend on the powder / metal used, but may include chemical or oxide treatments to enhance emissivity (e.g., increasing the absorption of copper or steel through surface treatment of the powder), or by adding chemical dopants to the powder to obtain specific printing parameters.

[0094] Other volumetric diagnostic stations 55P will include X-ray computed tomography, surface scanning imaging, high-resolution surface and temperature recording imaging, to name just a few examples of how printed parts can be manipulated while minimizing processing damage and avoiding exposure to hazardous metrological methods, such as in the case of X-ray computed tomography.

[0095] Other processing stations will allow customer needs to be met by isolating potentially hazardous processes, testing, or diagnostic processes from workers and / or printed parts.

[0096] Advantageously, the described additive manufacturing system describes a cartridge comprising the entire printing chamber and all its components. The cartridge can be transported between mating devices. The use of a camera and a virtual window eliminates the need for a physical window. In one embodiment, a display screen can allow for remote inspection of the cartridge. A laser can pass through a top window to weld, preheat, heat-treat, or provide other thermal operations on powder. The laser can be directed to an auxiliary printing station to utilize laser emission that would otherwise be wasted and increase manufacturing throughput.

[0097] Other advantages of the described additive manufacturing system are based on the use of an electronically readable storage device (EMS) for the cartridge, allowing data to be stored or associated with its intended use. The cartridge design allows for mating with a mating device using a standard interface. The EMS on the cartridge can inform actions taken on the print engine before, during, or after the printing process. The mating device can read and / or write information to the EMS. An operator can access the EMS using a handheld unit. Storage shelves can servicing the cartridge and allocating information to the EMS, or for heat treatment of the prints before removal from the print platen.

[0098] The described additive manufacturing system protects workers by isolating them from hazardous printer byproduct materials (metal powder, soot, welding slag, inert gases, etc.) contained within a printing cartridge. All machine parts exposed to printer byproduct materials are removed along with the cartridge, which can be opened within a dedicated powder handling station. This arrangement limits the chance of printer byproduct materials escaping into the factory environment. When the cartridge is installed in a powder or preparation station, workers have full access through glove holes to maintain all cartridge components, so workers never need to wear special protective equipment to maintain the cartridge. Alternatively, the powder or preparation station can be installed in a cleanroom, and workers will wear respirators and protective clothing to maintain the cartridge. This approach isolates all contaminants from the cleanroom, eliminating exposure to the rest of the factory.

[0099] Another advantage of the described additive manufacturing system is increased printer uptime by reducing idle time between prints. When printing is complete, the operator can remove the print cartridge, immediately install a new cartridge, and begin a new print. Idle time between prints is reduced from hours to minutes. Print cartridges can be cleaned, maintained, and loaded with new powder and new print plates offline in the preparation station. This work is done in a sealed environment, ensuring that the print chamber and powder are never exposed to air, high humidity, or plant contaminants. New cartridges can be prepared in advance to meet customer production schedules. New cartridges are placed in storage shelves where they can be preheated, cooled, pressurized, or depressurized in any desired atmosphere. When space is available on the printer, any new cartridge is inserted and printing begins immediately, as there is no waiting time to preheat the cartridge or purge atmospheric gases.

[0100] Another advantage of the described additive manufacturing system is that it allows the printer to create prints in any material—metals (such as steel, aluminum, ferrochrome, titanium), wood, glass, or ceramics)—and then, once printing is complete, print any other material, with little or no downtime for maintenance between prints. Because no powder remains in the printer, there is no need to clean the printer before it can print in cartridges filled with different materials. This not only saves time but also provides maximum flexibility for the customer, as the printer does not have to be dedicated to processing only one material.

[0101] Another advantage of the described additive manufacturing system is that the cartridge and / or station can be slightly or significantly modified to suit customer requirements. For example, the cartridge can be designed as a print plate with a much smaller surface area or a different shape (i.e., round instead of square). This, for example, can allow customers to print small volumes of very expensive materials (such as gold). This small-capacity cartridge can be designed to engage with a variety of print stations to maximize the flexibility of the printing materials offered to customers.

[0102] Another advantage of the described additive manufacturing system is that it allows for high-temperature treatment of the prints (e.g., heat treatment, annealing, controlled cooling) without removing the prints from the controlled environment in which they were printed (i.e., the print cartridge is heated and cooled in a controlled atmosphere). The cartridges can be placed on storage shelves and stored at any temperature in any gas environment, according to customer requirements. Since the prints are not exposed to atmospheric air or allowed to cool, customers have excellent control over influencing material properties. This also mitigates the problem of print plate warping due to thermal stress.

[0103] Another advantage of the described additive manufacturing system is that it allows prints to be created in any of multiple print cassettes that can be simultaneously installed in one or more auxiliary print stations. This further reduces total print time by utilizing laser energy that would otherwise be wasted. The additive manufacturing system also provides customers with flexibility in scheduling prints and improves machine utilization.

[0104] Another advantage of the described additive manufacturing system is that features in the cassette and mating equipment can be implemented as standard or optional features on additive manufacturing systems manufactured by other equipment manufacturers. This technology is provided as a subsystem to be incorporated into additive manufacturing equipment using laser powder bed melting or other 3D printing methods. Any additive manufacturing system utilizing the cassette / station solution will benefit from this solution. The cassette and station can be slightly or heavily modified to suit the specific needs of the manufacturer or customer.

[0105] Various alternatives or enhancements to the components of the described additive manufacturing system are envisioned. For example:

[0106] about Figure 1H , Figure 1I and Figure 1J The bellows of the illustrated embodiment can be replaced or supplemented by a series of sliding plates (cables, etc.) that support the window, allowing the window to move freely on the X and Y axes, but preventing the window from drooping on the Z axis.

[0107] If a particular print job requires less powder, the user can partially fill the powder hopper.

[0108] The scraper-type distributor can be replaced by a roller or an electrostatic distributor.

