System for additive manufacturing with movable outlet

Abstract

Systems and methods for additive manufacturing include a fusion mechanism, an outlet, and a controller. The systems and methods are performed in a chamber containing a layer of particles. The fusing mechanism transports a bundle for fusing particles in the layer of particles. The fusion mechanism is configured to move the beam in a first direction in a fusion path extending from one end of the chamber to the other end of the chamber. The outlet is movable in a first direction and configured to blow air in a second direction opposite the first direction. The controller is configured to move the outlet in a first direction and hold the outlet upstream of the bundle.

Description

Technical Field

[0001] The information provided in this section is for the purpose of generally presenting the content of the present disclosure. The work of the presently named inventors, to the extent it is described in this section and in respect of the description that may not qualify as prior art at the time of filing, is neither explicitly nor implicitly admitted to be prior art against the present disclosure. Background Art

[0002] The present disclosure generally relates to systems and methods for additive manufacturing. Figure 1 , shows a demonstration of an additive manufacturing process generally referred to as powder bed fusion. The additive manufacturing process is performed in a chamber 100 having a layer 102 of particles to be fused together to form a desired part. The particles are fused together by a beam "B," such as a laser beam or an electron beam. The process is an iterative process where particles in a layer 102 are fused together and then another layer 102 of particles is added and fused together until the part has been printed.

[0003] The energy of beam "B" produces a cloud of particles "CP" that disperses upward from particle layer 102. As a result, the cloud of particles "CP" absorbs energy from the beam and may cause an undesirable fusing process. For example, energy from the beam may be absorbed by particles in the cloud, resulting in a reduction in the power used to fuse the particles. In addition, energy from the beam may fuse particles in the cloud to form fused particles "FP," which may land in undesirable / unintended locations, thereby causing defects in the printed part.

[0004] Reference now Figure 2 , the current system uses a blower 104 and an outlet 106 fixed to one end of the chamber 100. The outlet 106 directs gas (e.g., an inert gas) from one end of the chamber 100 to the inlet 108. The blower 104 is configured to blow the gas through the outlet 106 at a sufficiently strong flow rate to carry particles from the cloud to the inlet 108 without disturbing the particles in the particle layer 102. Therefore, Figure 2 Gas is depicted being blown through the particle layer 102 without blowing the particles away with the layer 102 and carrying the particles in the cloud into the inlet 108 .

[0005] Reference now Figure 3 , an illustrative depiction of a chamber 100 for additive manufacturing is provided. A beam generator 110 is disposed within the chamber 100 and is configured to generate a beam for fusing particles together. The chamber 100 includes an outlet 106 that is fixed to one end of the chamber 100 and is disposed above the particle layer 102 so as not to blow directly onto the particle layer 102. Therefore, it should be understood that the outlet 104 is positioned to affect only the particle cloud generated by the beam "B" fusing particles, and does not affect the particle layer 102 itself.

[0006] Reference again Figure 3 And now refer to Figure 4 , the intensity of the gas blown through the outlet 106 decreases with distance, as shown by the decrease in the size of the arrow. As described above, the outlet 106 is fixed to the first end of the chamber 100, and the inlet 108 can be fixed to the second end of the chamber 100. The beam is transmitted from the beam generator 110, which guides the beam along a fusion path that moves along the length of the chamber 100 from the first end to the second end. Since the outlet 106 is fixed to the first end of the chamber 100, when the fusion process occurs near the outlet 106, the blower 104 is very effective in carrying away the particles in the cloud. However, the further the fusion process occurs from the outlet 106, the efficiency of the blower decreases. Therefore, the conventional chamber 100 is designed to have a powder layer arranged along a length of approximately 400 mm. Figure 4 It is depicted that the intensity of the gas stream is relatively the same when the gas blows over a distance of 400 mm, and decreases rapidly when exceeding 400 mm. Therefore, increasing the length of the chamber 100 reduces the effectiveness of the blower, and increasing the intensity of the blower to increase the length of the chamber 100 will disturb the particles in the particle layer, resulting in uneven layer thickness after fusion.

[0007] Although conventional systems adequately blow away particles in the cloud created by the fusing process, the length of the particle layer within the chamber is limited to approximately 400 mm, and therefore, the length of the part is limited to less than 400 mm. Therefore, it remains desirable to increase the length of the chamber, thereby increasing the size of the part that can be printed. In addition, it is desirable to remove particles in the cloud created during fusing to provide an unobstructed path for the laser to perform the fusing. Furthermore, it is desirable to eliminate defects in the printing process by removing particles fused in the cloud from the chamber. Summary of the invention

[0008] In one configuration, a system for additive manufacturing includes a fusing mechanism, an outlet, and a controller. The system is performed in a chamber containing a particle layer. The fusing mechanism transmits a beam for fusing particles in the particle layer. The fusing mechanism is configured to move the beam in a first direction in a fusing path extending from one end of the chamber to the other end of the chamber. The outlet is movable in the first direction and is configured to blow air in a second direction opposite to the first direction. The controller is configured to move the outlet in the first direction and maintain the outlet upstream of the beam.

[0009] The system may include one or more of the following optional features.For example, the beam may be a laser beam or an electron beam.

[0010] In one arrangement, the outlet may extend along the width of the chamber.

