SYSTEMS AND METHOD FOR MANUFACTURING A POWDER REMOVAL TOOL BY ADDITIVE MATING

Abstract

A method for removing excess powder from a vehicle part during an additive manufacturing process, comprising defining parameters for a part, defining parameters for a removal tool comprising a plurality of links to create a chain-like structure, simultaneously producing the part and the removal tool by additive manufacturing, wherein the part forms an inner passage and the removal tool is produced within the inner passage, and upon completion of the production of the part and the removal tool, the removal tool is surrounded by excess powder in the inner passage, and wherein each link of the plurality of links is produced with a gap between adjacent links of the plurality of links, and removing the removal tool from the inner passage, wherein at least a portion of the excess powder is conveyed out of the inner passage.

Description

INTRODUCTION

[0001] The information in this section is intended to provide a general context for the disclosure. Work by the presently named inventors, to the extent described in this section, as well as aspects of the description that may not be prior art at the time of filing, are neither expressly nor impliedly admitted as prior art against the present disclosure.

[0002] The present disclosure generally relates to systems and methods for fabricating a powder removal tool using additive manufacturing. More specifically, the present disclosure relates to the additive manufacturing of powder-bed polymers. After printing, residual powder must be removed from additively manufactured parts. Because the powder compacts during the printing process, powder removal can be difficult if the parts have long, deep, or complex channels or tracks that are difficult to reach.

[0003] Accordingly, there is room for improvement in powder removal tools for parts produced by additive manufacturing. SUMMARY

[0004] One aspect of the disclosure is a method for removing excess powder from a part during an additive manufacturing process. The method includes specifying parameters for a part, specifying parameters for a removal tool comprising a plurality of links to create a chain-like structure, and simultaneously manufacturing the part and the removal tool by additive manufacturing. The part has an internal passage, and the removal tool is created within the internal passage, and upon completion of creation of the part and the removal tool, the removal tool is surrounded by excess powder in the internal passage. Each link of the plurality of links is created with a gap between adjacent links of the plurality of links.Removing the removal tool from the inner passage pushes or pushes at least a portion of the excess powder out of the inner passage. The method also includes performing at least one of the following operations to remove excess powder from the inner passage: providing a robotic powder removal attachment, vibratory powder removal, air blasting in the inner passage, or media blasting in the inner passage.

[0005] Implementations of the disclosure may include one or more of the following optional features. In some implementations, each member of the plurality of members is generally shaped like a spiral.

[0006] The part may be intended for a vehicle. The vehicle may be a passenger car.

[0007] The chain-like structure of the removal tool may be formed spirally throughout its entire internal passage. The spiral configuration of the removal tool may include a plurality of turns, wherein each turn of the plurality of turns is spaced from adjacent turns along a center of the spiral configuration.

[0008] The inner passage may be defined by inner sidewalls of the part. The removal tool may be spaced from the inner sidewalls.

[0009] Another aspect of the disclosure provides a method for removing excess powder from a part during an additive manufacturing process. The method includes defining parameters for a part, defining parameters for a removal tool comprising a plurality of links to create a chain-like structure, and simultaneously manufacturing the part and the removal tool by additive manufacturing. The part has an internal passage, and the removal tool is created within the internal passage. Removing the removal tool from the internal passage pushes or pushes at least a portion of the excess powder out of the internal passage.

[0010] Implementations of the disclosure may include one or more of the following optional features. In some implementations, each member of the plurality of members is generally shaped like a spiral.

[0011] The part may be intended for a car.

[0012] The method may further comprise performing at least one of the following steps to remove excess powder from the inner passage: providing a robotic powder removal extension, vibratory powder removal, air blasting in the inner passage, or media blasting in the inner passage.

[0013] The chain-like structure of the removal tool can be formed spirally throughout the entire inner passage.

[0014] The helical configuration of the removal tool may include a plurality of turns, wherein each turn of the plurality of turns is spaced from adjacent turns along a center of the helical configuration.

[0015] The inner passage may be defined by inner sidewalls of the part. The removal tool may be spaced from the inner sidewalls.

