Direct metal laser printing gas manifold

Abstract

A gas manifold for a single nozzle deposition chamber, the gas manifold comprising: a base having a top surface and a bottom surface defining a thickness; a main nozzle having an inlet and an outlet extending through the thickness of the base; and a secondary nozzle having an inlet extending partially through the top surface of the base and at least one channel having an outlet extending a distance from a sidewall of the base, the channel being in fluid communication with the inlet of the secondary nozzle. The inlet of the main nozzle has a hollow protrusion extending from the top surface of the base into a gas feed port. The passage of the secondary nozzle includes a bend between the side wall of the base and the outlet, the bend configured to pass between a first direct energy source and a second direct energy source, the first and second energy sources disposed on a top wall of the chamber.

Description

Technical Field

[0001] The present disclosure relates generally to additive manufacturing systems, and more particularly to gas manifolds for use with metal laser printing systems. Background Art

[0002] Additive manufacturing systems, such as direct metal laser sintering (DMLS), direct metal laser melting (DMLM), selective laser sintering (SLS), direct metal laser deposition (DMLD) and / or direct metal laser deposition (DMLD), direct an energy beam at a target component to deposit layers of powdered material onto the target component. The target component is manufactured by depositing layers of material on the top surface of the target component and sintering or bonding each layer before depositing another layer.

[0003] The deposition process occurs in an inert deposition chamber that includes a direct energy source, a gas nozzle, and a stacking fixture. In a laser power bed fusion (LPBF) system, powder is spread on a stacking fixture having a recoater assembly, a stacking platform, and a powder reservoir. Between depositing additional layers onto a target object, the recoater assembly purges powder onto the target object and the stacking platform while the gas nozzle supplies an inert purge gas into the chamber to ensure that weld spatter is not redeposited onto the target object or the stacking plate. The inert purge gas also reduces interference of soot particles with the laser path of the direct energy source because the direct energy source produces an energy beam that melts, sinters, or otherwise bonds the powdered material to the target component. The target component is at least partially suspended or supported within the stacking fixture, and an energy beam is produced on the stacking fixture to bond the powdered material to the target component.

[0004] The deposition chamber may include a single direct energy source or multiple direct energy sources. The direct energy source is positioned above the stacking fixture and oriented to cover the target area of ​​the stacking fixture. The deposition chamber may include a single gas nozzle or multiple gas nozzles to evenly distribute the gas above the stacking fixture. In some embodiments, the deposition chamber includes a single centrally positioned gas nozzle. In other embodiments, the deposition chamber may include multiple gas nozzles to cover a larger target area. The single nozzle configuration may suffer from variations in deposition or purge uniformity and gas delivery. Although a multi-nozzle configuration can provide better deposition or purge uniformity and gas delivery than a single nozzle configuration, a multi-nozzle configuration is typically more complex and has more failure modes. Therefore, there is a need to improve deposition and purge uniformity and gas delivery in a single nozzle additive manufacturing system configuration. Summary of the invention

[0005] In one aspect, a gas manifold for use in an additive manufacturing system is disclosed. The gas manifold includes a base having a top surface and a bottom surface, with a thickness of the base defined between the top surface and the bottom surface. The gas manifold also includes a primary nozzle having an inlet and an outlet extending through the thickness of the base. The inlet of the primary nozzle is in fluid communication with an inlet of a chamber of the additive manufacturing system. The gas manifold also includes a secondary nozzle having an inlet extending partially through the top surface of the base and at least one channel extending a distance from a side wall of the base. The channel includes an outlet, and the channel is in fluid communication with the inlet of the secondary nozzle. The inlet of the secondary nozzle is in fluid communication with the inlet of the chamber.