[0011] In one arrangement, the system may further comprise a track extending along the length of the chamber, and the outlet may be movably disposed along the track.

[0012] In one configuration, the system can include an inlet configured to draw air from within the chamber to an environment outside the chamber. In this configuration, the inlet can be fixed to one end of the chamber and spaced from the outlet. The inlet can be sized to extend along the width of the chamber. Alternatively, the inlet can be moved relative to the outlet to accommodate the fusion path of the bundle.

[0013] In one configuration, the controller is configured to move the outlet and the inlet between a starting position and an ending position. In such a configuration, the controller can be configured to maintain the outlet upstream of the bundle and the inlet downstream of the bundle as the bundle moves in the fusion path. The controller can also be configured to return the bundle to the starting position when the bundle completes the fusion path.

[0014] In another configuration, a system for additive manufacturing includes a chamber containing a particle layer, the system including a fusing mechanism that transmits a beam to fuse particles in the particle layer. The fusing mechanism can be configured to move the beam in a first direction in a fusing path extending from one end of the chamber to the other end of the chamber. The system includes an inlet and a controller that is movable in the first direction and configured to draw air in the first direction, the controller being configured to move the inlet in the first direction and keep the inlet upstream of the beam. In such a configuration, the system may also include an outlet that is configured to blow air in the first direction, the outlet being spaced apart from the inlet.

[0015] In another configuration, a method for performing additive manufacturing includes fusing particles in a particle layer with a beam. The beam moves in a first direction from one end of a chamber to another end of the chamber in a fusion path. The method includes providing an outlet for blowing air in a second direction opposite to the first direction, and moving the outlet along the first direction. The method includes maintaining the outlet upstream of the fusion path so as to blow air downstream of the fusion path.

[0016] In one configuration, beam fusing particles in the particle layer includes using one of a laser beam and an electron beam.

[0017] In one arrangement, the outlet may extend along the width of the chamber.

[0018] In one configuration, moving the outlet in the first direction includes moving the outlet along a track that extends along the length of the chamber. In such a configuration, the method can include providing an inlet configured to draw air from within the chamber to an environment outside the chamber. In one aspect, the inlet can be spaced a predetermined distance from the outlet to accommodate the fusion path. In one aspect, the inlet can extend along the width of the chamber.

[0019] In one configuration, the method includes moving, by a controller, an inlet relative to an outlet to accommodate a fusion path of the bundle. In such a configuration, the method may include moving, by a controller, the outlet and the inlet between a starting position and an ending position. In yet another aspect of this configuration, the method may include maintaining, by the controller, the outlet upstream of the bundle and the inlet downstream of the bundle as the bundle moves in the fusion path, and returning the bundle to the starting position when the bundle completes the fusion path. BRIEF DESCRIPTION OF THE DRAWINGS

[0020] The drawings described herein are for illustrative purposes only of selected configurations and are not intended to limit the scope of the present disclosure.

[0021] Figure 1 is a perspective view of the particle fusion process using a beam;

[0022] Figure 2 is a side view of a conventional system for additive manufacturing using a beam;

[0023] Figure 3 is a perspective view of a conventional chamber for additive manufacturing showing an outlet secured to one end of the chamber and the intensity of the gas decreasing from one end of the chamber to the other end;

[0024] Figure 4 is a schematic diagram showing how the strength of an air flow decreases with distance;

[0025] Figure 5 is a perspective view of a system for additive manufacturing showing an outlet movable in a first direction and blowing air in a second direction opposite to the first direction;

[0026] Figure 6 yes Figure 5 A top view of the system shown in , depicting a track configured to provide gas into an outlet;

[0027] Figure 7 It is shown Figure 5 A side view of the operation of the system;

[0028] Figure 8is a perspective view of a system for additive manufacturing showing an inlet spaced apart from an outlet and movable in a first direction;

[0029] Fig. 9 yes Figure 8 A top view of the system shown in , depicting a track configured to provide gas into an outlet;

[0030] Fig.10 It is shown Figure 8 A side view of the operation of the system;

[0031] Fig.11 is a top view of a system for additive manufacturing showing an inlet movable in a first direction and drawing air in the first direction;

[0032] Fig.12 is a top view of a system for additive manufacturing showing an inlet and an outlet both movable in a first direction; and

[0033] Fig.13 is a flow chart illustrating a method for additive manufacturing.

[0034] Corresponding reference characters indicate corresponding parts throughout the several views of the drawings. DETAILED DESCRIPTION

[0035] Example configurations will now be described more fully with reference to the accompanying drawings. Example configurations are provided so that the present disclosure will be thorough and will fully convey the scope of the present disclosure to those of ordinary skill in the art. Specific details, such as examples of specific components, devices, and methods, are set forth to provide a thorough understanding of the configurations of the present disclosure. It will be apparent to those of ordinary skill in the art that specific details need not be employed, that example configurations may be embodied in many different forms, and that the specific details and example configurations should not be construed as limiting the scope of the present disclosure.

