System and method for creating a powder removal tool with additive manufacturing

Abstract

A method for removing excess powder from a vehicle part in an additive manufacturing process includes: defining a parameter of the part; defining parameters of a removal tool, wherein the removal tool comprises a plurality of chain links to create a chain structure; a part and a removal tool are simultaneously created by additive manufacturing, where the part defines an internal channel, the removal tool is created within the internal channel, and upon completion of creation of the part and the removal tool, the removal tool is surrounded by excess powder in the internal channel, and wherein each of the plurality of links creates a gap between adjacent ones of the plurality of links and removes the removal tool from the internal channel forcing at least some of the excess powder out of the internal channel.

Description

Technical Field

[0001] The present disclosure generally relates to systems and methods for creating powder removal tools through additive manufacturing. In particular, the present disclosure relates to powder bed polymer additive manufacturing. Background Art

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

[0003] After printing, residual powder must be removed from parts created via additive manufacturing. As the powder compacts during the printing process, powder removal can be challenging when parts have long, deep, or complex channels or paths that are difficult to reach.

[0004] Therefore, there is room for improvement in powder removal tools in parts created by additive manufacturing. Summary of the invention

[0005] One aspect of the present disclosure provides a method for removing excess powder from a part during an additive manufacturing process. The method includes defining parameters of a part, defining parameters of a removal tool, the removal tool including a plurality of links to create a chain-like structure, and simultaneously creating the part and the removal tool by additive manufacturing. The part defines an internal channel, the removal tool is created within the internal channel, and when the creation of the part and the removal tool is completed, the removal tool is surrounded by excess powder in the internal channel. Each link of the plurality of links creates a gap between adjacent links of the plurality of links. The removal tool is removed from the internal channel, forcing at least some of the excess powder to leave the internal channel. The method also includes performing at least one of the following operations to remove any remaining excess powder from the internal channel: providing a robotic attachment for powder removal; vibrating powder removal; air jetting in the internal channel; or media jetting in the internal channel.

[0006] Implementations of the present disclosure may include one or more of the following optional features.In some implementations, each link of the plurality of links is generally spiral-shaped.

[0007] The part may be for a vehicle. The vehicle may be a car.

[0008] The chain-like structure of the removal tool can be created in a spiral configuration throughout the internal channel. The spiral configuration of the removal tool can include a plurality of rotations, wherein each rotation of the plurality of rotations is spaced apart from an adjacent rotation along the center of the spiral configuration.

[0009] The internal passage may be defined by an internal side wall of the part.The removal tool may be spaced apart from the internal side wall.

[0010] Another aspect of the present disclosure provides a method for removing excess powder from a part during an additive manufacturing process. The method includes defining parameters of the part, defining parameters of a removal tool, the removal tool including a plurality of links to create a chain-like structure, and simultaneously creating the part and the removal tool by additive manufacturing. The part defines an internal channel, and the removal tool is created within the internal channel. The removal tool is removed from the internal channel, forcing at least some of the excess powder to leave the internal channel.

[0011] Implementations of the present disclosure may include one or more of the following optional features.In some implementations, each link of the plurality of links is generally spiral-shaped.

[0012] Parts can be used in cars.

[0013] The method may further include performing at least one of the following operations to remove any remaining excess powder from the interior passage: providing a robotic attachment for powder removal; vibrational powder removal; air blasting in the interior passage; or media blasting in the interior passage.

[0014] A chain of removal tools may be created in a spiral configuration throughout the interior passage.

[0015] The spiral configuration of the removal tool may include a plurality of rotations, wherein each rotation of the plurality of rotations is spaced apart from an adjacent rotation along a center of the spiral configuration.

[0016] The internal passage may be defined by an internal side wall of the part.The removal tool may be spaced apart from the internal side wall.

[0017] Another aspect of the present invention provides a method for removing excess powder from a vehicle part during an additive manufacturing process. The method includes defining parameters of the part, defining parameters of a removal tool, the removal tool including a plurality of links to create a chain-like structure, and simultaneously creating the part and the removal tool by additive manufacturing. The part defines an internal channel, and the removal tool is created within the internal channel. When the creation of the part and the removal tool is completed, the removal tool is surrounded by excess powder in the internal channel. Each link of the plurality of links creates a gap between adjacent links of the plurality of links. The removal tool is removed from the internal channel, forcing at least some of the excess powder to leave the internal channel.

[0018] Implementations of the present disclosure may include one or more of the following optional features.In some implementations, each link of the plurality of links is generally spiral-shaped.

[0019] A chain of removal tools may be created in a spiral configuration throughout the interior passage.

[0020] The spiral configuration of the removal tool may include a plurality of rotations, wherein each rotation of the plurality of rotations is spaced apart from an adjacent rotation along a center of the spiral configuration.