[0006] On the other hand, an additive manufacturing system is disclosed. The additive manufacturing system includes: a chamber having a top wall and a gas feed port extending through the top wall; and at least one direct energy source, the at least one direct energy source being disposed on the top wall. The direct energy source directs an energy beam that bonds a powdered material to a target component positioned within the chamber. The additive manufacturing system also includes a gas manifold having a base, the base including a top surface and a bottom surface, and a thickness of the base defined between the top surface and the bottom surface. The gas manifold also includes a primary nozzle having an inlet and an outlet extending through the thickness of the base. The inlet of the primary nozzle is in fluid communication with an inlet of the chamber of the additive manufacturing system. The gas manifold also includes a secondary nozzle having an inlet extending partially through the top surface of the base and at least one channel extending a distance from the side wall of the base. The channel includes an outlet, and the channel is in fluid communication with the inlet of the secondary nozzle. The inlet of the secondary nozzle is in fluid communication with the inlet of the chamber. A top surface of the base of the gas manifold abuts the top wall of the chamber, and a gas feed port is in fluid communication with the primary nozzle and the secondary nozzle.

[0007] In another aspect, a method of forming a gas manifold for use in an additive manufacturing system is disclosed. The method includes the step of forming a base having a top surface and a bottom surface with a thickness defined therebetween. The method also includes the step of forming a primary nozzle having an inlet and an outlet extending through the thickness of the base. The inlet of the primary nozzle is in fluid communication with an inlet of a chamber. The method also includes the step of forming a secondary nozzle having an inlet extending partially through the top surface of the base. The secondary nozzle also has at least one channel extending a distance from a sidewall of the base and having an outlet. The channel is in fluid communication with the inlet of the secondary nozzle, and the inlet of the secondary nozzle is in fluid communication with the inlet of the chamber. BRIEF DESCRIPTION OF THE DRAWINGS

[0008] The presently disclosed subject matter will be explained in more detail hereinafter with reference to exemplary embodiments shown in the drawings.

[0009] Figure 1is a cross-sectional view of an exemplary additive manufacturing system including a gas manifold.

[0010] Figure 2 Along the section line A-A' Figure 1 Bottom view of the additive manufacturing system.

[0011] Figure 3 yes Figure 1 B is an enlarged detailed cross-sectional view of a detail of the additive manufacturing system.

[0012] Figure 4 yes Figure 1 A perspective view of the gas manifold.

[0013] Figure 5 is with Figure 1 A perspective view of the secondary nozzle used in conjunction with a gas manifold.

[0014] The reference numerals used in the drawings and their meanings are listed in summary form in the reference numeral list. In principle, identical components are provided with the same reference numerals in the drawings. DETAILED DESCRIPTION

[0015] In the following specification and claims, reference will be made to a number of terms which shall be defined to have the following meanings.

[0016] As used herein, the singular forms "a," "an," and "the" include plural references unless the context clearly dictates otherwise. The terms "comprising," "including," and "having" are intended to be inclusive and mean that there may be additional elements other than the listed elements. The term "optional" or "optionally" means that the subsequently described event or circumstance may or may not occur, and that the description includes instances where the event occurs and instances where it does not occur.

[0017] Unless otherwise indicated, approximate language as used herein, such as "substantially", "substantially", and "about" indicate that as one of ordinary skill in the art will recognize, the terms so modified may apply only to an approximate degree, rather than an absolute or perfect degree. Therefore, values ​​modified by one or more terms (such as "about", "approximately", and "substantially") are not limited to the precise values ​​specified. In at least some cases, approximate language may correspond to the precision of an instrument used to measure a value. Here, as well as throughout the specification and claims, range limitations may be identified. Unless otherwise indicated by context or language, these ranges may be combined and / or interchanged, and include all subranges contained therein.

[0018] In addition, unless otherwise indicated, the terms "first", "second", etc. are used herein merely as labels and are not intended to impose order, position, or hierarchical requirements on the items to which these terms refer. Furthermore, for example, reference to a "second" item does not require or exclude the existence of, for example, a "first" or lower numbered item or a "third" or higher numbered item.

