Build plate assembly for additive manufacturing

Abstract

A build plate assembly is configured for use with an additive manufacturing machine. The build plate assembly includes a build plate defining a receptacle. The insert is disposed in and movable within the receptacle. The insert includes a build surface configured to support a product built thereon by an additive manufacturing machine. The insert is configured to expand within the receptacle in response to heat transferred from a product built on the insert to the insert, and the receptacle is configured to accommodate the expansion.

Description

Technical Field

[0001] The present disclosure relates to a build plate assembly for an additive manufacturing machine. Background Art

[0002] The information provided in this section is for the purpose of generally introducing the background of the present disclosure. To the extent described in this section, the work of the presently named inventors and aspects of the description that may not constitute prior art at the time of filing are neither explicitly nor implicitly admitted as prior art against the present disclosure.

[0003] Additive manufacturing, also known as 3D printing, is a manufacturing process that creates objects by adding material layer by layer on a build plate. Unlike traditional subtractive manufacturing methods, which involve cutting material from a solid block to achieve the desired shape, additive manufacturing builds objects on top of a build plate. Each layer of material is fused together to form a cohesive product. This process typically generates heat, which is transferred to the build plate. Summary of the invention

[0004] In various features, the present disclosure includes a build plate assembly configured for use with an additive manufacturing machine, the build plate assembly including: a build plate defining a receptacle; and an insert disposed in and movable within the receptacle, the insert including a build surface configured to support a product built thereon by the additive manufacturing machine. The insert is configured to expand within the receptacle in response to heat transferred to the insert from a product built on the insert, and the receptacle is configured to accommodate the expansion.

[0005] In further features, the build plate includes an outer plate surface; and the insert includes an insert outer surface configured as a build surface, the insert outer surface protruding beyond the outer plate surface prior to expansion.

[0006] In further features, the present disclosure includes a backing plate located on an inner plate surface of the build plate, the inner plate surface opposite the outer plate surface.

[0007] In further features, the well is defined by an inner side wall of the build plate, the inner side wall tapering outward from an outer plate surface of the build plate so that the well is smallest at the outer plate surface; the insert includes an inclined side surface opposite the inner side wall; and in response to the expansion, the inclined side surface of the insert slides along the inner side wall of the well to pull the insert from an outward position into the well to an inward position.

[0008] In further features, the inner sidewall tapers at 5° to 40°.

[0009] In further features, the sloped side surfaces of the insert contact the inner sidewall of the build plate before and after expansion.

[0010] In further features, the present disclosure includes a biasing member cooperating with the insert to bias the insert in an outward position.

[0011] In further features, the build plate assembly is configured to be mounted to a lift platform of an additive manufacturing machine.

[0012] In further features, the insert is a first insert and the receptacle is a first receptacle; the build plate defines a second receptacle; and the second insert is disposed in and movable within the second receptacle.

[0013] In further features, the product includes an insert.

[0014] In further features, the insert includes tabs configured to cooperate with recesses of the build plate to align features of the insert with a product built on the insert.

[0015] In various features, the present disclosure includes a build plate assembly configured for use with an additive manufacturing machine. The build plate assembly has a build plate, the build plate including: an outer plate surface and an inner plate surface opposite the outer plate surface; and an inner sidewall extending from the outer plate surface to the inner plate surface to define a socket in the build plate. The inner sidewall tapers outwardly from the outer plate surface to the inner plate surface. An insert is disposed in the socket of the build plate. The insert includes: an insert outer surface and an insert inner surface opposite the insert outer surface, the insert outer surface being configured as a build surface to support a product built thereon by an additive manufacturing machine; and an inclined side surface extending from the insert outer surface to the insert inner surface, the inclined side surface being opposite the inner sidewall. In response to heat transferred from a product built on the insert to the insert, the insert is configured to expand within the socket and slide from an outward position into the socket to an inward position.

[0016] In further features, the insert is spring biased in the outward position.

[0017] In further features, the sloped side surface contacts the inner sidewall.

[0018] In further features, the product includes a build plate.

[0019] In further features, the backing plate is secured to the build plate.

[0020] In further features, the inclined side surface of the insert tapers outwardly from the insert outer surface to the insert inner surface.