[0109] The powder dispenser drive can be remotely installed and driven by a suitable interface that transmits power to the mechanism (e.g., a flexible shaft). The powder dispenser can be actuated by various types of actuators, including gear drives. In some embodiments, the powder dispenser can be a removable and upgradeable subsystem of a cartridge.

[0110] HEPA filters can be installed on the print cartridge, on the mating device, or on both the mating device and the print cartridge. HEPA filters can also have pre-filters, such as vortex separators or screens, to handle large volumes of soot.

[0111] It can support multiple gas supply ports and gas return ports, and the gas supply ports and gas return ports can be physically positioned at different locations on the box to prevent mixing of different types of powders.

[0112] In some embodiments, the camera can capture video and still images to provide a virtual window. The camera and light can illuminate and image using multiple light wavelengths (e.g., IR, visible light, or UV). The camera can be an array of several cameras that can record still and / or video images from many different angles at one or more light wavelengths. The light can be a single lamp or an array of many lamps that illuminate the box from many angles and at many different wavelengths. The virtual window can be viewed from anywhere, so the image can be sent to a remote viewing location. The virtual window monitor can be positioned on the box itself, on the front of the printing station, or as a display on a monitor mounted on an industrial monitor / keyboard arm. In some embodiments, the box may also have a physical window or port to allow direct visual observation or observation via an external camera or other sensor.

[0113] Imagine various types of box transport. In some embodiments, rollers can be replaced by telescopic tubes, pick-and-place robots, overhead lifts, rails, or conveyors. Forklift tubes can be replaced by carts, automated equipment (such as conveyor belts), rails, robotic equipment (such as bottom lift stockers), robotic tugs, or robotic forklifts. Alternative embodiments include using overhead platform / crane mechanisms; floor-rolling (manual or fully automated) carts or delivery vehicles (accessible via wheeled or non-wheeled manual or automated track systems (magnetic levitation, air bearings)); robotic manipulators; and conformalbody power suits.

[0114] The plunger / z-axis piston can be used with a zero-point clamp or some other type of automatic clamp.

[0115] The safety shield can be part of the housing, attached to the printing engine, or some combination of both. The material of the safety shield will be opaque to the laser. When the system is running, the outer surface of the safety shield will need to feel cool to the touch.

[0116] To prevent cross-contamination between powder types, the interface plate can be constructed or positioned in different areas (e.g., shifted left or right, or up or down) depending on the type of gas or powder used in the cartridge. For example, the gas recovery port for a cartridge containing steel powder may be on the left, while the gas recovery port for a cartridge containing aluminum powder may be on the right. Ports for different materials are not aligned, so the operator does not mistakenly insert the wrong cartridge into the gas recoverer. In some embodiments, multiple gas recoverers in each print engine can support printing different materials. For example, the impellers of the gas recoverers driven by an external motor can be switched between two sets of impellers. This allows for the use of only one expensive motor to drive two relatively inexpensive impellers in separate gas lines for individual materials. In some embodiments, the gas recovery module (gas cartridge) can be inserted into or removed from the print engine depending on the material to be processed. In some embodiments, the gas recovery device, including a filter, can be directly mounted on the print engine. In other embodiments, the filter and material-dependent device are mounted in the cartridge unit itself, thus completely avoiding any cross-contamination when installing different cartridges containing different materials.

[0117] Storage shelves can be made in many different sizes to hold one or more boxes. The boxes can be programmed at the storage shelf and automatically set up for the jobs to be run according to a pre-determined job schedule. Electronic memory held within each box can engage with robot maneuvers, cranes, tracks, transport equipment, or communicate with transporters and / or their operators or systems to tell them which print station / engine to connect to in the production setup. The boxes can be battery-powered, thus enabling sensors or information-providing functions during disassembly.

[0118] A print engine can have one or more auxiliary print stations (i.e., 1-N) attached to it, where N can be 1, 10, 100 or 1000, or somewhere in between, or more.

[0119] While printing simultaneously or sequentially, the print box can be filled with the same or different materials.

[0120] Prior to patterning, the laser can be split between printing stations, each with its own light valve or patterning device. In other embodiments, the laser can be split in chambers after patterning, with the first chamber receiving the positive (preferred) image and subsequent chambers receiving the remaining (negative) image.

[0121] The energy flux directed to each box can be the same, or it can vary based on the material type.

[0122] In one embodiment, the use of print cartridges and / or print engines can be prioritized, where the use of each print cartridge or print engine can be prioritized before or during printing. For example, a prioritized cartridge can remain static or can change based on input (i.e., input from the user, such as a change in job priority, or due to print completion, printing errors, or other external expectations). The priority of any cartridge can be promoted or demoted. For example, if there are two cartridges, and the highest priority cartridge becomes idle (due to user intervention, subsystem processes such as scattering, image loading, or similar), errors, etc.), the priority will then be changed to the previously lower priority cartridge, thereby maximizing overall print yield. This change is correct for any number of cartridges greater than one. As another example, a customer can prioritize printing high-temperature prints in the main print station where the main cartridge is inserted, and assign lower priority to room-temperature, less demanding prints in the auxiliary print station. Low-temperature printing can be performed at a much slower rate without sacrificing print quality, or it may not be necessary to keep the auxiliary chamber hot.

[0123] Each print cartridge in each print station can print the same or different print files. Each print job can be started and stopped, while prints in auxiliary print cartridges continue printing. During print operations with more than one chamber, print cartridges can be installed into or removed from the print station without interrupting the printing process in the chambers that have not been removed.

[0124] Figure 1Q The illustration shows a field replaceable unit (FRU) located within a print engine and its associated facility station 1Q. A cartridge 3Q is shown loaded into a print station (15Q), to which a laser engine (13Q) is attached to form the print engine (9Q). The laser is generated, modulated, patterned, and analyzed within the FRU (e.g., 5Q) before entering the print station 15Q from the laser engine 13Q via a galvanometer optics system 4Q. The laser engine is constructed from an active or passive vibration damping frame (11Q) that holds multiple FRUs (5Q). The facility station (7Q) supplies the print engine (9Q) with gas, electrical, communication (to the control system and database), and fluid systems. The FRU (5Q) is a subsystem of the laser engine, containing laser optics, patterning optics, various compensation optics, and various diagnostic subsystems and their optics.