[0036] The terms used herein are for the purpose of describing specific exemplary configurations only and are not intended to be limiting. As used herein, the singular articles "a", "an" and "the" may also be intended to include the plural forms, unless the context clearly indicates otherwise. The terms "comprises", "containing", "includes" and "having" are inclusive and therefore specify the presence of features, steps, operations, elements and / or parts, but do not exclude the presence or addition of one or more other features, steps, operations, elements, parts and / or groups thereof. The method steps, processes and operations described herein should not be construed as necessarily requiring them to be performed in the particular order discussed or shown, unless specifically identified as an order of execution. Additional or alternative steps may be employed.

[0037] When an element or layer is referred to as being "on another element or layer," "engaged to," "connected to," "attached to," or "coupled to" another element or layer, it may be directly on, directly engaged with, connected to, attached to, or coupled to another element or layer, or there may be intermediate elements or layers. Conversely, when an element is referred to as being "directly on another element or layer," "directly engaged to," "directly connected to," "directly attached to," or "directly coupled to" another element or layer, there may be no intermediate elements or layers. Other words used to describe the relationship between elements should be interpreted in a similar manner (e.g., "between" versus "directly between," "adjacent" versus "directly adjacent," etc.). As used herein, the term "and / or" includes any and all combinations of one or more associated listed items.

[0038] The terms first, second, third, etc. can be used in this article to describe various elements, components, regions, layers and / or parts. These elements, components, regions, layers and / or parts should not be limited by these terms. These terms can only be used to distinguish an element, component, region, layer or part from another region, layer or part. Unless the context clearly indicates, terms such as "first", "second" and other numerical terms do not imply order or sequence. Therefore, without departing from the teaching of the example configuration, the first element, component, region, layer or part discussed below can be referred to as the second element, component, region, layer or part.

[0039] In this application, including the definitions below, the term "module" may be replaced with the term "circuit". The term "module" may refer to, be a part of, or include an application specific integrated circuit (ASIC); a digital, analog, or mixed analog / digital discrete circuit; a digital, analog, or mixed analog / digital integrated circuit; a combinational logic circuit; a field programmable gate array (FPGA); a processor (shared, dedicated, or group) that executes code; a processor (shared, dedicated, or group) that stores code executed by a memory; other suitable hardware components that provide the described functionality; or a combination of some or all of the above, such as in a system on a chip.

[0040] The term "code" as used above may include software, firmware and / or microcode, and may refer to a program, a routine, a function, a class and / or an object. The term "shared processor" covers a single processor that executes some or all codes from multiple modules. The term "group processor" covers a processor that executes some or all codes from one or more modules in combination with an additional processor. The term "shared memory" covers a single memory that stores some or all codes from multiple modules. The term "group memory" includes a memory that stores some or all codes from one or more modules in combination with an additional memory. The term "memory" may be a subset of the term "computer-readable medium". The term "computer-readable medium" does not include transient electrical signals and electromagnetic signals propagated through the medium, and therefore can be considered to be tangible and non-transient memory. Non-limiting examples of non-temporary memory include tangible computer-readable media, which include non-volatile memory, magnetic memory, and optical memory.

[0041] The apparatus and methods described in this application may be implemented in part or in whole by one or more computer programs executed by one or more processors. The computer program includes processor executable instructions stored on at least one non-transitory tangible computer readable medium. The computer program may also include and / or rely on stored data.

[0042] Software applications (i.e., software resources) may refer to computer software that enables a computing device to perform tasks. Example applications include, but are not limited to, system diagnostic applications, system management applications, system maintenance applications, word processing applications, spreadsheet applications, messaging applications, media streaming applications, social networking applications, and gaming applications.

[0043] Non-transitory memory can be a physical device used to temporarily or permanently store programs (e.g., instruction sequences) or data (e.g., program state information) for use by a computing device. Non-transitory memory can be volatile and / or non-volatile addressable semiconductor memory. Examples of non-volatile memory include, but are not limited to, flash memory and read-only memory (ROM) / programmable read-only memory (PROM) / erasable programmable read-only memory (EPROM) / electrically erasable programmable read-only memory (EEPROM) (e.g., commonly used for firmware, such as bootloaders). Examples of volatile memory include, but are not limited to, random access memory (RAM), dynamic random access memory (DRAM), static random access memory (SRAM), phase change memory (PCM), and disk or tape.

[0044] These computer programs (also referred to as programs, software, software applications, or code) include machine instructions for a programmable processor and may be implemented in high-level procedural and / or object-oriented programming languages ​​and / or assembly / machine languages. As used herein, the terms "machine-readable medium" and "computer-readable medium" refer to any computer program product, non-transitory computer-readable medium, memory, and / or device (e.g., disk, optical disk, processor, programmable logic device (PLD)) for providing machine instructions and / or data to a programmable device, including a machine-readable medium that receives machine instructions as a machine-readable signal. The term "machine-readable signal" refers to any signal for providing machine instructions and / or data to a programmable processor.

[0045] Various implementations of the systems and techniques described herein can be implemented in digital electronic and / or optical circuits, integrated circuits, specially designed ASICs (application specific integrated circuits), computer hardware, firmware, software, and / or combinations thereof. These various implementations may include implementations in one or more computer programs executable and / or interpretable on a programmable system that includes at least one programmable processor, which may be special purpose or general purpose, coupled to receive data and instructions from a storage system, at least one input device, and at least one output device, and to send data and instructions to the storage system, at least one input device, and at least one output device.