[0021] In various features, the present disclosure also includes an additive manufacturing machine having a lift platform and a build plate assembly configured to be mounted to the lift platform. The build plate assembly includes a build plate and an insert, the build plate defining a receptacle extending through the build plate, the insert being disposed in the receptacle and movable within the receptacle. The insert includes a build surface configured to support a product built thereon by the additive manufacturing machine. The insert is configured to expand within the receptacle in response to heat transferred from a product built on the insert to the insert, and the receptacle is configured to accommodate the expansion.

[0022] In further features, the well is defined by an inner sidewall of the build plate. The inner sidewall tapers outwardly from an outer plate surface of the build plate such that the well is smallest at the outer plate surface. The insert includes an inclined side surface opposite the inner sidewall. In response to the expansion, the inclined side surface of the insert slides along the inner sidewall of the well to pull the insert from an outward position into the well to an inward position.

[0023] In further features, the angled side surfaces of the insert taper outwardly from the build surface to the insert interior surface.

[0024] The present invention provides the following technical solutions:

[0025] 1. A build plate assembly configured for use with an additive manufacturing machine, the build plate assembly comprising:

[0026] a build plate defining a receptacle; and

[0027] an insert disposed in and movable within the receptacle, the insert including a build surface configured to support a product built thereon by the additive manufacturing machine;

[0028] Therein, the insert is configured to expand within the receptacle in response to heat transferred to the insert from a product built on the insert, and the receptacle is configured to accommodate the expansion.

[0029] 2. The building plate assembly of claim 1, wherein:

[0030] The build plate includes an outer plate surface; and

[0031] The insert includes an insert outer surface configured as a built-up surface that protrudes beyond the outer panel surface prior to expansion.

[0032] 3. The building plate assembly according to Option 2 further includes a back plate located on an inner plate surface of the building plate, wherein the inner plate surface is opposite to the outer plate surface.

[0033] 4. The building plate assembly of claim 1, wherein:

[0034] The receptacle is defined by an inner sidewall of the build plate, the inner sidewall tapering outwardly from an outer plate surface of the build plate such that the receptacle is smallest at the outer plate surface;

[0035] The insert includes an inclined side surface opposite the inner side wall; and

[0036] In response to the expansion, the inclined side surfaces of the insert slide along the inner sidewalls of the well to draw the insert into the well from the outward position to the inward position.

[0037] 5. A building plate assembly according to Option 4, wherein the inner wall is tapered at 5° to 40°.

[0038] 6. The build plate assembly of claim 4, wherein the sloped side surface of the insert contacts the inner side wall of the build plate before and after expansion.

[0039] 7. The building plate assembly according to Option 4 also includes a biasing member that cooperates with the insert to bias the insert in an outward position.

[0040] 8. The build plate assembly of claim 1 , wherein the build plate assembly is configured to be mounted to a lift platform of the additive manufacturing machine.

[0041] 9. The building plate assembly of claim 1, wherein:

[0042] The insert is a first insert and the receptacle is a first receptacle;

[0043] The build plate defines a second receptacle; and

[0044] The second insert is disposed in the second receptacle and is movable within the second receptacle.

[0045] 10. The build plate assembly of claim 1 wherein the product comprises the insert.

[0046] 11. The build plate assembly of claim 1 , wherein the insert includes a tab configured to cooperate with a recess of the build plate to align features of the insert with a product built on the insert.

[0047] 12. A build plate assembly configured for use with an additive manufacturing machine, the build plate assembly comprising:

[0048] Build plate, including:

[0049] The outer plating surface and the inner plating surface opposite to the outer plating surface; and

[0050] an inner sidewall extending from the outer plate surface to the inner plate surface to define a receptacle in the build plate, the inner sidewall tapering outwardly from the outer plate surface to the inner plate surface;

[0051] An insert disposed within a receptacle of a build plate, the insert comprising:

[0052] an insert outer surface and an insert inner surface opposite the insert outer surface, the insert outer surface being configured as a build surface to support a product built thereon by an additive manufacturing machine; and

[0053] an inclined side surface extending from an outer surface of the insert to an inner surface of the insert, the inclined side surface being opposite to the inner side wall;

[0054] Therein, the insert is configured to expand within the receptacle and slide into the receptacle from an outward position to an inward position in response to heat being transferred to the insert from a product built on the insert.