[0125] The galvanometer optical system 4Q includes an optical alignment system to aid in alignment (see the periscope section of FRU below), a rapid galvanometer for dynamic tile printing instructions, an optical system for delivering patterned light to the bed, bed diagnostics, and systems for cooling, control, and communication.

[0126] The FRUs are individually packaged and aligned before being encased in their own inert and clean atmosphere. The FRUs are loaded onto alignment rails into the laser engine station and have connection panels similar to those shown for the cartridges, allowing the FRUs to automatically connect to the frame system 11Q upon loading. The frame system (11Q) is a structured housing, which may be 3D printed or machined, and forms the mechanical, electrical, fluid, gas, control, and communication infrastructure specifically for the FRUs, but also for the print station and cartridges. Each FRU includes active and / or passive vibration isolation within its housing, while the frame includes active and / or passive vibration control (6Q) to isolate the FRU from the environment of the print engine and from internal vibrations from fluid and airflow pumps, cooling fans, and noise and vibration from the print cartridges. For example, the rails and / or frame on each FRU may have pneumatic, piezoelectric, voice coil, or similar mechanical or electromechanical actuators to adjust the FRU's coordinate system relative to the frame or other FRUs, thereby counteracting vibrations sensed by accelerometers within each FRU and compensated for via system control logic. The FRU interface within the frame is a kinematic alignment feature that allows the FRU to easily slide in and connect to the facility services and optical path provided by the frame. This optical path allows the FRU to transmit high-throughput laser light from the high-throughput laser-generating FRU through the compensated FRU, through the diagnostic FRU, to the patterned FRU, and into the print station and cartridge. While the cartridge may contain diagnostic devices, specialized diagnostic devices are positioned within the FRU, where bed information illuminated by the laser and other collinear light sources is propagated from the cartridge to these diagnostic devices for real-time, high-speed, and specialized imaging diagnostics, such as LUIS. The FRU system allows for complete versatility, where various sources, optical systems, and diagnostic devices can be mixed and matched to optimally optimize the printing system.

[0127] The method of aligning and fitting the FRU into the frame system ensures easy assembly of the laser engine for rapid repositioning without requiring trained personnel to supervise the alignment of the complex laser system. The kinematic characteristics of the frame used for the FRU allow the relative position of the optical FRU to be maintained at the level required by the optical alignment subsystem. Furthermore, since each laser, optics, and diagnostic subsystem is integrated into one or more discrete FRUs, replacing these subsystems becomes routine, simplifying ownership, upgrades, and consumables without requiring trained personnel. Additionally, each FRU is assembled as a unit and can be considered a "plug and play" component, meaning that if some components within the FRU need to be replaced, the entire FRU can be replaced and shipped back for repair / servicing with minimal downtime for the print engine and print jobs.

[0128] Figure 1Q - Figure 1IThe passive and active vibration damping structures 1Q(i) within the frame are shown. Figure 1Q The printing engine is shown in 2Q(i), where a section of the frame 3Q(i) is depicted in sectional detail. The structured frame, which can be 3D printed or mechanically assembled, can be constructed from a structured material 5Q(i) and has pathways for various services provided by the facility station (such as electrical / communication, power, and control systems delivered via appropriate conduits 7Q(i)) and pathways for gas and / or cooling fluid conduits (9Q(i)) and active and passive damping conduits filled with fluid (11Q(i)). The passive vibration damping feature in this exemplary system can be a mechanical bladder region, in which, in the case of a fluid delivery system such as a pump or impeller, the fluid conduit widens to disrupt the pathway for vibrations propagating along the fluid lines. In active damping, sensors (15Q(i) and 19Q(i)) placed in the conduit before activation will sense unwanted vibrations in the damping conduit 11Q(i), and the control system will instruct actuator 17Q(i) to alter the bladder regions to eliminate or suppress these vibrations by changing the impedance load experienced by the fluid within 11Q(i) as it passes through any of these bladder regions. Subsequent sensors 19Q(i) can be placed to ensure compliance with 17Q(i) and additional regulation, or other such regulation upstream and downstream from the depicted regulating bladder. While a depiction of a linear layout of the conduit is shown relative to passive / active damping conduits, this arrangement can be modified so that the damping conduit 11Q(i) can be more distributed throughout the frame. In some embodiments, the internal structure of the frame can be foam, with control fluid filling the foam to provide distributed passive damping, while also having a series of distributed sensors 15Q(i) distributed along the frame supplying control regulation into a distributed bladder array to control vibrations across the entire frame structure.

[0129] Figure 1RThe illustration shows various features of the FRU 1R. The FRU is an optical subsystem within a box. The external structure of the FRU allows it to easily slide into the laser engine frame system on a guide rail (5R), which guides the FRU to an interface panel within the frame. At this interface panel, the FRU's connector (2R) locks into the frame service for access to the facility station and control system, which supplies the FRU with the necessary gas, fluid, electrical, and communication supplies. Features 3R and 7R on the FRU's external structure kinematically position and lock the FRU in place relative to the frame system and thus relative to other FRUs within the system; this method ensures optical alignment between FRUs, minimizes alignment requirements, and ensures that the laser system can operate without requiring any component alignment performed by trained laser experts. Inside the FRU, alignment reference 13R (as an example) is incorporated into the optical platform to facilitate the construction of any optical subsystem. Optical alignment of any FRU is performed during FRU assembly relative to the same system coordinate system used in the frame system. During insertion and connection to the frame system, a final optical adjustment is performed using a mechanized periscope 15R to ensure that the exit point parameters of any FRU match the requirements of the next FRU. The same method is used between the last FRU in the laser engine and the receiving optics system of the print station to ensure continuous alignment throughout the print engine. Furthermore, the diagnostic FRU contains the same mechanized optical output periscope to ensure that the image on the bed is accurately imaged back to the imaging sensor within the diagnostic FRU.