[0046] The process and logic flow described in this specification can be performed by one or more programmable processors (also referred to as data processing hardware), which execute one or more computer programs to perform functions by operating on input data and generating outputs. The process and logic flow can also be performed by a dedicated logic circuit (e.g., FPGA (field programmable gate array) or ASIC (application-specific integrated circuit)). As an example, a processor suitable for executing a computer program includes both general-purpose and special-purpose microprocessors, and any one or more processors of any type of digital computer. Typically, the processor will receive instructions and data from a read-only memory or a random access memory or both. The basic elements of a computer are a processor for executing instructions and one or more memory devices for storing instructions and data. Typically, a computer will also include one or more large-capacity storage devices (e.g., magnetic disks, magneto-optical disks, or optical disks) for storing data, or be operably connected to receive data from it or transmit data to it or both. However, a computer does not need to have such a device. Computer readable media suitable for storing computer program instructions and data include all forms of nonvolatile memory, media and memory devices, including, for example, semiconductor memory devices, such as EPROM, EEPROM and flash memory devices; magnetic disks, such as internal hard disks or removable disks; magneto-optical disks; and CD ROM and DVD-ROM disks. The processor and memory may be supplemented by, or incorporated in, special purpose logic circuits.

[0047] To provide interaction with a user, one or more aspects of the present disclosure may be implemented on a computer having a display device (e.g., a CRT (cathode ray tube), LCD (liquid crystal display) monitor, or touch screen) for displaying information to the user and optionally a keyboard and pointing device (e.g., a mouse or trackball) through which the user can provide input to the computer. Other kinds of devices may also be used to provide interaction with the user; for example, the feedback provided to the user may be any form of sensory feedback, such as visual feedback, auditory feedback, or tactile feedback; and input from the user may be received in any form, including sound, voice, or tactile input. In addition, the computer may interact with the user by sending documents to and receiving documents from a device used by the user; for example, by sending a web page to a web browser on a user's client device in response to a request received from the web browser.

[0048] The system and method for additive manufacturing include a fusing mechanism, an outlet, and a controller. The controller moves the outlet in a first direction and maintains the outlet upstream of the beam, and the outlet is configured to blow air in a second direction opposite to the first direction, thereby blowing particles in the cloud away from the path of the beam of the fusing mechanism. Since the outlet is movable along the chamber, the size of the chamber is not limited, and therefore the size of the part to be printed by the additive manufacturing process is also not limited. In addition, as the outlet moves with the fusing path of the beam, particles from the cloud are blown into the inlet and removed from the chamber, thereby eliminating defects caused by particles of the cloud that are fused and land on the printed layer.

[0049] Additionally, the system and method may include an inlet spaced apart from the outlet and movable in a first direction. The inlet provides a passage for particles from the particle cloud to be removed from the chamber.

[0050] In one aspect, the outlet and inlet are mounted to a track system and can be moved along the track system by a controller. The track system can be configured to provide a conduit for gas. In yet another aspect, the track system can be configured to distribute a layer of particles for fusion.

[0051] refer to Figure 5-7 , a system 10 for additive manufacturing is provided, which is configured to print a part (not shown). The system 10 is disposed in a chamber 12. The chamber 12 is composed of a bottom wall 14a, four side walls 16 and a top wall 14b (such as Figure 7 As shown). Figure 5 One of the side walls and the top wall is removed to facilitate description of the system 10. One of the four side walls is a first wall 16a, and another of the four side walls is a second wall 16b spaced apart from and facing the first wall 16a. The distance from the first wall 16a to the second wall 16b defines the length "L" of the chamber 12, and the width of the first wall 16a and the second wall 16b defines the width "W" of the chamber 12.

[0052] The layer of particles 18 to be fused together is placed on the bottom wall 14a of the chamber 12. As the particles fuse together, another layer of particles 18 is added, and the process is repeated until the part is printed. In other words, the part is printed layer by layer. It should be understood that the added layer of particles 18 need not cover the entire bottom surface, but can be discretely placed on the previous layer based on the configuration of the printed part. Any particles suitable for a fusion process currently known or later developed can be modified for use with the system 10, illustratively including metal particles and polymer particles, such as titanium, aluminum alloys, stainless steel, nickel and copper-based alloys, nylon, nylon composites, polypropylene, thermoplastic resins, etc.

[0053] The system 10 includes a fusing mechanism 20 (e.g. Figure 7). The fusing mechanism 20 is configured to generate an energy beam (as shown by the arrow) having sufficient power to fuse the particles together. The fusing mechanism 20 may include one or more beam generators 20a, 20b. In one aspect, the beam generator 20a is a laser beam generator for generating a laser beam, and the beam generator 20b is an electron beam generator for generating an electron beam. It should be understood that any fusing mechanism 20 currently known or later developed for fusing particles together may be modified for use herein.

[0054] The system 10 may include a dispensing mechanism 22 configured to dispense particles to form a particle layer 18, such as Figure 7 As shown. Any dispensing mechanism 22 currently known and used in the art may be modified for use herein, illustratively including a hopper, a rake, a powder pumping device, etc. The dispensing mechanism 22 is disposed above the bottom wall 14a of the chamber 12 and is configured to selectively disperse the particles. For example, the dispensing mechanism 22 may be movable within the chamber 12, or may be fixed and include a movable or rotatable nozzle for dispensing particles to a predetermined area of ​​the chamber 12.