[0016] Another aspect of the disclosure provides a method for removing excess powder from a vehicle part during an additive manufacturing process. The method includes establishing parameters for a part, establishing parameters for a removal tool comprising a plurality of links to create a chain-like structure, and simultaneously manufacturing the part and the removal tool by additive manufacturing. The part has an internal passageway, and the removal tool is created within the internal passageway. Upon completion of manufacturing of the part and the removal tool, the removal tool is surrounded by excess powder in the internal passageway. Each link of the plurality of links is created with a gap between adjacent links of the plurality of links.By removing the removal tool from the inner passage, at least some of the excess powder is pushed or expelled from the inner passage.

[0017] Implementations of the disclosure may include one or more of the following optional features. In some implementations, each member of the plurality of members is generally shaped like a spiral.

[0018] The chain-like structure of the removal tool can be formed spirally throughout the entire inner passage.

[0019] The helical configuration of the removal tool may include a plurality of turns, wherein each turn of the plurality of turns is spaced from the adjacent turn along a center of the helical configuration.

[0020] The method may further comprise performing at least one of the following steps to remove excess powder from the inner passage: providing a robotic powder removal extension, vibratory powder removal, air blasting in the inner passage, or media blasting in the inner passage.

[0021] The details of one or more implementations of the disclosure are set forth in the accompanying drawings and the description below. Other aspects, features, and advantages will become apparent from the description and drawings, as well as from the claims. BRIEF DESCRIPTION OF THE DRAWINGS

[0022] The drawings described herein are for illustrative purposes only and are not intended to limit the scope of the present disclosure. Fig. 1 is a perspective view of an exemplary powder removal tool according to the teachings of the present disclosure; Fig. 2 is a perspective view of the exemplary powder removal tool of Fig. 1, which is arranged in an exemplary part; Fig. 3 is a perspective view of the exemplary powder removal tool of Fig. 1, which is arranged in an exemplary part; Fig. 4 is a perspective view of the exemplary powder removal tool of Fig. 1, which is arranged in an exemplary part; Fig. 5 is a perspective view of an exemplary powder removal tool according to the teachings of the present disclosure; Fig. 6 is a perspective view of an exemplary powder removal tool according to the teachings of the present disclosure; Fig. 7 is a perspective view of an exemplary powder removal tool according to the teachings of the present disclosure; Fig. 8 is a perspective view of an exemplary powder removal tool according to the teachings of the present disclosure; and Fig. 9 is a flow diagram of a method for manufacturing the exemplary powder removal tools and parts of the Fig. 1 - 8, according to the teaching of this revelation.

[0023] Corresponding reference numbers indicate corresponding parts in the drawings. DETAILED DESCRIPTION

[0024] Example configurations will now be described in more detail with reference to the accompanying drawings. Example configurations are provided so that this disclosure will be thorough and will convey the full scope of the disclosure to those skilled in the art. Specific details are set forth, such as examples of specific components, devices, and methods, in order to provide a thorough understanding of configurations of the present disclosure. Those skilled in the art will appreciate that specific details need not be used, that example configurations may be implemented in many different forms, and that the specific details and example configurations should not be construed to limit the scope of the disclosure.

[0025] In Fig. 1 generally depicts a powder removal tool 100. The powder removal tool 100 includes a plurality of links 102 connected together to form a chain. In some implementations, the chain is printed in a generally spiral shape. That is, the chain forms a central cavity, and the chain wraps around the central cavity, with each successive layer, stage, or row of the chain spaced from an adjacent layer, stage, or row along the central cavity by a gap 110. The gap 110 prevents the links 102 from fusing together during the additive manufacturing process.

[0026] Each link 102 includes a body portion 104 defining a central cavity 106. The links 102 are connected to each other by the body portion 104 of one link extending through the central cavity 106 of an adjacent link 102. In some implementations, as in the Fig. As shown in Figures 1-4, the links 106 may have a general helical shape. The links 102 are printed with a gap 108 between the body portion 104 of one link and the body portion 104 of an adjacent link 102. The gap 108 prevents the links 102 from fusing together during the additive manufacturing process.