[0055] 13. The building plate assembly of claim 12, wherein the insert is spring biased in an outward position.

[0056] 14. The building plate assembly of claim 12, wherein the inclined side surface contacts the inner side wall.

[0057] 15. The build plate assembly of claim 12, wherein the product comprises the build plate.

[0058] 16. The build plate assembly of claim 12, further comprising a backing plate secured to the build plate.

[0059] 17. The build plate assembly of claim 12, wherein the inclined side surface of the insert tapers outwardly from the insert outer surface to the insert inner surface.

[0060] 18. An additive manufacturing machine comprising:

[0061] Lifting platform;

[0062] A build plate assembly configured to be mounted to a lift platform, the build plate assembly comprising:

[0063] a build plate defining a receptacle extending through the build plate; and

[0064] an insert disposed in and movable within the receptacle, the insert including a build surface configured to support a product built thereon by the additive manufacturing machine;

[0065] Therein, the insert is configured to expand within the receptacle in response to heat transferred to the insert from a product built on the insert, and the receptacle is configured to accommodate the expansion.

[0066] 19. The additive manufacturing machine of claim 18, wherein:

[0067] The receptacle is defined by an inner sidewall of the build plate, the inner sidewall tapering outwardly from an outer plate surface of the build plate such that the receptacle is smallest at the outer plate surface;

[0068] The insert includes an inclined side surface opposite the inner side wall; and

[0069] In response to the expansion, the inclined side surfaces of the insert slide along the inner sidewalls of the well to draw the insert into the well from the outward position to the inward position.

[0070] 20. The additive manufacturing machine of claim 19, wherein the inclined side surface of the insert tapers outwardly from the build surface to an inner surface of the insert.

[0071] Further areas of applicability of the present disclosure will become apparent from the detailed description, claims and drawings.The detailed description and specific examples are intended for purposes of illustration only and are not intended to limit the scope of the present disclosure. BRIEF DESCRIPTION OF THE DRAWINGS

[0072] The present disclosure will be more fully understood from the detailed description and accompanying drawings, in which:

[0073] Figure 1 is a perspective view of a build plate assembly according to the present disclosure mounted to an additive manufacturing machine;

[0074] Figure 2 is a cross-sectional view of a build plate assembly mounted to a lift platform of an additive manufacturing machine;

[0075] Figure 3 is a cross-sectional view of a build plate assembly wherein a product is formed on an insert thereof by additive manufacturing, heat generated by forming the product being transferred to the insert causing the insert to expand into a socket;

[0076] Figure 4 is a cross-sectional view of a build plate assembly having a product formed therein, with an insert shrinking after cooling;

[0077] Figure 5 is a plan view of another build plate assembly according to the present disclosure, the build plate assembly including a plurality of inserts, each insert having a build surface; and

[0078] Figure 6 is along Figure 5 A cross-sectional view taken along line 6-6.

[0079] Among the drawings, reference numerals may be repeated to identify similar and / or identical elements. DETAILED DESCRIPTION

[0080] Figure 1A build plate assembly 10 according to the present disclosure is shown. The build plate assembly 10 is configured to be mounted to an additive manufacturing machine 110, which is configured to build any suitable product on the build plate assembly 10. The additive manufacturing machine 110 can be any suitable machine configured to build a product by depositing multiple layers of material on the build plate assembly 10 (e.g., by three-dimensional printing). For example, the additive manufacturing machine 110 can be a metal additive manufacturing machine. The additive manufacturing machine 110 can be configured to build any suitable vehicle-related product, such as, but not limited to, engine parts, dashboard parts, user interface parts (e.g., buttons, knobs, switches, etc.), body parts, door handles, interior door parts, exhaust pipe ends, etc. The additive manufacturing machine 110 can be configured to build products for use with any suitable vehicle, such as any suitable passenger car, public transportation vehicle, aircraft, watercraft, commercial vehicle, construction vehicle, etc. The additive manufacturing machine 110 can also be configured to build products for any suitable non-vehicle application.