[0055] The fusing mechanism 20 delivers a beam "B" having sufficient energy for fusing particles in the particle layer 18. As discussed above, the fusing process creates a cloud of particles that can block the beam, and / or the beam can fuse particles in the cloud and the fused particles can fall on the printed layer, thereby creating undesirable defects. The fusing mechanism 20 is configured to move the beam "B" in a first direction "1D" in a fusing path extending from one end of the chamber 12 to the other end of the chamber 12, and the first direction "1D" extends along the length of the chamber 12 from the first wall 16a to the second wall 16b.

[0056] It should be understood that the fusion path is not necessarily limited to one direction, but rather includes a pattern to be applied to a portion of the layer of particles 18 to be fused together to form a corresponding layer of a printed component. For example, the fusion mechanism 20 can guide the beam along the entire width of the chamber 12 and along a predetermined length of the chamber 12 to define the fusion area before advancing the beam in the first direction "1D". Therefore, as the beam moves along the width, the beam can be further guided to cover a predetermined length of the layer of particles 18. In aspects using multiple laser beam generators 20a and / or electron beam generators 20b, multiple beams can be deployed, each beam moving in a certain pattern, when combined, forming a printed layer of the component. Therefore, the term fusion path is not limited to the movement of the beam in a single direction, but refers to the movement of the beam to complete the printed component layer by layer.

[0057] The system 10 includes an outlet 24 that is movable in a first direction "1D" and is configured to direct gas in a second direction "2D" opposite to the first direction "1D". In one aspect, the gas can be an inert gas, such as argon and nitrogen. A blower 26 is fluidly coupled to the outlet 24 and is configured to blow gas at a predetermined flow rate that is sufficient to carry particles formed in the cloud produced by the fusion process without disturbing particles in the layer. For example, the blower 26 can be configured to blow gas at 150-350 m / s during the additive process. 3 The gas is blown at a flow rate of 1000 g / hr to fuse aluminum particles having an average particle size of 15-63 μm. Such a flow rate is sufficient to carry / blow the aluminum particles in the cloud out of the path of the beam without disturbing or otherwise moving the particles in the particle layer 18 to be fused. It should be understood that the flow rate of the gas can vary based on the type, size and mass of the particles being fused, and the flow rate can be increased or decreased relative to the described flow rate without departing from the scope of the appended claims. Figure 5 depicts a configuration in which a blower 26 is disposed within the outlet 24, and Figure 6 A configuration is depicted in which the blower 26 is disposed outside of the chamber 12 and is fluidly coupled to the outlet 24. For purposes of illustration, the system 10 is shown with a pair of blowers 26, each fluidly coupled to an opposite end of the outlet 24. However, it should be understood that the system 10 can be configured to use a single blower 26.

[0058] Reference now Figure 5 , the outlet 24 is schematically shown as an elongated member having a generally cubic shape having a slit 28 that extends substantially the length of the outlet 24 through which the gas is blown. The length of the outlet 24 is less than the width of the chamber 12. The cubic shape of the outlet 24 is for illustrative purposes only, and it should be understood that the outlet 24 can be shaped in other ways. For example, the outlet 24 can be cylindrical. The outlet 24 can also include pivotable fins (not shown) that direct the gas through the slit 28. In one aspect, the outlet 24 extends across the width of the chamber 12, and in such an aspect, the slit 28 can also extend across the width of the chamber, such as Figure 6 shown.

[0059] In another aspect of the system 10, the outlet 24 can be mounted on a track system 30. The track system 30 is configured to guide the outlet 24 in a first direction "1D" along the length of the chamber 12. In one aspect, the track system 30 includes a pair of tracks 30a, 30b, and each track 30a, 30b is spaced apart from each other and configured to receive a length of the outlet 24. A moving mechanism 32 moves the outlet 24 along the track system 30. The moving mechanism 32 can be disposed on the outlet 24, on the track system 30, or on both the outlet 24 and the track system 30. In one aspect, the moving mechanism 32 is an expandable and retractable drive piston along the length of the chamber 12. The drive piston includes a first end fixed to the first wall 16a and a second end fixed to the rear side 24a of the outlet 24, the rear side 24a of the outlet 24 being opposite to the front side 24b of the outlet where the slit 28 is disposed. Any moving mechanism 32 currently known, used, or later developed can be adapted and modified for use herein. For example, the moving mechanism 32 can be a rotary motor (not shown) disposed on the outlet 24 and connected to a gear (not shown), and the guide rails 30a, 30b are tracks having teeth (not shown), and the gear can engage with the teeth to move the outlet 24 forward and backward along the track.

[0060] The system 10 includes a controller 34 in communication with the outlet 24 and the fusing mechanism 20. The controller 34 is configured to move the outlet 24 in a first direction "1D" and keep the outlet 24 upstream of the beam. The controller 34 may be a programmable logic controller configured to provide a set of operating instructions for printing a component to the outlet 24 and the fusing mechanism 20. It should be understood that the controller 34 may include memory hardware 34a, which includes multiple sets of instructions, each set of instructions being associated with a component to be printed. Therefore, the system 10 can be configured to print different components. It should be understood that the fusing path of the fusing mechanism 20 will be different and correspond to the component to be printed. However, the operation and movement of the outlet 24 relative to the fusing path are substantially the same for all different components. That is, as the fusing path of the fusing mechanism 20 advances in the first direction "1D", the outlet 24 advances, thereby keeping the outlet 24 upstream of the fusing path of the fusing mechanism 20.