[0130] All mechanized periscopes in the FRU are controlled by a control system in conjunction with the printing station and other diagnostic devices in the FRU. Mechanized periscopes may include real-time corrections (such as piezoelectric, voice coil, pneumatic, or similar actuators), which will mitigate some vibration modulation, especially if the vibration modulation is in a frequency band that cannot be compensated for by the frame system, such as high-speed drilling and other shock operations that occur in some plant settings.

[0131] In some FRUs, additional enhancements include a telescope and a laser tracker. The telescope allows for variations in the focal plane to be adjusted according to the tile printing instructions. The telescope also allows the tiles to rotate to ensure edge and seam alignment, regardless of the tile printing instructions. The laser tracker is calibrated to the bed position to ensure the tile printing position. As a few examples, the tile printing position can be designed for FRU to FRU, FRU to print bed, or end-use position configuration.

[0132] The diagnostic subsystem is included within each FRU or can be packaged in a separate housing. The diagnostic subsystem contains sensors and metrology devices for monitoring bed and powder conditions, components, subsystem safety, laser damage thresholds and evolution of laser damage in components, and ensuring optimal alignment for optimal laser flux to the bed. Diagnostics may include methods such as imaging the print at various frame rates at different wavelengths (generated in the laser FRU) and querying print quality during and after the printing process with varying phase and polarization parameters in the LUIS. Measurement modes include, but are not limited to: bed, powder, and print temperature; fast and slow imaging; grain growth; grain strain magnitude and orientation; porosity; contamination and nucleation sites; backscattering for monitoring damage thresholds and evolution; and phase information for adaptively correcting optical aberrations and improving print quality.

[0133] Figure 1S The diagram illustrates a block diagram of an additive manufacturing system 1S, which includes an additive manufacturing printing system 2S, which is at least partially composed of one or more stations (e.g., such as...). Figure 1P (as listed in box 40P) forms one or more stations via a control system / database (e.g., Figure 1P The blocks 2P in the diagram are connected to each other. The additive manufacturing system 1S may include a print engine 4S (which has a print station 6S, for example, connected to a laser engine 10S) and various other modules, such as facility stations 12S and transport units 16S for transporting parts or materials. In some embodiments, the laser engine 10S may include one or more field-replaceable units 14S, which may further include a laser, a laser amplifier, or at least some laser optics and patterning optics. In some embodiments, the field-replaceable units 14S are moved to a suitable location by the transport unit 16S and arranged to distribute laser beams among each other, allowing the use of dedicated field-replaceable units that, for example, primarily provide one or more of laser generation, laser amplification, laser patterning, laser reorientation or alignment, and beam quality testing. In some embodiments, the laser engine 10S may provide two-dimensional patterned laser beams. The print station 6S may be loaded with a removable print cartridge 8S by the transport unit 16S. The laser engine 10S delivers a patterned high-throughput energy beam 15S to the printing station 6S, which manipulates the high-throughput energy beam in the space of the layered powder area within the printing cartridge 8S to print one layer of the object at a time, piece by piece. The desired object can be printed within the printing cartridge 8S on a series of layers.

[0134] Figure 1T The diagram illustrates a block diagram of an embodiment of a laser engine 4T used in an additive manufacturing system 2T.Figure 1T The laser engine 4T is a station that is part of the additive manufacturing printing system 2T. The laser engine can include an arrangement of various substations that can be used to print objects within the additive manufacturing system 2T. When used for printing objects within the additive manufacturing system 2T, the laser engine 4T can include subsystems arranged to allow the generation and modulation of one or more wavelengths of laser light (each consisting of low, medium, or high flux), which is delivered through an optical subsystem, a patterning subsystem, a diagnostic subsystem, and a control subsystem into the print chamber for the creation, inspection, measurement, or post-processing of 3D printed parts. The subsystems can be hard-mounted or arranged in a field-replaceable unit (FRU). The FRU system can include multiple laser subsystems 6T that generate light and modulate it in terms of flux, space, time, polarization, phase, or wavelength, which will be used for printing, as part of a diagnostic system (illumination and reference), or for post-processing of previously printed parts. The optical subsystem or FRU 8T can deliver, regulate, pattern the light generated within the laser FRU / subsystem, or change the position, scale, and intensity of the light generated within the laser FRU / subsystem, delivering it from and from the origin of the laser FRU / subsystem to the printhead. The diagnostic subsystem or FRU 10T can consist of any number of metrology or diagnostic subsystems to measure the quality of light delivered to, emitted by, or printed parts from the bed via any structure in the laser FRU 6T or optical FRU 8T, in order to monitor the health and potential faults of these subsystems, the health and potential faults of the printed parts, and the supporting environment and printing conditions. The control subsystem or FRU 12T can be circuitry, mechanisms, fixtures, or components that apply management, communication, or corrective actions to other subsystems within the additive manufacturing system 2T. Various subsystems can be packaged in a single FRU, or any functional FRU can be combined in any FRU as convenient. For example, in some embodiments, the laser FRU may contain some or all of various optical, diagnostic, and control subsystems.

[0135] Figure 2 The diagram illustrates a process flow 200 for operating a cassette-based additive manufacturing system. In step 202, a new or reused cassette is positioned in the print engine. In step 204, laser energy is directed into the cassette to build a 3D part. In step 204, laser energy is directed into the cassette to melt, sinter, dissolve, or otherwise alter powder layers. In step 206, added powder is positioned and subjected to laser energy, wherein this process is repeated additively to build each layer and produce a 3D printed structure. In step 208, the cassette can be removed and maintained at a separate powder handling station. The maintained cassette or a new cassette can be positioned in the print engine for the manufacture of additional or new 3D printed items.