[0021] The method may further include performing at least one of the following operations to remove any remaining excess powder from the interior passage: providing a robotic attachment for powder removal; vibrational powder removal; air blasting in the interior passage; or media blasting in the interior passage.

[0022] The details of one or more embodiments of the disclosure are set forth in the accompanying drawings and the description below. Other aspects, features, and advantages will be apparent from the description and drawings, and from the claims. BRIEF DESCRIPTION OF THE DRAWINGS

[0023] The drawings described herein are for illustrative purposes only of selected configurations and are not intended to limit the scope of the present disclosure.

[0024] Figure 1 is a perspective view of an exemplary powder removal tool according to the teachings of the present invention;

[0025] Figure 2 is provided in the exemplary part Figure 1 A perspective view of an exemplary powder removal tool;

[0026] Figure 3 is provided in the exemplary part Figure 1 A perspective view of an exemplary powder removal tool;

[0027] Figure 4 is provided in the exemplary part Figure 1 A perspective view of an exemplary powder removal tool;

[0028] Figure 5 is a perspective view of an exemplary powder removal tool according to the teachings of the present invention;

[0029] Figure 6 is a perspective view of an exemplary powder removal tool according to the teachings of the present invention;

[0030] Figure 7 is a perspective view of an exemplary powder removal tool according to the teachings of the present invention;

[0031] Figure 8 is a perspective view of an exemplary powder removal tool according to the teachings of the present invention; and

[0032] Fig. 9 is used to create according to the teachings of the present invention Figure 1-8 A flow chart of an exemplary powder removal tool and part process.

[0033] Corresponding reference characters indicate corresponding parts throughout the several views. DETAILED DESCRIPTION

[0034] 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 implemented in many different forms, and that the specific details and exemplary configurations should not be construed as limiting the scope of the present disclosure.

[0035] Reference Figure 1 , generally showing a powder removal tool 100. The powder removal tool 100 includes a plurality of links 102 linked together to form a chain. In some embodiments, the chain is printed in a generally spiral configuration. That is, the chain defines a central void, and the chain is wound around the central void, with each successive layer, step, or row of the chain separated from adjacent layers, steps, or rows along the central void by a gap 110. The gaps 110 prevent the links 102 from fusing to each other during the additive manufacturing process.

[0036] Each link 102 includes a body portion 104 defining a central cavity 106. The links 102 are interconnected by the body portion 104 of one link extending through the central cavity 106 of an adjacent link 102. Figure 1-4 As shown, the link 106 may include a generally spiral shape. The links 102 are printed with gaps 108 between the body 104 of one link and the body 104 of an adjacent link 102. The gaps 108 prevent the links 102 from fusing to each other during the additive manufacturing process.

[0037] refer to Figure 2-4 , the powder removal tool 100 is printed in situ in the part 10, 10a-c by additive manufacturing, which greatly reduces the de-powdering efforts required after the part 10, 10a-c is formed. The part 10 can be a part for a vehicle, which can be a car. It should be understood that the vehicle can be any of a variety of different types of cars, such as a sedan, a van, a truck, or a sports utility vehicle (SUV), and can be a two-wheel drive (2WD) (i.e., rear-wheel drive or front-wheel drive), a four-wheel drive (4WD) or an all-wheel drive (AWD), and / or various other types of vehicles in certain configurations. The vehicle can also include a truck, a ship, an airplane, and / or one or more other types of vehicles. In other embodiments, the part 10 can be used for any suitable application, including but not limited to consumer products, medical products, etc.

[0038] The part 10 may include one or more internal channels 12. The internal channel 12 may be a conduit, a channel, a chamber, or any other suitable channel defined by an internal sidewall 14. By printing the powder removal tool 100 into a coil / spiral form factor so that it follows the internal sidewall 14 of the internal channel 12, powder can be removed by simply pulling the powder removal tool 100 from the outside of the part 10. The powder removal tool 100 reduces the labor required to remove bulk powder by loosening a small amount of powder at each link (as opposed to loosening a large amount of powder at a time), thereby minimizing the force and relative strength requirements required for the powder removal tool 100. The powder removal tool 100 also removes a small amount of powder near the internal sidewall 14 of the internal channel 12, thereby releasing a bulk center powder block from the internal channel 12. The powder removal tool 100 can also reduce waste, integrate with automated equipment, and make subsequent processing steps more efficient, thereby saving time and money. The powder removal tool 100 can be scaled and customized without an upper limit on size to accommodate complex geometries with varying cross-sections and non-linear paths.