[0061] In one configuration, the system 10 can include an inlet 36 configured to receive the gas and particles blown out by the outlet 24 and direct the gas and blown particles out of the chamber 12. The inlet 36 can be disposed on the second wall 16b and is substantially coplanar with the outlet 24. In one aspect, the inlet 36 is fluidly coupled to a trap (not shown), which can include a filter or the like for capturing particles. In another aspect, the inlet 36 is coupled to a vacuum 38 for sucking the gas and particles in the cloud generated by the fusion process out of the chamber 12. It should be understood that the vacuum 38 can be configured to sufficiently suck the particles in the cloud into the inlet 36 without disrupting the particles in the particle layer 18. Thus, the vacuum device 38 can generate a flow rate that is substantially the same as or less than the flow rate of the blower 26.

[0062] Reference again Figure 5 , the inlet 36 can be fixed on one end of the chamber 12 and spaced apart from the outlet 24. For example, in a configuration where the fusion path of the beam begins at the second wall 16b and moves toward the first wall 16a, the inlet 36 can be formed on the second wall 16b so as to be in a fixed position. Thus, the distance between the inlet 36 and the outlet 24 increases as the outlet 24 moves during the fusion process. In one configuration, the inlet 36 can be an elongated slit 40 formed on the second wall 16b and is substantially coplanar with the outlet 24. In yet another aspect, the inlet 36 can be sized to extend along the width of the chamber 12 and be substantially the same length as the outlet 24.

[0063] Reference now Figure 7 , describing the operation of system 10. Figure 7 The system 10 is depicted at the initial stage of the first pass of the fusing mechanism 20. The dispensing mechanism 22 has dispensed a layer of particles 18 to be fused before the first pass. As used herein, a "pass" refers to the movement of the beam from one end of the chamber 12 to the other, such as from the first wall 16a to the second wall 16b, which indicates the completion of the fusing process for forming the layers of the printed part. The system 10 will make multiple passes to complete the printed part layer by layer, and the dispensing mechanism 22 dispenses another layer of particles 18 after each pass until the part is complete.

[0064] The fusion mechanism 20 generates a beam at a predetermined position of the particle layer 18 to initiate a fusion path. When the particles within the area defined by the width and length of the chamber 12 have been fused, the fusion path will advance in a first direction "1D" toward the other end of the chamber 12. When the fusion process occurs, the blower 26 is activated, and the particles in the cloud generated by the fusion process are blown out of the path of the beam along a second direction "2D" opposite to the first direction "1D". When the fusion path advances along the first direction "1D", the outlet 24 also advances. The movement of the beam and the outlet 24 is controlled by the controller 34, which can maintain a predetermined distance between the fusion path of the beam and the outlet 24 to prevent the outlet 24 from blocking the path of the beam.

[0065] Reference now Figures 8 to 10 , inlet 36 can be movable relative to outlet 24. In such an aspect, inlet 36 is a separate component having a conduit 42 fluidly connected to the space outside chamber 12. Outlet 24 is configured to direct gas into inlet 36, where particles of the cloud are carried out of chamber 12. The shape of inlet 36 can be the same as outlet 24, such as Figure 8 shown.

[0066] The inlet 36 and the outlet 24 are mounted to the track system 30 . Fig. 9 An aspect of a track system 30 is shown, the track system 30 is configured to supply gas to the outlet 24, and the distribution mechanism 22 is disposed in the inlet 36. In such an aspect, the track system 30 includes a pair of tracks 30a, 30b, each track having a conduit 44 for guiding gas from the blower 26 to the outlet 24. The blower 26 can be disposed in the track 30a, 30b or outside the track 30a, 30b. The distribution mechanism 22 is disposed in the inlet 36 and can include a spreader (not shown) that is configured to distribute the particle layer 18 when the inlet 36 moves along the first direction "1D".

[0067] The inlet 36 is spaced a distance from the outlet 24 to accommodate the fusion path of the beam. The inlet 36 may be fixed in position relative to the outlet 24, or it may be movable relative to the outlet 24. In either case, the inlet 36 and the outlet 24 are movable in a first direction "1D" along the track system 30. Thus, as the beam progresses along the length of the chamber 12 from one end to the other, the inlet 36 and the outlet 24 move to accommodate the fusion path of the beam, such as Fig. 9 and Fig.10 As the beam fuses particles, a cloud of particles is created, and the particles in the cloud are blown into the inlet 36 by the gas flowing from the outlet 24. The path of the beam is relatively unimpeded, as any particles in the cloud that have fused together are drawn out of the chamber 12, thereby reducing defects in the printed part.