[0027] As in the Fig. 2-4, the powder removal tool 100 is printed in place in a part 10, 10a-c by additive manufacturing, which significantly reduces the required depowdering effort after the part 10, 10a-c is manufactured. The part 10 may be a part for a vehicle, e.g., an automobile. As can be seen, the vehicle may be one of any number of different vehicle types, such as a sedan, station wagon, truck, or sport utility vehicle (SUV), and it may include two-wheel drive (2WD) (i.e., rear-wheel drive or front-wheel drive), four-wheel drive (4WD), or all-wheel drive (AWD), and / or various other vehicle types in certain configurations. The vehicle may also be a truck, a watercraft, an aircraft, and / or one or more other types of vehicles.In other implementations, Part 10 may be used for any suitable application, including but not limited to consumer products, medical products, etc.

[0028] The part 10 may include one or more internal passageways 12. The internal passageways 12 may be conduits, channels, chambers, or other suitable passageways defined by internal sidewalls 14. By printing the powder removal tool 100 in a spiral / helical shape to follow the internal sidewalls 14 of the internal passageway 12, powder can be removed from outside the part 10 by simply pulling on the powder removal tool 100. The powder removal tool 100 reduces the labor required to remove large amounts of powder by dislodging small amounts of powder with each link (as opposed to large amounts at once), thereby minimizing the required force and the relative strength requirements of the powder removal tool 100.The powder removal tool 100 also removes small amounts of powder near the inner side walls 14 of the inner passages 12, thus separating the central powder mass from the inner passages 12. The powder removal tool 100 can also reduce waste, be integrated into automation systems, and make subsequent processing steps more efficient, saving time and money. The powder removal tool 100 can be scaled and customized without size limitations and adapts to complex geometries with changing cross-sections and non-linear paths.

[0029] In Fig. 2 shows a first exemplary part 10a in which the powder removal tool 100 is arranged in the inner passage 12 formed by the inner side walls 14. In Fig. 3 shows a second exemplary part 10b in which the powder removal tool 100 is arranged in the inner passage 12 formed by the inner side walls 14. In Fig. 4, a third exemplary part 10c is shown having a plurality (ie, five) of powder removal tools 100 arranged in four internal passages 12 that converge into a single internal passage 12, all defined by internal side walls 14. As shown in Fig. 4, there may be any 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.

[0030] In Fig. 5, a second powder removal tool 200 is generally illustrated. The second powder removal tool 200 can be manufactured by additive manufacturing and operate according to the same principles as the powder removal tool 100. As shown in Fig. However, as shown in Figure 5, the second powder removal tool 200 may have a different shape and geometry than the powder removal tool 100.

[0031] In particular, the second powder removal tool 200 may include a plurality of spherical members 202 defining one or more radial openings 204 around the members 202 and a central cavity 206 extending through each member 202. The second powder removal tool 200 includes a linkage 208 having a first head 210 disposed at a first end and a second head 212 disposed at a second end remote from the first end of the linkage 208. The heads 210, 212 may be larger than the diameter of the central opening 206 such that the heads 210, 212 prevent the linkage 208 from detaching from the members 202.

[0032] The links 202 and the rods 208 can be printed such that a first link 202 is spaced from a second adjacent link 202 by a first distance 214. The heads 210, 212 can be spaced apart by a second distance 216. The links 202 can move freely along the rod 208, reducing the first distance 214 to zero when adjacent links 202 touch each other. However, the heads 210, 212 prevent the links 202 from being spaced further apart than the second distance 216.

[0033] In Fig. 6, a third powder removal tool 300 is generally illustrated. The third powder removal tool 300 can be manufactured by additive manufacturing and functions according to the same principles as the powder removal tool 100. As shown in Fig. 6, however, the third powder removal tool 300 may have a different shape and geometry than the powder removal tool 100.

[0034] Specifically, the third powder removal tool 300 includes a plurality of members 302 that form a central cavity 304, a first opening 306a, and a second opening 306b. The central cavity 304 extends through each member 302, and the openings 306a, 306b extend into the central cavity 304. A first member 302 extends through the openings 306a, 306b and into the central cavity 304 of a second adjacent member 302 to connect the first member 302 to the second member 302. The members 302 are printed with a gap 308 between adjacent members. The gap 308 prevents the members 302 from fusing together during the additive manufacturing process.

[0035] In Fig. 7, a fourth powder removal tool 400 is generally illustrated. The fourth powder removal tool 400 can be manufactured by additive manufacturing and operate according to the same principles as the powder removal tool 100. As shown in Fig. However, as shown in Figure 7, the fourth powder removal tool 400 may have a different shape and geometry than the powder removal tool 100.