[0081] Continue to refer Figure 1 , also refer to Figure 2 , build plate assembly 10 includes build plate 20 defining a plurality of openings 22 configured to receive any suitable fasteners 24. Fasteners 24 are configured to mount build plate assembly 10 to lift platform 112 of additive manufacturing machine 110. Build plate 20 includes outer plate surface 30 and inner plate surface 32 opposite outer plate surface 30. Back plate 34 is mounted to inner plate surface 32 by any suitable fasteners 36. Alternatively, springs 60 may be mounted to lift platform 112 and back plate 34 need not be included.

[0082] Build plate 20 defines receptacle 40 between outer plate surface 30 and inner plate surface 32. More specifically, inner sidewall 42 of build plate 20 extends from outer plate surface 30 to inner plate surface 32. Inner sidewall 42 defines receptacle 40. Inner sidewall 42 is angled outwardly from outer plate surface 30 to inner plate surface 32. For example, inner sidewall 42 may be angled from about 5° to about 40°.

[0083] Insert 50 is disposed within receptacle 40. Insert 50 is movable within receptacle 40 to accommodate expansion and contraction of insert 50 in response to heat generated during manufacturing. Insert 50 includes an insert outer surface 52 and an insert inner surface 54 opposite insert outer surface 52. Insert outer surface 52 is configured as a build surface on which the additive manufacturing machine 110 builds a product. An inclined side surface 56 of insert 50 extends from insert outer surface 52 to insert inner surface 54. The inclined side surface 56 tapers outwardly from insert outer surface 52 to insert inner surface 54. The inclined side surface 56 is angled to match the angle of inner sidewall 42. The inclined side surface 56 abuts inner sidewall 42 to prevent powder from making a product from being trapped between insert 50 and build plate 20. When insert 50 expands and contracts during the additive manufacturing process, the inclined side surface 56 of insert 50 slides along inner sidewall 42, as explained herein.

[0084] The insert 50 defines one or more receptacles 58. The receptacles 58 include a biasing member 60, such as a spring. The biasing member 60 is configured to bias the insert 50 in a Figure 2 External location. Figure 2 In the outer position, the insert outer surface 52 is flush with the outer panel surface 30, such as Figure 2 Alternatively, in the outer position, the insert outer surface 52 may protrude outwardly beyond the outer panel surface 30, such as Figure 1 and Figure 4 As shown. In applications without backing plate 34, biasing member 60 is configured to apply a small preload (e.g., about 10% deformation of the biasing member) to insert 50 when build plate 20 is fastened to lifting platform 112 to ensure a tight fit between insert 50 and build plate 20. When backing plate 34 is included, backing plate 34 will compress spring 60 when backing plate 34 is mounted to build plate 20. Socket 58 may be formed in insert 50 in any suitable manner, such as by machining. Socket 58 may have a dowel pin or be threaded for securing insert 50 and a product formed on insert 50 for final surface finishing after building.

[0085] Insert 50 may be formed in any suitable manner. For example, insert 50 may be machined from build plate 20 by wire EDM, water jet, or any other suitable process. Insert 50 may also be machined from any suitable raw material rather than being formed from build plate 20. Socket 40 of build plate 20 may be machined into build plate 20 to provide an angle for inner sidewall 42 to match the angled side surface 56 of insert 50.

[0086] Prior to placement in the receptacle 40 of the build plate 20, the insert 50 may be machined to include various features. For example, the insert 50 may be machined to include inlet / outlet ports for cooling or heating channels, ejector pin holes, thermal sensing, vent lines, etc. Plugs may be inserted into pre-machined openings in the insert 50 to prevent powder from falling into the machined openings during the build process. After the finished product is removed from the build plate 20, the plugs may be removed and the internal features of the product de-powdered as needed. The plugs may be reusable and configured to fit into the openings and be held in place, for example, with threaded pipe plugs or press-fit pins.

[0087] Build plate 20 has a modulus and hardness that is the same as or greater than that of insert 50. To enhance the wear resistance of build plate 20, inner sidewall 42 may be carburized or nitrided to locally increase the hardness at inner sidewall 42 where insert 50 contacts inner sidewall 42. Alternatively, inner sidewall 42 may be coated with a material that is harder than insert 50. Inner sidewall 42 and inclined side surface 56 may be machined smooth, such as by polishing to less than about Ra=4 μm, and a lubricant (e.g., graphite) that is stable at elevated temperatures may be applied to inner sidewall 42 and / or inclined side surface 56 to allow insert 50 to move freely and smoothly.