[0019] The methods, systems, and devices described herein overcome at least some of the disadvantages of known additive manufacturing systems. More specifically, the system devices described herein improve the uniformity of gas flow delivery in a single nozzle additive manufacturing system configuration by utilizing a gas manifold having a primary nozzle and a secondary nozzle without modifying the deposition chamber. The primary nozzle and the secondary nozzle supply gas from a single inlet and are oriented to distribute the gas within the deposition chamber. The fluid passage of the gas manifold includes one or more bends positioned between the inlet and the outlet so as not to obstruct the operation of the direct energy source of the deposition chamber.

[0020] refer to Figure 1 In an exemplary embodiment, the additive manufacturing system 100 is a laser power bed fusion (LPBF) system. In alternative embodiments, the additive manufacturing system 100 is any other suitable additive manufacturing system, including but not limited to one of the following: a direct metal laser melting (DMLM) system, a selective laser sintering (SLS) system, a direct metal laser deposition (DMLD) system, a direct metal laser deposition (DMLD) system, a powder blowing additive system, and / or a LasergCusing system. Figure 1 A cross-sectional view of deposition chamber 110 is shown. Figure 2 A bottom view of the deposition chamber 110 taken along line AA' is shown.

[0021] In an exemplary embodiment, the additive manufacturing system 100 includes a deposition fixture assembly 120, a direct energy source 130 positioned within a deposition chamber 110, and a gas delivery system 140. In addition, in an exemplary embodiment, the direct energy source 130 includes four heads 134 arranged in a matrix on the top wall 112 of the deposition chamber. The four heads 134 are centrally located relative to an inlet 142 of the gas delivery system 140. In some embodiments, the direct energy source 130 includes at least two heads. In some embodiments, the direct energy source 130 includes more than four heads 134.

[0022] like Figure 1As shown, the stacking fixture assembly 120 includes a stacking plate 129 oriented and positioned within the stacking fixture 120 to support one or more target parts 102. The stacking fixture assembly 120 also includes a powder reservoir 122 that provides a continuous supply of powdered material 124. Between deposition cycles, the powder platform 126 raises the powdered material 124 while the recoater 128 spreads the raised powdered material 124 on the target parts 102. When depositing a layer, the stacking plate 129 lowers the target parts 102 while excess powdered material 124 exists in the volume above and near the stacking plate 129.

[0023] An inert gas 106 (shown as a flow vector) is supplied into the deposition chamber 110 and onto the buildup fixture 120 via a gas delivery system 140 to purge weld spatter and soot particles between deposition cycles. During a deposition cycle, a direct energy source 130 generates an energy beam 132 via a scanner system that selectively directs the energy beam 132 at one or more target parts 102 and the buildup fixture 120, typically at a preselected scan speed, such that the direct energy beam 132 sinters or more generally bonds the powdered material 124 to the buildup layer 104 of the target part 102. The direct energy beam 132 is sufficient to fuse a preselected region of the buildup layer 104 immediately below the buildup layer 104.

[0024] In an exemplary embodiment, the inlet 142 is a tube or cylindrical structure (eg, Figure 3 104). The inert gas 106 is supplied to the deposition chamber 110 through a nozzle positioned within the deposition chamber 110. In at least some known embodiments, the single nozzle configuration can result in poor distribution of the inert gas 106 around the periphery of the buildup fixture 120, causing weld spatter or soot particles to remain, resulting in variations in deposition uniformity. This variation can result in undesirable porosity levels when additional layers are melted onto the buildup layer 104 in subsequent deposition cycles. As explained in further detail below, the gas manifold 200 described herein can replace a single nozzle in a single nozzle configuration without having to change or modify other components of the additive manufacturing system 100.

[0025] Figure 4 shows a perspective view of the gas manifold 200, Figure 1 and Figure 3 A side view of a gas manifold 200 positioned within a deposition chamber is shown, and Figure 2The gas manifold 200 is shown oriented relative to the four heads 134 of the direct energy source 130. In an exemplary embodiment, the gas manifold 200 has a primary nozzle 220 and a secondary nozzle 250 that both supply the inert gas 106 from the inlet 142 of the gas delivery system 140. The primary nozzle 220 and the secondary nozzle 250 are in fluid communication with the inlet 142 of the gas delivery system 140 and distribute the inert gas 106 over a plurality of outlets, as explained in further detail below. Thus, the manifold 200 facilitates improved deposition uniformity and gas delivery of the inert gas 106 on the deposition fixture assembly 120.