[0136] In relation to Figure 3 In another embodiment illustrated, such as regarding Figure 1A - Figure 1H and Figure 2 The additive manufacturing system illustrated in the process flow diagram can be represented by various modules that form the additive manufacturing method and system 300. For example... Figure 3 As seen, the laser source and amplifier 312 can be configured as a continuous or pulsed laser. In other embodiments, the laser source includes a pulsed electrical signal source, such as an arbitrary waveform generator or an equivalent acting on a continuous laser source (such as a laser diode). In some embodiments, this can also be achieved via a fiber laser or a laser source emitted from an optical fiber, which is then modulated by an acousto-optic or electro-optic modulator. In some embodiments, a high-repetition-rate pulse source using a Pockelscell can be used to create pulse sequences of arbitrary length.

[0137] Possible laser types include, but are not limited to: gas lasers, chemical lasers, dye lasers, metal vapor lasers, solid-state lasers (e.g., fiber lasers), semiconductor lasers (e.g., diode lasers), free-electron lasers, gas dynamic lasers, "nickel-like" samarium lasers, Raman lasers, or nuclear-pumped lasers.

[0138] Gas lasers can include lasers such as helium-neon lasers, argon lasers, krypton lasers, xenon ion lasers, nitrogen lasers, carbon dioxide lasers, carbon monoxide lasers, or excimer lasers.

[0139] Chemical lasers can include lasers such as hydrogen fluoride lasers, deuterium fluoride lasers, COIL (chemical oxygen-iodine lasers), or Agil (all-gas phase iodine lasers).

[0140] Metal vapor lasers can include lasers such as helium-cadmium (HeCd) metal vapor lasers, helium-mercury (HeHg) metal vapor lasers, helium-selenium (HeSe) metal vapor lasers, helium-silver (HeAg) metal vapor lasers, strontium vapor lasers, neon-copper (NeCu) metal vapor lasers, copper vapor lasers, gold vapor lasers, or manganese (Mn / MnCl2) vapor lasers. Rubidium or other alkali metal vapor lasers can also be used. Solid-state lasers can include lasers such as: ruby ​​lasers, Nd:YAG lasers, NdCrYAG lasers, Er:YAG lasers, neodymium YLF (Nd:YLF) solid-state lasers, neodymium-doped yttrium orthovanadate (Nd:YVO4) lasers, neodymium-doped calcium yttrium borate Nd:YCa4O(BO3)3 or simply Nd:YCOB, neodymium glass (Nd:Glass) lasers, Ti:sapphire (Ti:sapphire) lasers, thulium YAG (Tm:YAG) lasers, ytterbium YAG (Yb:YAG) lasers, and ytterbium:2O3 (glass or ceramic). Lasers, ytterbium-doped glass lasers (rods, chips, and fibers), holmium YAG (Ho:YAG) lasers, chromium ZnSe (Cr:ZnSe) lasers, cerium-doped lithium strontium (or calcium) aluminum fluoride (Ce:LiSAF, Ce:LiCAF), promethium-doped 147 phosphate glass (147Pm+3:Glass) solid-state lasers, chromium-doped chrysoberyl (alexandrite) lasers, erbium-doped and erbium-doped ytterbium co-doped glass lasers, trivalent uranium-doped calcium fluoride (U:CaF2) solid-state lasers, divalent samarium-doped calcium fluoride (Sm:CaF2) lasers, or F-Center lasers.

[0141] Semiconductor lasers may include laser media types such as GaN, InGaN, AlGaInP, AlGaAs, InGaAsP, GaInP, InGaAs, InGaAsO, GaInAsSb, lead salts, vertical cavity surface emitting lasers (VCSELs), quantum cascade lasers, hybrid silicon lasers, or combinations thereof.

[0142] like Figure 3As illustrated, the additive manufacturing system 300 uses a laser capable of providing one-dimensional or two-dimensional directional energy as part of an energy patterning system 310. In some embodiments, one-dimensional patterning can be guided as linear or curved strips, grating lines, spirals, or any other suitable form. Two-dimensional patterning can include separate or overlapping tiles, or images with varying laser intensity. Two-dimensional image patterns with non-square boundaries can be used, overlapping or interpenetrating images can be used, and images can be provided by two or more energy patterning systems. The energy patterning system 310 uses a laser source and amplifier 312 to direct one or more continuous or intermittent energy beams toward a beamforming optics 314. After forming, the beams are patterned by an energy patterning unit 316 if desired, typically some energy is directed to a waste energy processing unit 318. The patterned energy is relayed by an image repeater 320 toward an article processing unit 340, in one embodiment as a two-dimensional image 322 focused near a bed 346. The article processing unit 340 can include a box, as discussed above. The article handling unit 340 has a plate or bed 346 (with walls 348) that together form a sealed chamber containing material 344 (e.g., metal powder) dispensed by a powder hopper or other material dispenser 342. Patterned energy guided by the image repeater 320 can melt, fuse, sinter, amalgamate, alter crystal structure, influence stress pattern, or otherwise chemically or physically alter the dispensed and distributed material 344 to form a structure with desired properties. The control processor 350 can be connected to various sensors, actuators, heating or cooling systems, monitors, and controllers to coordinate the operation of the laser source and amplifier 312, beamforming optics 314, laser patterning unit 316, and image repeater 320, as well as any other components of the system 300. As will be understood, the connection can be wired or wireless, continuous or intermittent, and includes the ability to provide feedback (e.g., heating can be adjusted in response to sensed temperature).

[0143] In some embodiments, the beamforming optics 314 may include a variety of imaging optics to combine, focus, diverge, reflect, refract, homogenize one or more laser beams received from the laser source and amplifier 312, adjust the intensity of one or more laser beams received from the laser source and amplifier 312, adjust the frequency of one or more laser beams received from the laser source and amplifier 312, or otherwise shape one or more laser beams received from the laser source and amplifier 312 and direct the one or more laser beams toward the laser patterning unit 316. In one embodiment, wavelength-selective mirrors (e.g., dichroic mirrors) or diffractive elements may be used to combine multiple beams, each beam having a different wavelength. In other embodiments, multifaceted mirrors, microlenses, and refractive or diffractive optics may be used to homogenize or combine multiple beams.