[0039] Reference Figure 2 , shows a first exemplary part 10a in which a powder removal tool 100 is disposed within an interior passage 12 defined by an interior sidewall 14. Figure 3 , shows a second exemplary part 10b, wherein a powder removal tool 100 is disposed within an interior passage 12 defined by an interior sidewall 14. Figure 4 , shows a third exemplary part 10c having a plurality (ie, five) of powder removal tools 100 disposed within four internal passages 12 that converge into a single internal passage 12, all of which are defined by internal sidewalls 14. Figure 4 As shown, there may be any suitable number of powder removal tools 100 depending on the geometry of the part 10 and the number of internal passages 12 within the part 10 .

[0040] Reference Figure 5 , generally showing a second powder removal tool 200. The second powder removal tool 200 may be created by additive manufacturing and operates using the same principles as the powder removal tool 100. However, as Figure 5 As shown, second powder removal tool 200 may include a different shape and geometry than powder removal tool 100 .

[0041] Specifically, the second powder removal tool 200 may include a plurality of spherical links 202 defining one or more radial holes 204 around the links 202 and a central cavity 206 extending through each link 202. The second powder removal tool 200 includes a connecting rod 208 having a first head 210 disposed at a first end and a second head 212 disposed at a second end opposite the first end of the connecting rod 208. The size of the heads 210, 212 may be larger than the diameter of the central hole 206, such that the heads 210, 212 prevent the connecting rod 208 from being disengaged from the links 202.

[0042] The links 202 and the connecting rods 208 may be printed such that a first link 202 is spaced a first distance 214 from a second adjacent link 202. The heads 210, 212 may be spaced a second distance 216 from one another. The links 202 may be free to move along the connecting rods 208, thereby reducing the first distance 214 to zero when adjacent links 202 contact one another. However, the heads 210, 212 prevent the links 202 from being spaced apart beyond the second distance 216.

[0043] Reference Figure 6 , generally showing a third powder removal tool 300. The third powder removal tool 300 may be created by additive manufacturing and operates using the same principles as the powder removal tool 100. However, as Figure 6 As shown, third powder removal tool 300 may include a different shape and geometry than powder removal tool 100 .

[0044] Specifically, the third powder removal tool 300 includes a plurality of links 302 that define a central cavity 304, a first hole 306a, and a second hole 306b. The central cavity 304 extends through each link 302, and the holes 306a, 306b extend into the central cavity 304. The first link 302 extends through the holes 306a, 306b and into the central cavity 304 of the second adjacent link 302 to connect the first link 302 to the second link 302. The links 302 are printed with gaps 308 between adjacent links. The gaps 308 prevent the links 302 from fusing to each other during the additive manufacturing process.

[0045] Reference Figure 7 , generally showing a fourth powder removal tool 400. The fourth powder removal tool 400 may be created by additive manufacturing and operates using the same principles as the powder removal tool 100. However, as Figure 7 As shown, fourth powder removal tool 400 may include a different shape and geometry than powder removal tool 100 .

[0046] Specifically, the fourth powder removal tool 400 may include a plurality of links 402 defining one or more radial holes 404 and a central hole 406 leading to a central cavity 408. Each link 402 includes a connecting rod 410 and a distal ball 412 disposed at a distal end of the connecting rod 410 away from the part 402. Each distal ball 412 is printed within the central cavity 408 of an adjacent link 402, and the distal ball 412 is separated from the adjacent link 402 by a gap 414. The gap 414 prevents the links 402 from fusing to each other during the additive manufacturing process.

[0047] Reference Figure 8 , generally showing a fifth powder removal tool 500. The fifth powder removal tool 500 may be created by additive manufacturing and operates using the same principles as the powder removal tool 100. However, as Figure 8 As shown, fifth powder removal tool 500 may include a different shape and geometry than powder removal tool 100 .

[0048] Specifically, the fifth powder removal tool 500 includes a plurality of links 502 including a lower ring 504 defining a lower hole 506 and an upper ring 508 defining an upper hole 510. The upper ring 504 of one link 502 is printed such that it is disposed within the lower hole 506 of an adjacent link 502 and is separated from the lower ring 504 by a gap 512. The gap 512 prevents the links 502 from fusing to each other during the additive manufacturing process.

[0049] refer to Fig. 9 , generally illustrates a method 900 for creating a powder removal tool 100, 200, 300, 400, 500 and a part 10, 10a-c. At step 902, an additive manufacturing or printing tool defines parameters of the powder removal tool 100, 200, 300, 400, 500 and the part 10, 10a-c. At steps 904 and 906, the additive manufacturing tool simultaneously prints the powder removal tool 100, 200, 300, 400, 500 and the part 10, 10a-c, with the powder removal tool 100, 200, 300, 400, 500 disposed within the interior passage 12 of the part 10, 10a-c.