[0026] The gas manifold 200 includes a base 210 having a top surface 212 and a bottom surface 214. The top surface 212 and the bottom surface 214 define a thickness t1 of the base 210 (eg, Figure 3 As shown in FIG. 2 ). The main nozzle 220 includes an inlet 222 and an outlet 224 extending through the thickness t1 of the base 210. Figure 2 As shown, in an exemplary embodiment, the outlet 224 of the main nozzle 220 has an elliptical shape, a slit shape, or a generally circular shape, and is configured to supply the inert gas 106 (such as Figure 1 224 can have any other shape that enables the nozzle 200 to function as described herein. In some embodiments, the inlet 222 of the primary nozzle includes a hollow protrusion 226 extending from the top surface 212 of the base 210. The secondary nozzle 250 includes an inlet 252 extending partially through the top surface 212 of the base 210 and at least one channel 260 in fluid communication with the inlet 252 extending from the side wall of the base 210. The at least one channel 260 includes an outlet 254 that is oriented to spray or distribute the inert gas 106 (such as Figure 1 shown).

[0027] like Figure 3 and Figure 4 As best shown, the inlet 222 of the primary nozzle 220 and the inlet 252 of the secondary nozzle 250 are circular in shape and are concentrically aligned with each other. In alternative embodiments, the inlet 222 of the primary nozzle 220 and the inlet 252 of the secondary nozzle 250 may have any shape or orientation that enables the inlet 222 of the primary nozzle 220 and the inlet 252 of the secondary nozzle 250 to function as described herein. At the top surface 212 of the base, the inlet 222 of the primary nozzle 220 has a diameter D3 that is smaller than the diameter D4 of the inlet 252 of the secondary nozzle 250.

[0028] The top surface 212 of the base 210 abuts against the top wall 112 of the deposition chamber 110 so that the inlet 222 of the primary nozzle 220 and the inlet 252 of the secondary nozzle 250 are in fluid communication with the inlet 142 of the gas delivery system 140. In embodiments where the primary nozzle 220 includes a hollow protrusion 226 extending from the top surface 212 of the base, the hollow protrusion 226 extends a distance into the inlet 142 of the gas delivery system 140 so that when the inert gas 106 is injected into the deposition chamber 110 through the inlet 142 of the gas delivery system 140, the hollow protrusion 226 captures a portion of the inert gas 106. In some embodiments, the protrusion 226 tapers inwardly from the base 210. The protrusion 226 has an end 228 opposite the base 210. The end 228 has a diameter D2 that is smaller than a diameter D3 of the inlet 222 of the primary nozzle 220 at the base 210. The end 228 of the protrusion 226 has a diameter D2 that is smaller than the diameter D1 of the gas feed port. The end 228 of the protrusion 226 is positioned a distance L1 from the edge 141 of the inlet 142 of the gas delivery system 140. In an exemplary embodiment, the inlet 142 has a generally cylindrical shape that can be coupled to a hose or coil.

[0029] Because the diameter D2 of the end 228 of the protrusion 226 is smaller than the diameter D1 of the inlet 142. The inert gas 106 supplied by the inlet 142 can flow to both the primary nozzle 220 and the secondary nozzle 250. The ratio of the size of the end 228 of the protrusion 226 relative to the diameter D1 of the gas feed port can vary depending on the desired amount of inert gas 106 delivered to the primary nozzle 220 and the secondary nozzle 250. In some embodiments, the ratio of the diameter D2 of the end 228 of the protrusion 226 relative to the diameter D1 of the inlet 142 is in the range of 1:10 to 9:10. In alternative embodiments, the diameter D2 of the end 228 of the protrusion 226 relative to the diameter D1 of the inlet 142 can have any ratio that enables the primary nozzle 220 and the secondary nozzle 250 to function as described herein.