[0036] In particular, the fourth powder removal tool 400 may include a plurality of members 402 defining one or more radial openings 404 and a central opening 406 leading to a central cavity 408. Each member 402 includes a linkage 410 and a distal ball 412 disposed at a distal end of the linkage 410 remote from the member 402. Each distal ball 412 is pressed into the central cavity 408 of an adjacent member 402, and the distal ball 412 is spaced from the adjacent member 402 by a gap 414. The gap 414 prevents the members 402 from fusing together during the additive manufacturing process.

[0037] In Fig. 8, a fifth powder removal tool 500 is generally illustrated. The fifth powder removal tool 500 can be manufactured by additive manufacturing and operate according to the same principles as the powder removal tool 100. As shown in Fig. However, as shown in Figure 8, the fifth powder removal tool 500 may have a different shape and geometry than the powder removal tool 100.

[0038] In particular, the fifth powder removal tool 500 includes a plurality of members 502 having a lower tab 504 defining a lower opening 506 and an upper tab 508 defining an upper opening 510. The upper tab 504 of one member 502 is printed to be located within the lower opening 506 of an adjacent member 502 and is spaced from the lower tab 504 by a gap 512. The gap 512 prevents the members 502 from fusing together during the additive manufacturing process.

[0039] In Fig.9 generally illustrates a method 900 for manufacturing the powder removal tools 100, 200, 300, 400, 500 and the parts 10, 10a-c. In step 902, an additive manufacturing or printing tool defines parameters for the powder removal tool 100, 200, 300, 400, 500 and the part 10, 10a-c. In step 904 and step 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 internal passageway 12 of the part 10, 10a-c.

[0040] In step 908, a user removes the powder removal tool 100, 200, 300, 400, 500 from the respective part 10, 10a-c by pulling on the powder removal tool 100, 200, 300, 400, 500 (e.g., the chain), thereby removing the powder removal tool 100, 200, 300, 400, 500 from the inner passage 12. As the powder removal tool 100, 200, 300, 400, 500 is pulled out of the inner passage 12, it loosens excess powder in the inner passage 12 so that the excess powder can be removed from the inner passage 12, e.g., by turning the part 10 over so that gravity pulls the excess powder out of the inner passage 12. When the powder removal tool 100, 200, 300, 400, 500 is completely removed from the inner passage 12, a completely open passage is created in the inner passage 12, that is, both ends of the inner passage 12 are open and can receive a liquid or other material.

[0041] In step 910, a user may perform additional post-processing operations on the part, such as deploying a robotic attachment that removes the powder from the inner passage 12, removing the powder through vibration, air blasting the inner passage 12, or blasting media into the inner passage 12 to remove any excess powder within the inner passage 12. Because the powder removal tool 100, 200, 300, 400, 500 has created a fully open passage within the inner passage 12, air or media blasting is possible within the inner passage 12. That is, without the fully open passage within the inner passage 12, it is difficult for the air or blasting media to remove excess powder because the air or blasting media has no outlet.

[0042] The terminology used herein is for the purpose of describing specific example configurations only and is not intended to be limiting. As used herein, the singular articles "a," "an," and "the" can also include the plural forms unless the context clearly indicates otherwise. The terms "comprises," "comprising," "containing," and "having" are inclusive and therefore specify the presence of features, steps, operations, elements, and / or components, but do not preclude the presence or addition of one or more other features, steps, operations, elements, components, and / or groups thereof. The method steps, processes, and operations described herein should not be construed as necessarily being performed in the order discussed or illustrated unless they are expressly identified as being in order of performance.Additional or alternative steps may be applied.

[0043] When an element or layer is described as being "on," "engaging," "connected," "attached to," or "coupled" with another element or layer, it may be directly on, engaging, connected, attached, or coupled with the other element or layer, or there may be intervening elements or layers. Conversely, when an element is described as being "directly on," "directly engaging," "directly connected to," "directly attached to," or "directly coupled with" another element or layer, there may be no intervening elements or layers. Other words used to describe the relationship between elements should be interpreted similarly (e.g., "between" versus "directly between," "adjacent" versus "directly next to," etc.).As used herein, the term “and / or” includes all combinations of one or more of the related listed items.