[0068] Reference now Fig. 9, the area between the inlet 36 and the outlet 24 accommodates the fusion path. It should be understood that the fusion path need not be achieved linearly. That is, the fusion path need not be achieved from one side of the chamber 12 to the other side of the chamber 12 or from the outlet 24 toward the inlet 36, but can span the width and length of the particle layer 18. For example, in a fusion mechanism 20 that employs multiple beam generators 20a, 20b, the fusion path of each of the beam generators 20a, 20b can start at a different location in the area between the inlet 36 and the outlet 24, and once the beam generator completes its fusion path, the outlet 24 and the inlet 36 advance along the first direction "1D". In one aspect, the inlet 36 is in a fixed position relative to the outlet 24, and thus the inlet 36 and the outlet 24 move together. On the other hand, the inlet 36 and the outlet 24 can move relative to each other, such as Fig. 9 In such an aspect, the outlet 24 can advance in the first direction “1D” before the inlet 36 advances, thereby increasing the distance between the inlet 36 and the outlet 24 .

[0069] Reference now Fig.10 , the controller 34 is operable to control the fusing mechanism 20, the dispensing mechanism 22, and the moving mechanism 32 to coordinate the movement of the outlet 24 and the inlet 36 relative to the fusion path of the bundle. In particular, the controller 34 can be configured to actuate the moving mechanism 32 to move the outlet 24 and the inlet 36 between a starting position ("SP") and an ending position ("EP") as the fusing mechanism 20 executes the fusion path. Fig.10 The outlet 24 and the inlet 36 are shown to have moved along the first direction "1D" from the starting position "SP" toward the ending position "EP". It should be understood that the controller 34 moves the outlet 24 and the inlet 36 in coordination with the fusion path so that the outlet 24 remains upstream of the beam and the inlet 36 remains downstream of the beam. Therefore, the particles in the cloud are blown into the inlet 36. When the outlet 24 reaches the ending position "EP", the controller 34 can also be configured to return the beam to the starting position "SP" after the fusion mechanism 20 completes the fusion path. The controller 34 is also configured to actuate the dispensing mechanism 22 to dispense another layer of particles 18 into the chamber 12.

[0070] In the aspect where the dispensing mechanism 22 is a hopper, such as Figure 7 As shown, after the outlet 24 reaches the end position "EP", or after the outlet 24 and the inlet 36 return to the start position "SP", the controller 34 can actuate the hopper to dispense the particle layer 18. This process is repeated until the part is complete.

[0071] In aspects where the dispensing mechanism 22 is disposed within the inlet 36, the controller 34 can be configured to actuate the dispensing mechanism 22 to dispense the particle layer 18 when the inlet 36 moves along the first direction "1D". Thus, the particle layer 18 is dispensed as the inlet 36 advances. Alternatively, the controller 34 can be configured to actuate the dispensing mechanism 22 when the inlet 36 returns from the end position "EP" to the start position "SP".

[0072] Reference now Fig.11 In one aspect of the system 10, the inlet 36 can be moved relative to the outlet 24. In such an aspect, the outlet 24 is fixed within the chamber 100. For illustrative purposes, the outlet 24 is shown as being fixed to the second side wall 16b. The outlet 24 is configured to blow an inert gas into the chamber 100 in the same direction as the first direction "1D". The inlet 36 may include a slit 28 for drawing air into the inlet 36 in the same direction as the first direction "1D". The inlet 36 is fluidly connected to a vacuum 38 that can draw air into a space outside the chamber 12.

[0073] The inlet 36 is mounted to the track system 30 and between a pair of tracks 30a, 30b, each track having a conduit 44 for directing gas from the inlet 36. The blower 26 can be disposed and fixed within the tracks 30a, 30b or outside the tracks 30a, 30b. The dispensing mechanism 22 is disposed in the inlet 36 and can include a spreader (not shown) configured to distribute the particle layer 18 when the inlet 36 moves along the first direction "1D". When the beam fuses the particles, a cloud of particles is generated, and the particles in the cloud are sucked into the inlet 36 by the vacuum 38. The path of the beam is relatively unimpeded because any particles in the cloud that have been fused together are sucked out of the chamber 12, thereby reducing defects in the printed parts.

[0074] The area disposed between the inlet 36 and the outlet 24 accommodates the fusion path. It should be understood that the fusion path need not be achieved linearly. That is, the fusion path need not be achieved from one side of the chamber 12 to the other side of the chamber 12 or from the outlet 24 toward the inlet 36, but can span the width and length of the particle layer 18. For example, in a fusion mechanism 20 that employs multiple beam generators 20a, 20b, the fusion path of each of the beam generators 20a, 20b can begin at a different location in the area between the inlet 36 and the outlet 24, and once the beam generator completes its fusion path, the inlet 36 advances along the first direction "1D". Therefore, Fig.11 The distance between the inlet 36 and the outlet 24 increases as the inlet 36 advances along the first direction "1D"

[0075] Reference now Fig.12In one aspect of the system 10, the inlet 36 and the outlet 24 are movable in a first direction "1D" along the track system 30. In such an aspect, the inlet 36 and the outlet 24 are also movable relative to each other to accommodate the fusion path. Fig.11 As in the aspects shown in , vacuum 38 is connected to inlet 36 and is configured to draw air into inlet 36 along a first direction “ 1D”, and outlet 24 is configured to blow an inert gas into chamber 12 along the first direction “ 1D”.