[0030] In some embodiments, due to the tapering of the protrusion 226, the cross-sectional surface area of ​​the inlet 142 decreases from the top surface 212 of the base 210 toward the end 228 of the protrusion 226. The reduced cross-sectional area results in a higher static pressure of the inert gas 106 at the inlet 252 of the secondary nozzle compared to the static pressure at the end 228 of the protrusion 226. As explained in more detail below, the inert gas 106 traveling through the secondary nozzle 250 requires additional static pressure because of the at least one passage 260 between the inlet 252 and the outlet 254 of the secondary nozzle 250. Likewise, as Figure 3As best shown, in some embodiments, the tapering of the protrusion 226 also results in a reduction in static pressure for the primary nozzle 220 , such that the primary nozzle 220 and the secondary nozzle 250 can exhaust a desired amount of the inert gas 106 .

[0031] like Figures 1 to 4 As shown, the inlet 252 of the secondary nozzle 250 is in fluid communication with at least one channel 260 extending from the side wall 216 of the base 210. In some embodiments, the gas manifold 200 includes two channels 260a and 260b, each of which has the same characteristics as the channel 260. The channel 260 is located between the two heads 134 and extends a length L3 (e.g., Figure 2 ), defining an XX' axis. In addition, the channel 260 extends a length L3 so that the first bend 262 of the channel 260 does not interfere with the operation of the head 134. In an exemplary embodiment, the first bend 262 extends substantially perpendicular to the XX' axis and substantially parallel to the YY' axis. The YY' axis is perpendicular to XX' at the base 210. In an exemplary embodiment, the first bend 262 extends a length L4 to the second bend 264 so that the first bend 262, the second bend 264 and the channel 260 generally do not interfere with the operation of the head 134. The second bend 264 extends substantially perpendicular to the first bend 262 and substantially parallel to the YY' axis. In some embodiments, the outlet 254 of the secondary nozzle 250 extends at least a length L3 from the second bend 264 so that the outlet 254 of the secondary nozzle 250 is on the same axis XX' as the outlet 224 of the primary nozzle 220. The first bend 262 is substantially perpendicular to the at least one channel 260 extending from the base 210, and the second bend 264 is substantially perpendicular to the first bend 262. In other words, the at least one channel 260 forms a U-shape or a semicircle so that the outlet 254 of the secondary nozzle 250 is on the same axis XX' as the outlet 224 of the primary nozzle 220. Alternatively, in some embodiments, the at least one channel 260 does not have a bend. Furthermore, in some embodiments, the outlet 254 of the secondary nozzle 250 extends a length L3 from the base 210. In alternative embodiments, the first bend 262 and the second bend 264 may have any shape or orientation that enables the channel 260 to function as described herein.

[0032] like Figure 2 and Figure 5As best shown, the outlet 254 of the secondary nozzle 250 includes a plurality of flow expansion passages 270, each flow expansion passage 270 having a first end 272 and a second end 274. The flow expansion passages 270 are oriented as gas diffusers, wherein the first end 272 has a cross-sectional area 278 that is smaller than a cross-sectional area 279 of the second end 274. The first end 272 of each flow expansion passage 270 is in fluid communication with the passage 260, and the second end 274 of each expansion passage 270 is oriented as the outlet 254 of the secondary nozzle 250.

[0033] like Figure 4 As shown, in some embodiments, the gas manifold 200 includes a support structure 202 that connects the outlet 254 of the secondary nozzle 250 to the base 210. In some embodiments, the top surface 261 of the channel 260 includes a plurality of legs 266 extending from the top surface 261. The legs 266 abut the top wall 112 of the deposition chamber 110 and provide structural rigidity to the at least one channel 260.