[0144] The laser patterning unit 316 may include static or dynamic energy patterning elements. For example, the laser beam may be blocked by a mask having fixed or movable elements. To increase the flexibility and ease of image patterning, pixel-addressable masking, image generation, or transmission may be used. In some embodiments, the laser patterning unit includes an addressable optical valve, which may be used alone or in combination with other patterning mechanisms to provide patterning. The optical valve may be transmissive, reflective, or use a combination of transmissive and reflective elements. The pattern may be dynamically changed using electrical addressing or optical addressing. In one embodiment, a transmissive optical addressable valve is used to rotate the polarization of light passing through the valve, wherein optically addressed pixels form a pattern defined by a light projection source. In another embodiment, a reflective optical addressable valve includes a write beam for changing the polarization of a read beam. In some embodiments, a non-optically addressable optical valve may be used. These may include, but are not limited to, electrically addressable pixel elements, movable mirrors or micro-mirror systems, piezoelectric or micro-actuated optical systems, fixed or movable shields or coveres, or any other conventional system capable of providing high-intensity light patterning.

[0145] Waste energy processing unit 318 is used to disperse, redirect, or utilize unpatterned energy that passes through image repeater 320. In one embodiment, waste energy processing unit 318 may include passive or active cooling elements that remove heat from both the laser source and amplifier 312 and the laser patterning unit 316. In other embodiments, waste energy processing unit may include a "beamdump" to absorb any beam energy not used in defining the laser pattern and convert it into heat. In still other embodiments, beamforming optics 314 may be used to recover waste laser beam energy. Alternatively or additionally, waste beam energy may be directed to article processing unit 340 for heating or further patterning. In some embodiments, waste beam energy may be directed to an additional energy patterning system or article processing unit.

[0146] In one embodiment, a "switchyard" optical system can be used. Switchyard systems are adapted to reduce light waste in additive manufacturing systems caused by discarding unwanted light due to the pattern to be printed. A switchyard involves redirecting a complex pattern from its generation (in this case, referring to a spatial pattern being given a structured or unstructured beam across a plane) to its delivery through a series of switching points. Each switching point can optionally alter the spatial distribution of the incident beam. Switchyard optical systems can be used, for example, but not limited to, laser-based additive manufacturing techniques, where a mask is applied to the light. Advantageously, in various embodiments according to this disclosure, the discarded energy can be recovered either as homogenized light or as patterned light to maintain high power efficiency or high productivity. Furthermore, the discarded energy can be recovered and reused to increase the intensity of printing more difficult materials.

[0147] Image repeater 320 can receive patterned images (one-dimensional or two-dimensional) directly or via a switching station from laser patterning unit 316 and guide them to article processing unit 340. Similar to beamforming optics 314, image repeater 320 may include optics for combining, focusing, diverging, reflecting, refracting patterned light, adjusting the intensity of patterned light, adjusting the frequency of patterned light, or otherwise shaping and guiding patterned light. Movable mirrors, prisms, diffractive optics, or solid-state optical systems that do not require substantial physical movement can be used to guide the patterned light. One of a plurality of lens assemblies can be configured to provide incident light with a magnification ratio, wherein the lens assembly has both a first set of optical lenses and a second set of optical lenses, and the second set of optical lenses is interchangeable from the lens assembly. Rotation of one or more sets of mirrors mounted on a compensation stage and a final mirror mounted on a construction platform stage can be used to guide incident light from the precursor mirror to a desired location. The translational movement of the compensation stage and the construction platform stage also ensures that the distance of the incident light from the forebody mirror to the article processing unit 340 is approximately equal to the image distance. In effect, this allows for rapid variations in the beam delivery size and intensity for different materials within the construction area, while ensuring high system availability.

[0148] Material dispenser 342 (e.g., powder hopper) in article handling unit 340 (e.g., cassette) can dispense material, remove material, mix material, provide gradations or variations in material type or particle size, or adjust the layer thickness of material. Materials may include metals, ceramics, glass, polymer powders, other fusible materials capable of undergoing a thermally induced phase transition from solid to liquid and back to solid, or combinations thereof. Materials may also include composites of fusible and infusible materials, wherein either or both components can be selectively targeted by the imaging relay system to melt the fusible component while retaining or subjecting the infusible material to evaporation / destruction / burning or other destructive processes. In some embodiments, the material may be used as a slurry, spray, coating, wire, strip, or sheet. Unwanted material may be removed for disposal or recycling by using a blower, vacuum system, sweeping, vibration, shaking, tilting, or inverting bed 346.

[0149] In addition to material handling components, the article handling unit 340 may include components for holding and supporting the 3D structure, mechanisms for heating or cooling chambers, auxiliary or supporting optics, and sensors and control mechanisms for monitoring or regulating material or environmental conditions. The article handling unit may be wholly or partially supported by a vacuum or inert gas atmosphere to reduce unwanted chemical interactions and mitigate the risk of fire or explosion (especially for reactive metals). In some embodiments, various pure gases or mixtures of other atmospheres may be used, including those containing Ar, He, Ne, Kr, Xe, CO2, N2, O2, SF6, CH4, CO, N2O, C2H2, C2H4, C2H6, C3H6, C3H8, i-C4H 10 C4H 10 ,1-C4H8, cic-2, C4H7, 1,3-C4H6, 1,2-C4H6, C5H 12 n-C5H 12 i-C5H 12 n-C6H 14 C2H3Cl, C7H 16 C8H 18 C 10 H 22 C 11 H 24 C 12 H 26 C 13 H 28 C 14 H 30 C 15 H 32 C 16 H 34 C6H6, C6H5-CH3, C8H 10 Pure gases or mixtures of C2H5OH, CH3OH, and iC4H8 may be used. In some embodiments, refrigerants or large inert molecules (including, but not limited to, sulfur hexafluoride) may be used. An enclosure atmospheric composition may be used having at least about 1% He by volume (or by number density) and a selected percentage of inert / non-reactive gases.