[0044] The terms "first," "second," "third," etc., may be used herein to describe various elements, components, regions, layers, and / or sections. These elements, components, regions, layers, and / or sections should not be limited by these terms. These terms may only be used to distinguish one element, component, region, layer, or section from another region, layer, or section, respectively. Terms such as "first," "second," and other numerical terms do not imply a sequence or order unless clearly indicated by the context. Thus, a first element, component, region, layer, or section discussed below could be referred to as a second element, component, region, layer, or section without departing from the teachings of the example configurations.

[0045] The devices and methods described in this application may be implemented partially or entirely by one or more computer programs executed by one or more processors. The computer programs include processor-executable instructions stored on at least one non-transitory, tangible, computer-readable medium. The computer programs may also include and / or access stored data.

[0046] A software application (i.e., a software resource) may refer to computer software that causes a computing device to perform a task. In some examples, a software application may be referred to as an "application," "app," or "program." 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.

[0047] Non-transitory memory can be physical devices 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 flash memory and read-only memory (ROM) / programmable read-only memory (PROM) / erasable programmable read-only memory (EPROM) / electronically erasable programmable read-only memory (EEPROM) (e.g., typically used for firmware such as boot programs). Examples of volatile memory include random-access memory (RAM), dynamic random-access memory (DRAM), static random-access memory (SRAM), phase-change memory (PCM), and floppy disks or tapes.

[0048] These computer programs (also referred to as programs, software, software applications, or code) contain machine instructions for a programmable processor and may be implemented in a procedural and / or object-oriented high-level language and / or assembly / machine language. 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., magnetic disks, optical disks, memory, programmable logic devices (PLDs)) designed to deliver 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 used to convey machine instructions and / or data to a programmable processor.

[0049] A number of implementations have been described. However, it should be understood that various changes may be made without departing from the spirit and scope of the disclosure. Accordingly, other embodiments are also within the scope of the following claims.

[0050] The foregoing description is for purposes of illustration and description. It is not intended to be exhaustive or limiting of the disclosure. Individual elements or features of a particular configuration are generally not limited to that particular configuration, but are optionally interchangeable and may be used in a selected configuration even if not specifically shown or described. The same may also be varied in many respects. Such variations are not to be considered as departing from the disclosure, and all such changes are intended to be included within the scope of the disclosure.

Claims

[1] A method for removing excess powder from a part during an additive manufacturing process, the method comprising: Defining parameters for a part; Defining parameters for a removal tool comprising a plurality of links to create a chain-like structure; simultaneously producing the part and the removal tool by additive manufacturing, wherein the part forms an internal passage and the removal tool is produced within the internal passage, and upon completion of the production of the part and the removal tool, the removal tool is surrounded by excess powder in the internal passage, and wherein each member of the plurality of members is produced with a gap between adjacent members of the plurality of members; Removing the removal tool from the inner passage, thereby removing at least a portion of the excess powder from the inner passage; and Perform at least one of the following operations to remove excess powder from the inner passage: Providing a robotic approach to powder removal; Powder removal by vibration; Air jets in the inner passage; or Radiation from media into the inner passage. [2] The method of claim 1, wherein each member of the plurality of members is generally in the shape of a spiral. [3] The method of claim 1, wherein the part is for a vehicle. [4] The method of claim 3, wherein the vehicle is an automobile. [5] The method of claim 1, wherein the chain-like structure of the removal tool is created in a spiral configuration through the inner passage. [6] The method of claim 5, wherein the helical configuration of the removal tool comprises a plurality of revolutions, each revolution of the plurality of revolutions being spaced from adjacent revolutions along a center of the helical configuration. [7] The method of claim 1, wherein the inner passage is defined by inner sidewalls of the part and the removal tool is spaced from the inner sidewalls. [8] A method for removing excess powder from a part during an additive manufacturing process, the method comprising: Defining parameters for a part; Defining parameters for a removal tool comprising a plurality of links to create a chain-like structure; simultaneously producing the part and the removal tool by additive manufacturing, wherein the part forms an internal passage and the removal tool is produced within the internal passage; and Removing the removal tool from the inner passage, thereby expelling at least a portion of the excess powder from the inner passage. [9] The method of claim 1, wherein each member of the plurality of members is generally in the shape of a spiral. [10] A method according to claim 8, wherein the part is intended for a motor vehicle.

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