[0034] The above-described embodiments overcome at least some of the disadvantages of known methods for repairing parts. Specifically, the embodiments improve the uniformity of gas delivery in a single nozzle additive manufacturing system configuration by utilizing a gas manifold having a primary nozzle and a secondary nozzle without modifying the deposition chamber to distribute the gas. The primary nozzle and the secondary nozzle supply gas from a single inlet and are oriented to distribute the gas within the deposition chamber. The fluid passage of the gas manifold includes one or more bends positioned between the inlet and the outlet so as not to obstruct operation of the direct energy source of the deposition chamber. The gas manifold described herein can replace a single nozzle in a single nozzle configuration without having to change or modify other components of the additive manufacturing system.

[0035] The methods, systems, and compositions disclosed herein are not limited to the specific embodiments described herein, but rather the steps of the methods, the elements of the systems, and / or the elements of the compositions can be used independently and separately from other steps and / or elements described herein. For example, the methods, systems, and compositions are not limited to being practiced with only the rotating machines as described herein. Instead, the methods, systems, and compositions can be implemented and used in conjunction with many other applications.

[0036] Although specific features of various embodiments may be shown in some drawings and not in others, this is for convenience only. Furthermore, reference to "one embodiment" in the above description is not intended to be interpreted as excluding the existence of additional embodiments that also incorporate the described features. In accordance with the principles of the present disclosure, any feature of a drawing may be referenced and / or claimed in conjunction with any feature of any other drawing.

[0037] This written description uses examples, including the best mode, to enable any person skilled in the art to practice the present disclosure, including making and using any device or system and performing any combined method. The patentable scope of the present disclosure is defined by the claims and may include other examples that occur to those skilled in the art. Such other examples are intended to be within the scope of the claims if they have structural elements that do not differ from the literal language of the claims, or if they include equivalent structural elements that are not substantially different from the literal language of the claims.

[0038] Further aspects of the invention are provided by the subject matter of the following clauses:

[0039] A gas manifold for use in an additive manufacturing system, the gas manifold comprising: a base having a top surface and a bottom surface defining a thickness therebetween; a primary nozzle having an inlet and an outlet extending through the thickness of the base, the inlet of the primary nozzle being in fluid communication with an inlet of a chamber; and a secondary nozzle having an inlet extending partially through the top surface of the base and at least one channel extending a distance from a sidewall of the base and having an outlet, the channel being in fluid communication with the inlet of the secondary nozzle, the inlet of the secondary nozzle being in fluid communication with the inlet of the chamber.

[0040] 2. The gas manifold according to the preceding clause, wherein the outlet of the main nozzle has one of an elliptical shape, a slit shape and a circular shape.

[0041] 3. A gas manifold according to any of the preceding clauses, wherein the inlet of the secondary nozzle has a substantially circular shape oriented substantially concentrically with the inlet of the primary nozzle, the inlet of the secondary nozzle having a substantially circular shape, wherein the diameter of the inlet of the primary nozzle is smaller than the diameter of the inlet of the secondary nozzle.

[0042] 4. A gas manifold according to any preceding clause, wherein the inlet of the primary nozzle has a protrusion extending from the top surface of the base.

[0043] 5. A gas manifold according to any preceding clause, wherein the projection tapers inwardly from the base such that an end of the projection is smaller than the diameter of the inlet of the primary nozzle at the base.

[0044] 6. A gas manifold according to any of the preceding clauses, wherein the top surface of the base contacts the top wall of a chamber, the chamber having a gas feed inlet extending through the top wall of the chamber and connected to the primary nozzle and the secondary nozzle fluids, and the protrusion extends a distance into the gas feed inlet.

[0045] 7. A gas manifold according to any preceding clause, wherein the diameter of the end of the protrusion is smaller than the diameter of the gas feed opening.

[0046] 8. A gas manifold according to any preceding clause, wherein the ratio of the diameter of the end of the protrusion to the diameter of the gas feed opening is in the range of 1:10 to 9:10.

[0047] 9. A gas manifold according to any preceding clause, wherein the at least one channel of the secondary nozzle comprises at least one bend defined between the side wall of the base and the outlet.

[0048] 10. A gas manifold according to any preceding clause, wherein the at least one bend is one of a U-shape and a semi-circular shape.