[0150] In some embodiments, multiple article handling units, cartridges, or build chambers (each with a build platform accommodating a powder bed) can be used in conjunction with multiple optomechanical assemblies arranged to receive one or more incident energy beams and guide them into the cartridges. Multiple cartridges allow for the simultaneous printing of one or more print jobs.

[0151] In another embodiment, one or more article handling units, cassettes, or build chambers may have cassettes held at a fixed height, while the optics are vertically movable. The distance between the final optics of the lens assembly and the top surface of the powder bed can be managed to be substantially constant by indexing the final optics upwards by a distance equivalent to the powder layer thickness, while maintaining the build platform at a fixed height. Advantageously, large and heavy objects can be manufactured more easily compared to a vertically moving build platform because precise micron-level movement of the build platform's constantly changing mass is not required. Typically, build chambers designed for metal powders with volumes greater than about 0.1–0.2 cubic meters (i.e., greater than 100–200 liters or weighing more than 500–1,000 kg) will benefit most from maintaining the build platform at a fixed height.

[0152] In one embodiment, a portion of the powder bed in the cartridge may be selectively melted or fused to form one or more temporary walls from the molten portion of the powder bed, thereby accommodating another portion of the powder bed on the build platform. In selected embodiments, fluid channels may be formed in one or more first walls to achieve improved thermal management.

[0153] In some embodiments, the additive manufacturing system may include an article handling unit or cassette supporting a powder bed that can be tilted, inverted, and rocked to substantially separate the powder bed from the build platform in a hopper. The powder material forming the powder bed can be collected in the hopper for reuse in subsequent printing jobs. The powder collection process can be automated, and vacuum or gas jet systems are also used to assist in powder removal and disposal.

[0154] In some embodiments, the additive manufacturing system can be configured to easily handle parts longer than the available build chambers or boxes. Continuous (long) parts can sequentially advance from a first region to a second region in the longitudinal direction. In the first region, selected particles of granular material can be merged. In the second region, unmerged particles of granular material can be removed. A first portion of the continuous part can advance from the second region to a third region, while the last portion of the continuous part is formed within the first region, and the first portion remains in the same position in both the lateral and transverse directions as it occupied in the first and second regions. In practice, additive manufacturing and removal (e.g., separation and / or reuse of unused or unmerged granular material) can be performed in parallel (i.e., simultaneously) at different locations or regions on the part conveyor without requiring a stop for the removal of granular material and / or parts.

[0155] In another embodiment, additive manufacturing capabilities can be enhanced by using a housing that restricts gaseous material exchange between the interior and exterior of the housing. An airlock provides an interface between the interior and exterior; the interior contains multiple additive manufacturing chambers, including chambers supporting powder bed melting. A gas management system maintains gaseous oxygen within the interior at or below the limiting oxygen concentration, thereby increasing the types of powders usable in the system and the flexibility of processing.

[0156] In another manufacturing embodiment, capability can be increased by housing article handling units, boxes, or build chambers within an enclosure, the build chambers being capable of creating parts weighing 2,000 kg or more. A gas management system can maintain gaseous oxygen within the enclosure at a concentration below atmospheric levels. In some embodiments, wheeled vehicles can transport parts from inside the enclosure through an airlock, as the airlock serves as a buffer between the gaseous environments inside and outside the enclosure, and transports the parts to a location outside both the enclosure and the airlock.

[0157] Other manufacturing embodiments involve the real-time collection of powder samples from a powder bed. The intake system is used for in-process collection and characterization of the powder samples. Collection can be performed periodically, and the results of characterization lead to adjustments in the powder bed melting process. The intake system can optionally be used for one or more of the following: auditing, process regulation, or actions such as modifying printer parameters or verifying the correct use of licensed powder materials.

[0158] Another improvement to the additive manufacturing process is described, which can be provided by using a manipulator device, such as a crane, lifting platform, robotic arm, or similar device, that allows manipulation of parts that are difficult or impossible for a human to move. The manipulator device can grasp various permanent or temporary additive manufacturing manipulator points on the part, enabling the part to be repositioned or manipulated.

[0159] The control processor 350 can be connected to control any component of the additive manufacturing system 300 described herein, including lasers, laser amplifiers, optics, thermal controls, build chambers, and manipulator devices. The control processor 350 can be connected to a variety of sensors, actuators, heating or cooling systems, monitors, and controllers to coordinate operation. A wide range of sensors, including imagers, light intensity monitors, thermal sensors, pressure sensors, or gas sensors, can be used to provide information used in control or monitoring. The control processor can be a single central controller, or alternatively, it can include one or more independent control systems. The controller processor 350 is provided with an interface that allows input of manufacturing instructions. The use of a wide range of sensors allows for various feedback control mechanisms to improve quality, manufacturing yield, and energy efficiency.

[0160] Figure 4The diagram illustrates one embodiment of the operation of a manufacturing system suitable for additive or subtractive manufacturing. In this embodiment, flowchart 400 illustrates one example of a manufacturing process supported by the described optical and mechanical components. In step 402, material is positioned in a box, bed, chamber, or other suitable support. The material may be a sheet of metal laser-cut using subtractive manufacturing techniques, or a powder that can be melted, fused, sintered, induced to alter its crystal structure, have an affected stress distribution pattern, or otherwise chemically or physically modified by additive manufacturing techniques to form a structure with desired properties.