[0088] Figure 3 A first portion 170 of a product formed on insert 50 by additive manufacturing machine 110 is shown. To form first portion 170, powder 150 is first deposited on outer plate surface 30 of build plate 20 and on insert outer surface 52 of insert 50. Build plate 20 may be made of any suitable material, such as any suitable alloy. Insert 50 may also be made of any suitable material, such as any suitable alloy that is the same or different from the alloy of build plate 20. Powder 150 is any suitable powder alloy that is configured to be welded to insert outer surface 52 by laser 160. The alloy of insert 50 may be the same or different from the alloy of powder 150.

[0089] The laser 160 melts the powder 150 disposed on the outer surface 52 of the insert to build a first portion 170 of the product. Many layers of powder 150 are deposited and heated by the laser 160 to build the product layer by layer. When the powder 150 is heated by the laser 160, the heat is transferred to the insert 50. For example, when the insert 50 is heated, the insert 50 may be Figure 3 When the insert 50 expands outward against the tapered inner wall 42 of the insertion hole 40, the insert 50 expands downward toward the back plate 34 and outward from the back plate 34. Figure 1 or Figure 2 Outward position to Figure 3The inward position is shown into the receptacle 40. Specifically, as the insert 50 expands, the side surface 56 slides along the inner sidewall 42 of the receptacle 40, both being angled to allow the insert 50 to expand into the receptacle 40 to the inward position.

[0090] Figure 4 A second portion 172 of the product is shown formed on the first portion 170. The second portion 172 is formed by melting the powder 150 deposited on the first portion 170 with the laser 160. After the product is fully formed, the first portion 170 and the second portion 172 cool, and the insert 50 will also cool. As the insert 50 cools, the insert 50 shrinks back to its original shape and size, or close to its original shape and size. Figure 4 As shown, the biasing member 60 moves the insert 50 back to the outer position where it is Figure 2 In the example of FIG. 5 , the insert outer surface 52 is flush with the outer panel surface 30 , or as Figure 4 As shown in the example of FIG. 5 , the insert outer surface 52 protrudes outwardly beyond the outer panel surface 30 .

[0091] After the product has been fully formed, excess powder 150 is removed and build plate assembly 10 is removed from additive manufacturing machine 110. Insert 50 with the product formed thereon is removed from receptacle 40 from the side of inner plate surface 32. In some applications, insert 50 is part of the product. Thus, insert 50 does not need to be separated from first portion 170 of the product or any other portion of the product. In other applications, insert 50 may not be part of the product, and thus insert 50 will be separated from first portion 170 in any suitable manner.

[0092] Once insert 50 is removed from engagement with build plate 20, build plate 20 may be reused to form additional products on additional inserts placed within receptacles 40. Thermal stresses resulting from repeated, rapid heating and cooling of build layers are contained within insert 50. Thus, build plate 20 does not experience permanent deformation due to plastic deformation. Preventing permanent deformation of build plate 20 also extends the life of build plate assembly 10 and other components of additive manufacturing machine 110. For example, fasteners 24 may also be reused and protect a powder recoating arm used to apply powder 150 from any possible damage.

[0093] refer to Figure 5 , another build plate 20' according to the present invention is shown. Build plate 20' defines a plurality of receptacles, each receptacle configured to receive a different insert, such as a first insert 50A, a second insert 50B, and a third insert 50C. Figure 5A build plate 20' is shown configured to accommodate three inserts, but build plate 20' can be configured to accommodate any suitable number of inserts, such as two inserts or more than three inserts. The inserts can have any suitable size and shape. Figure 5 In the example of , insert 50A is rectangular, insert 50B is square, and insert 50C is circular. Each of inserts 50A, 50B, and 50C includes a building surface configured to support a product formed thereon by additive manufacturing machine 110.

[0094] One or more of inserts 50A, 50B, 50C may include any suitable features that align with features of the product built on insert 50A, 50B, 50C. For example, insert 50C includes a plurality of openings 90, which may be configured as cooling lines. Openings 90 will align with corresponding cooling lines of the product built on insert 50C. Thus, insert 50C will be included as part of the product. To prevent powder 150 from falling into openings 90 when the product is formed, plugs may be inserted into openings 90. Openings 90 may be formed in insert 50C in any suitable manner, such as by machining before build plate 20′ is connected to lift platform 112. Reference Figure 6 , insert 50C may include tabs 92 configured to be received in recesses 94 of build plate 20. The cooperation between tabs 92 and recesses 94 rotationally aligns insert 50C and opening 90 during the build process.