[0049] 11. A gas manifold according to any preceding clause, wherein the at least one bend extends between a first direct energy source and a second direct energy source, the first energy source and the second energy source being located on a top wall of the chamber.

[0050] 12. A gas manifold according to any of the preceding clauses, wherein the at least one channel of the secondary nozzle comprises a first bend and a second bend, the first bend being perpendicular to the at least one channel, the second bend being perpendicular to the first bend, the outlet of the secondary nozzle extending a distance from the second bend.

[0051] 13. A gas manifold according to any preceding clause, wherein the outlet of the secondary nozzle comprises a plurality of flow channels, each of the flow channels having a first end and a second end, the first end having a smaller cross-sectional area than the second end.

[0052] 14. An additive manufacturing system, the additive manufacturing system comprising: a chamber, the chamber comprising a top wall and a gas feed port extending through the top wall and at least one direct energy source disposed on the top wall, the direct energy source directing an energy beam, the energy beam bonding a powdered material to a target component positioned within the chamber; and a gas manifold, the gas manifold comprising: a base, the base having a top surface and a bottom surface, the top surface and the bottom surface defining a thickness; a primary nozzle, the primary nozzle having an inlet and an outlet extending through the thickness of the base; and a secondary nozzle, the secondary nozzle having an inlet extending partially through the top surface of the base and at least one channel extending a distance from the side wall of the base and having an outlet, the channel being in fluid communication with the inlet of the secondary nozzle; wherein the top surface of the base is adjacent to the top wall of the chamber, the gas feed port being in fluid communication with the primary nozzle and the secondary nozzle.

[0053] 15. The system according to the preceding clause, wherein the inlet of the primary nozzle has a hollow protrusion extending from the top surface of the base.

[0054] 16. A system according to any preceding clause, wherein the projection tapers inwardly from the base, the projection having an end opposite the base, the end having a diameter smaller than a diameter of the inlet of the primary nozzle at the base.

[0055] 17. A system according to any preceding clause, wherein the projection extends a distance into the gas feed port.

[0056] 18. A system according to any of the preceding clauses, wherein the at least one channel of the secondary nozzle includes a first bend and a second bend, the first bend is perpendicular to the at least one channel, the second bend is perpendicular to the first bend, and the outlet of the secondary nozzle extends a distance from the second bend.

[0057] 19. A system according to any preceding clause, wherein the first bend and the second bend are positioned to pass between a first direct energy source and a second direct energy source.

[0058] 20. A method of forming a gas manifold for use in an additive manufacturing system, the method comprising: forming a base having a top surface and a bottom surface defining a thickness between the top surface and the bottom surface; forming a primary nozzle having an inlet and an outlet extending through the thickness of the base, the inlet of the primary nozzle being fluidly connected to an inlet of a chamber; and forming a secondary nozzle having an inlet extending partially through the top surface of the base and at least one channel extending a distance from a side wall of the base and having an outlet, the channel being fluidly connected to the inlet of the secondary nozzle, the inlet of the secondary nozzle being fluidly connected to the inlet of the chamber.

Claims

1. A gas manifold for use in an additive manufacturing system, the gas manifold comprising: a base having a top surface and a bottom surface defining a thickness therebetween; a primary nozzle having an inlet and an outlet extending through the thickness of the base, the inlet of the primary nozzle being in fluid communication with an inlet of the chamber; as well as, a secondary nozzle having an inlet extending partially through the top surface of the base and at least one channel extending a distance from the side wall of the base and having an outlet, the channel being in fluid communication with the inlet of the secondary nozzle, the inlet of the secondary nozzle being in fluid communication with the inlet of the chamber. 2 . The gas manifold according to claim 1 , wherein the outlet of the main nozzle has one of an elliptical shape, a slit shape, and a circular shape.