[0161] In step 404, unpatterned laser energy is emitted by one or more energy emitters, including but not limited to solid-state or semiconductor lasers, and then amplified by one or more laser amplifiers. In step 406, the unpatterned laser energy is shaped and modified (e.g., intensity modulation or focusing). In step 408, the unpatterned laser energy is patterned, wherein the energy in the portion not forming a pattern is processed in step 410 (this may include conversion into waste heat, as recovery of patterned or unpatterned energy, or waste heat generated by cooling the laser amplifier in step 404). In step 412, the patterned energy, now forming a one-dimensional or two-dimensional image, is relayed toward the material. In step 414, the image is applied to the material, subtractively or additively constructing a portion of a 3D structure. For additive manufacturing, these steps can be repeated (cycle 418) until the image (or different subsequent images) has been applied to all necessary areas of the top layer of the material. When the energy application to the top layer of the material is complete, a new layer can be applied (cycle 416) to continue constructing the 3D structure. These processes continue in a loop until the 3D structure is complete, at which point any remaining excess material can be removed or recycled.

[0162] Many modifications and other embodiments of the invention will occur to those skilled in the art upon receiving the teachings given in the foregoing description and the accompanying drawings. Therefore, it should be understood that the invention is not limited to the specific embodiments disclosed, and that modifications and embodiments are intended to be included within the scope of the appended claims. It should also be understood that other embodiments of the invention may be practiced without elements / steps not specifically disclosed herein.

Claims

1. A printing engine for an additive manufacturing system, comprising: A printing station configured to hold a removable cartridge including a powder bed; A laser engine includes a frame configured to hold a plurality of removable field-replaceable units, each removable field-replaceable unit including at least some laser optics or patterned optics to guide a laser beam from the laser engine into the removable cartridge for printing an object at the powder bed. as well as An optical alignment system, attached to the print station or the laser engine, aligns at least one of the plurality of removable field-replaceable units relative to the removable cartridge, wherein one or more periscopes are used to adjust the optical alignment between the plurality of removable field-replaceable units and between the last removable field-replaceable unit in the laser engine and the receiving optics of the print station.

2. The printing engine of the additive manufacturing system according to claim 1, wherein, The removable box includes a sealable chamber having the powder bed and a laser-clear window.

3. The printing engine of the additive manufacturing system according to claim 2, wherein, The removable box also includes a powder hopper positioned within the sealable chamber and a powder dispenser positioned within the sealable chamber for dispensing powder from the powder hopper onto the powder bed.

4. The printing engine of the additive manufacturing system according to claim 1, wherein, The frame of the laser engine is actively mechanically damped.

5. The printing engine of the additive manufacturing system according to claim 1, wherein, The laser passes between multiple field-replaceable units.

6. The printing engine of the additive manufacturing system of claim 1 further includes a connection to a facility station that provides gas, fluid, electrical, control, and database systems to at least one of the plurality of removable field-replaceable units and the removable cartridge.

7. The printing engine of the additive manufacturing system according to claim 1 further includes a print cartridge transport unit.

8. The printing engine of the additive manufacturing system of claim 1 further includes a transport unit configured for transporting field-replaceable units.

9. The printing engine of the additive manufacturing system according to claim 1, wherein, The laser engine is configured to guide a two-dimensional patterned laser beam into the removable box.

10. An additive manufacturing printing method, comprising: A removable cartridge is positioned in the printing station, wherein the removable cartridge includes a powder bed; A laser beam from a laser engine is directed into the removable box, wherein the laser engine includes a frame that holds multiple removable field-replaceable units, each of which includes some laser optics or patterned optics. as well as The field-replaceable unit is aligned relative to the removable cartridge using an optical alignment system attached to the print station or the laser engine, wherein one or more periscopes are used to adjust the optical alignment between the plurality of removable field-replaceable units and between the last removable field-replaceable unit in the laser engine and the receiving optics of the print station.

11. The additive manufacturing printing method according to claim 10, wherein, The removable box includes a sealable chamber having the powder bed and a laser-clear window.

12. The additive manufacturing printing method according to claim 11, wherein, The removable box also includes a powder hopper positioned within the sealable chamber and a powder dispenser positioned within the sealable chamber for dispensing powder from the powder hopper onto the powder bed.

13. The additive manufacturing printing method according to claim 10, wherein, The frame of the laser engine is actively mechanically damped.

14. The additive manufacturing printing method according to claim 10, wherein, The laser passes between multiple field-replaceable units.

15. The additive manufacturing printing method of claim 10, further comprising a connection to a facility station that provides gas, fluid, electrical, control, and database systems to at least one of the plurality of removable field-replaceable units and the removable cartridge.

16. The additive manufacturing printing method according to claim 10, further comprising a print box transport unit.

17. The additive manufacturing printing method of claim 10, further comprising a transport unit configured for transporting field-replaceable units.

18. The additive manufacturing printing method according to claim 10, wherein, The laser engine is configured to guide a two-dimensional patterned laser beam into the removable box.

19. A printing engine for an additive manufacturing system, comprising: A printing station configured to hold a removable cartridge including a powder bed; A laser engine includes a frame configured to hold a plurality of removable field-replaceable units, each having at least some laser optics or patterned optics to direct a laser beam toward the removable cartridge in the printing station. as well as An optical alignment system, attached to the print station or the laser engine, aligns at least one of the plurality of removable field-replaceable units relative to the removable cartridge, wherein one or more periscopes are used to adjust the optical alignment between the plurality of removable field-replaceable units and between the last removable field-replaceable unit in the laser engine and the receiving optics of the print station.

20. A printing engine for an additive manufacturing system, comprising: A printing station configured to hold a removable cartridge including a powder bed; A laser engine includes a frame configured to hold a plurality of removable field-replaceable units, each having at least some laser optics or patterned optics to direct a laser beam toward the removable cartridge in the printing station, wherein the laser beam passes through the plurality of removable field-replaceable units before being directed into the removable cartridge. as well as An optical alignment system, attached to the print station or the laser engine, is used to align at least one of the plurality of removable field-replaceable units relative to the removable cartridge, wherein one or more periscopes are used to adjust the optical alignment between the plurality of removable field-replaceable units and between the last removable field-replaceable unit in the laser engine and the receiving optics of the print station.

Images