[0050] At step 908, the user removes the powder removal tool 100, 200, 300, 400, 500 from the particular part 10, 10a-c by pulling the powder removal tool 100, 200, 300, 400, 500 (e.g., a chain), which removes the powder removal tool 100, 200, 300, 400, 500 from the internal passage 12. As the powder removal tool 100, 200, 300, 400, 500 is pulled out of the internal passage 12, it loosens excess powder within the internal passage 12 so that the excess powder can be removed from the internal passage 12, such as by flipping the part 10 so that gravity forces the excess powder out of the internal passage 12. When the powder removal tool 100, 200, 300, 400, 500 is completely removed from the internal passage 12, a fully open channel is created within the internal passage 12, such as both ends of the internal passage 12 are open and able to receive fluid or other materials.

[0051] At step 910, the user may perform additional post-processing operations on the part, such as providing a robotic attachment to remove powder from the internal passage 12, vibratory powder removal, air blasting in the internal passage 12, or media blasting in the internal passage 12 to remove any remaining excess powder in the internal passage 12. Air or media blasting in the internal passage 12 is possible because the powder removal tools 100, 200, 300, 400, 500 create a completely open passage in the internal passage 12. That is, in the absence of a completely open passage in the internal passage 12, it would be difficult for air or media blasting to remove excess powder because there would be no outlet for the air or media.

[0052] The terms used herein are only for describing specific exemplary configurations, not for limiting. As used herein, the singular articles "a", "an" and "the" may also be intended to include plural forms, unless the context clearly indicates otherwise. The terms "comprise", "include", "contain" and "have" are inclusive, thus specifying 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 interpreted as necessarily requiring them to be performed in the specific order discussed or shown, unless specifically identified as an execution order. Additional or alternative steps may be adopted.

[0053] 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, engaged, connected, 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 of the associated listed items.

[0054] The terms first, second, third, etc. can be used here 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 are only used to distinguish each element, component, region, layer or part. Terms such as "first", "second" and other numerical terms do not imply order or sequence unless the context clearly indicates. Therefore, the first element, component, region, layer or part discussed below can be referred to as the second element, component, region, layer or part, without departing from the teaching of the example configuration.

[0055] 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.

[0056] Software applications (i.e., software resources) may refer to computer software that enables a computing device to perform tasks. In some examples, software applications may be referred to as "applications," "apps," or "programs." 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.

[0057] 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.

[0058] 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, apparatus, and / or device (e.g., disk, optical disk, memory, programmable logic device (PLD)) for providing machine instructions and / or data to a programmable processor, 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.

[0059] 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 also within the scope of the following claims.

[0060] The foregoing description has been provided for the purpose of illustration and description. It is not intended to be exhaustive or to limit the present disclosure. Individual elements or features of a particular configuration are generally not limited to that particular configuration, but where applicable, they are interchangeable and can be used in a selected configuration even if not specifically shown or described. This can also be varied in a variety of ways. Such variations should not be considered a departure from the present disclosure, and all such modifications are intended to be included within the scope of the present disclosure.

Claims

1. A method for removing excess powder from a part during an additive manufacturing process, the method comprising: Define the parameters of the part; defining parameters of a removal tool, the removal tool comprising a plurality of chain links to create a chain-like structure; creating a part and a removal tool simultaneously by additive manufacturing, wherein the part defines an internal channel, the removal tool is created within the internal channel, and upon completion of the creation of the part and the removal tool, the removal tool is surrounded by excess powder in the internal channel, and wherein each link of the plurality of links creates a gap between adjacent links of the plurality of links; removing the removal tool from the interior passage, forcing at least some of the excess powder out of the interior passage; and Do at least one of the following to remove any remaining excess powder from the interior passages: A robotic attachment is available for powder removal; Vibration powder removal; Air jets in internal passages; or Media injection in internal channels.

2. The method according to claim 1, wherein: Each link of the plurality of links is generally spiral-shaped.

3. The method according to claim 1, wherein: The parts are for vehicles.

4. The method according to claim 3, wherein: The vehicle is a car.

5. The method according to claim 1, wherein: The chain-like structure of the removal tool is created in a spiral configuration throughout the interior passageway.

6. The method according to claim 5, wherein: The spiral configuration of the removal tool includes a plurality of rotations, wherein each rotation of the plurality of rotations is spaced apart from an adjacent rotation along a center of the spiral configuration.

7. The method according to claim 1, wherein: The interior passage is defined by an interior sidewall of the part, and the removal tool is spaced apart from the interior sidewall.

8. A method for removing excess powder from a part during an additive manufacturing process, the method comprising: Define the parameters of the part; defining parameters of a removal tool, the removal tool comprising a plurality of chain links to create a chain-like structure; creating a part and a removal tool simultaneously by additive manufacturing, wherein the part defines an internal passage and the removal tool is created within the internal passage; as well as The removal tool is removed from the interior passage, forcing at least some of the excess powder out of the interior passage.

9. The method according to claim 1, wherein: Each link of the plurality of links is generally spiral-shaped.

10. The method according to claim 8, wherein: The parts are used in automobiles.

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