3. The gas manifold of claim 1 , wherein the inlet of the secondary nozzle has a substantially circular shape oriented substantially concentrically with the inlet of the primary nozzle, the inlet of the secondary nozzle having a substantially circular shape, wherein a diameter of the inlet of the primary nozzle is smaller than a diameter of the inlet of the secondary nozzle. 4 . The gas manifold of claim 1 , wherein the inlet of the primary nozzle has a protrusion extending from the top surface of the base. 5 . The gas manifold of claim 4 , wherein the protrusion tapers inwardly from the base such that an end of the protrusion is smaller than the diameter of the inlet of the primary nozzle at the base.

6. A gas manifold according to claim 5, wherein the top surface of the base contacts a top wall of a chamber, the chamber having a gas feed port extending through the top wall of the chamber and in fluid communication with the primary nozzle and the secondary nozzle, and the protrusion extends a distance into the gas feed port. 7 . The gas manifold of claim 6 , wherein the end of the protrusion has a diameter smaller than a diameter of the gas feed port. 8 . The gas manifold according to claim 7 , wherein a ratio of the diameter of the end of the protrusion to the diameter of the gas feed port is in a range of 1:10 to 9:

10.

9. The gas manifold of claim 1, wherein the at least one passage of the secondary nozzle includes at least one bend defined between the sidewall of the base and the outlet.

10. The gas manifold of claim 9, wherein the at least one bend is one of a U-shape and a semicircular shape.

11. The gas manifold of claim 9, wherein the at least one bend extends between a first direct energy source and a second direct energy source, the first energy source and the second energy source being located on a ceiling of the chamber.

12. The gas manifold of claim 1, wherein the at least one channel of the secondary nozzle comprises a first bend and a second bend, the first bend being perpendicular to the at least one channel, the second bend being perpendicular to the first bend, the outlet of the secondary nozzle extending a distance from the second bend.

13. The gas manifold of claim 1, wherein the outlet of the secondary nozzle comprises a plurality of flow channels, each of the flow channels having a first end and a second end, the first end having a smaller cross-sectional area than the second end.

14. An additive manufacturing system, the additive manufacturing system comprising: a chamber including a top wall and a gas feed port extending through the top wall and at least one direct energy source disposed on the top wall, the direct energy source directing an energy beam that bonds a powdered material to a target component positioned within the chamber; as well as, A gas manifold, the gas manifold comprising: a base having a top surface and a bottom surface, the top surface and the bottom surface defining a thickness; a main nozzle having an inlet and an outlet extending through the thickness of the base; and, a secondary nozzle having an inlet extending partially through the top surface of the base and at least one passage extending a distance from a sidewall of the base and having an outlet in fluid communication with the inlet of the secondary nozzle; Wherein the top surface of the base abuts a top wall of the chamber, the gas feed port is in fluid communication with the primary nozzle and the secondary nozzle.

15. The system of claim 14, wherein the inlet of the primary nozzle has a hollow protrusion extending from the top surface of the base.

16. The system of claim 15, wherein the projection tapers inwardly from the base, the projection having an end opposite the base, the end having a diameter that is smaller than a diameter of the inlet of the primary nozzle at the base.

17. The system of claim 15, wherein the projection extends a distance into the gas feed port.

18. The system of claim 14, wherein the at least one passage of the secondary nozzle comprises a first bend perpendicular to the at least one passage and a second bend perpendicular to the first bend, the outlet of the secondary nozzle extending a distance from the second bend.

19. The system of claim 19, wherein the first bend and the second bend are positioned to pass between a first direct energy source and a second direct energy source.

20. A method of forming a gas manifold for use in an additive manufacturing system, the method comprising: forming a base having a top surface and a bottom surface defining a thickness therebetween; forming a primary nozzle having an inlet and an outlet extending through the thickness of the base, the inlet of the primary nozzle being in fluid communication with an inlet of the chamber; and, A secondary nozzle is formed having an inlet extending partially through the top surface of the base and at least one channel extending a distance from the side wall of the base and having an outlet, the channel being in fluid communication with the inlet of the secondary nozzle, the inlet of the secondary nozzle being in fluid communication with the inlet of the chamber.

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