[0095] The foregoing description is merely illustrative in nature and is in no way intended to limit the present disclosure, its application or use. The broad teachings of the present disclosure can be implemented in a variety of forms. Therefore, although the present disclosure includes specific examples, the true scope of the present disclosure should not be so limited, because after studying the drawings, the specification and the appended claims, other modifications will become apparent. It should be understood that one or more steps in the method can be performed in different orders (or simultaneously) without changing the principles of the present disclosure. In addition, although each embodiment is described as having certain features above, any one or more of those features described with respect to any embodiment of the present disclosure can be implemented in any other embodiment and / or combined with the features of any other embodiment, even if the combination is not explicitly described. In other words, the described embodiments are not mutually exclusive, and the replacement of one or more embodiments with each other is still within the scope of the present disclosure.

[0096] Various terms are used, including "connected," "engaged," "coupled," "adjacent," "next to," "on," "above," "below," and "disposed," to describe the spatial and functional relationships between elements (e.g., between modules, circuit elements, semiconductor layers, etc.). Unless explicitly described as "direct," when a relationship between a first element and a second element is described in the above disclosure, the relationship can be a direct relationship in which there are no other intermediate elements between the first element and the second element, but can also be an indirect relationship in which there are one or more intermediate elements (spatially or functionally) between the first element and the second element. As used herein, the phrase at least one of A, B, and C should be interpreted to mean a logical (A or B or C) using a non-exclusive logical "or", and should not be interpreted to mean "at least one of A, at least one of B, and at least one of C."

[0097] In the drawings, the direction of the arrows (as indicated by the arrows) generally indicates the flow of information (such as data or instructions) of interest to the diagram. For example, when component A and component B exchange various information, but the information sent from component A to component B is relevant to the diagram, the arrow may point from component A to component B. This unidirectional arrow does not mean that no other information is sent from component B to component A. In addition, for information sent from component A to component B, component B may send a request for the information or a confirmation of receipt of the information to component A.

Claims

1. A build plate assembly configured for use with an additive manufacturing machine, the build plate assembly comprising: a build plate defining a receptacle; and an insert disposed in and movable within the receptacle, the insert including a build surface configured to support a product built thereon by the additive manufacturing machine; Therein, the insert is configured to expand within the receptacle in response to heat transferred to the insert from a product built on the insert, and the receptacle is configured to accommodate the expansion.

2. The build plate assembly of claim 1 , wherein: The build plate includes an outer plate surface; and The insert includes an insert outer surface configured as a built-up surface that protrudes beyond the outer panel surface prior to expansion.

3. The build plate assembly of claim 2, further comprising a backing plate located on an inner plate surface of the build plate, the inner plate surface opposite the outer plate surface.

4. The build plate assembly of claim 1 , wherein: The receptacle is defined by an inner sidewall of the build plate, the inner sidewall tapering outwardly from an outer plate surface of the build plate such that the receptacle is smallest at the outer plate surface; The insert includes an inclined side surface opposite the inner side wall; and In response to the expansion, the inclined side surfaces of the insert slide along the inner sidewalls of the well to draw the insert into the well from the outward position to the inward position.

5. The build plate assembly of claim 4, wherein the inner sidewall tapers at 5° to 40°.

6. The build plate assembly of claim 4, wherein the angled side surfaces of the insert contact an inner sidewall of the build plate before and after expansion.

7. The build plate assembly of claim 4, further comprising a biasing member cooperating with the insert to bias the insert in an outward position.

8. The build plate assembly of claim 1, wherein the build plate assembly is configured to be mounted to a lift platform of the additive manufacturing machine.

9. The build plate assembly of claim 1 , wherein: The insert is a first insert and the receptacle is a first receptacle; The build plate defines a second receptacle; and The second insert is disposed in the second receptacle and is movable within the second receptacle.

10. The build plate assembly of claim 1 wherein the product comprises the insert.

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