[0076] Reference now Fig.13 , a method 200 for performing additive manufacturing is provided. At step 202, the method includes fusing particles in a particle layer 18 with a beam. The beam moves from one end of the chamber 12 to the other end of the chamber 12 along a first direction "1D" in a fusion path. Fusing particles in the particle layer 18 with the beam can be performed using a laser beam or an electron beam. The fusion path can extend along a portion of the length of the chamber 12 and a portion of the width of the chamber 12 based on the design of the part to be printed.

[0077] At step 204, the method includes providing an outlet 24 for blowing gas in a second direction "2D" opposite to the first direction "1D", and moving the outlet 24 along the first direction "1D". The gas may be an inert gas configured to minimize disturbance of the beam. The outlet 24 may extend along the width of the chamber 12 and may move along tracks 30a, 30b that extend along the length of the chamber 12. It should be understood that steps 102 and 104 may be performed simultaneously.

[0078] At step 206, the method includes maintaining the outlet 24 upstream of the fusion path so as to blow air downstream of the fusion path. Thus, the outlet 24 moves when the beam produced by the fusion mechanism 20 moves in the first direction "1D". It should be understood that the outlet 24 does not move immediately or simultaneously with the beam moving in the first direction "1D", but can move when the beam is within a predetermined distance of the outlet 24. For example, when the beam approaches within 50 mm of the outlet 24, the outlet 24 can move in the first direction "1D".

[0079] At step 208, the method may include providing an inlet 36 configured to draw air from within the chamber 12 to an environment outside the chamber 12. The inlet 36 may be spaced a predetermined distance from the outlet 24 to accommodate the fusion path. The inlet 36 may be a tubular or cubic structure extending along the width of the chamber 12. The inlet 36 includes a slit for receiving particles blown by the outlet 24.

[0080] The method may include moving the inlet 36 relative to the outlet 24 by the controller 34, wherein the controller 34 moves the inlet 36 and the outlet 24 to accommodate the fusion path of the beam. The controller 34 may also be configured to move the outlet 24 and the inlet 36 between a starting position "SP" and an end position "EP". The printing process begins at the starting position "SP", and the first layer of the part is printed when the outlet 24 reaches the end position "EP". The method may include: when the beam moves in the fusion path, the controller 34 keeps the outlet 24 upstream of the beam and the inlet 36 downstream of the beam, and when the beam completes the fusion path, returns the beam to the starting position. The method may include adding another layer of particles 18 to be printed. This can be accomplished by providing the inlet 36 with a dispensing mechanism 22 for dispensing particles when the inlet 36 moves from the starting position "SP" to the end position "EP". In the case where the dispensing mechanism 22 is a hopper, the particles can be dispensed after the outlet 24 reaches the end position "EP" or the starting position "SP".

[0081] Thus, a system and method for additive manufacturing includes an outlet that is movable in a first direction "1D" and maintained upstream of the beam. The outlet is configured to blow air in a second direction "2D" opposite the first direction "1D" to blow particles in the cloud away from the path of the beam of the fusing mechanism. In addition, any particles in the fused cloud are pulled out of the chamber and reduce defects in the printed part. In addition, because the outlet is movable along the chamber, the size of the chamber is unlimited, and therefore, the size of the part to be printed by the additive manufacturing process is also unlimited.

[0082] Many embodiments have been described. However, it should be understood that various modifications can be made without departing from the spirit and scope of the present disclosure. Therefore, other embodiments are within the scope of the appended claims.

[0083] The foregoing description is provided for the purpose of illustration and description. It is not intended to be exhaustive or to limit the present disclosure. The individual elements or features of a particular configuration are generally not limited to that particular configuration, but are interchangeable where applicable and can be used in a selected configuration, even if not specifically shown or described. It can also be varied in many ways. Such variations should not be considered as departing from the present disclosure, and all such modifications are intended to be included within the scope of the present disclosure.

Claims

1. A system for additive manufacturing, the system comprising a chamber containing a particle layer, the system comprising: a fusing mechanism that delivers a beam for fusing particles in the particle layer, the fusing mechanism being configured to move the beam in a fusing path that extends in a first direction from one end of the chamber to another end of the chamber; an outlet movable in the first direction and configured to blow air in a second direction, the second direction being opposite to the first direction; as well as A controller is configured to move the outlet in the first direction and maintain the outlet upstream of the beam, the outlet blowing particles in the particle cloud away from the particle layer.

2. The system according to claim 1, wherein: The beam is one of a laser beam and an electron beam.

3. The system of claim 1, wherein the outlet extends along a width of the chamber.

4. The system of claim 1 further comprising a track extending along a length of the chamber, the outlet being movably disposed along the track.

5. The system of claim 1, further comprising an inlet configured to draw air from within the chamber to an environment external to the chamber.

6. The system according to claim 5, wherein: The inlet is spaced apart from the outlet.

7. The system according to claim 5, wherein: The inlet extends along the width of the chamber.

8. The system according to claim 6, wherein: The inlet is movable relative to the outlet to accommodate a fusion path of the beam.

9. The system according to claim 8, wherein: The controller is configured to move the outlet and the inlet between a starting position and an ending position.

10. The system according to claim 9, wherein: The controller is configured to maintain the outlet upstream of the beam and the inlet downstream of the beam as the beam moves in the fusion path, and to return the beam to the starting position when the beam completes the fusion path.

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