Build structures and related methods

Abstract

Systems and methods for additive manufacturing are generally provided. The systems and methods provided herein may allow one or more build surfaces to be aligned with a formation plane and locked into a desired pose. Such systems and methods may have advantages for parallelized additive manufacturing and / or for additive manufacturing of features on parts manufactured without additive manufacturing.

Description

BUILD STRUCTURES AND RELATED METHODSRELATED APPLICATIONS

[0001] This application claims priority under 35 U.S.C. § 119(e) to U.S. Provisional Application No. 63 / 509,860, filed June 23, 2023, the content of which is incorporated by reference in its entirety for all purposes.FIELD

[0002] Disclosed embodiments are related to build structures and related methods for use in additive manufacturing.BACKGROUND

[0003] Powder bed fusion processes are an example of additive manufacturing processes in which a three-dimensional shape is formed by selectively joining material in a layer-by-layer process. In metal powder bed fusion processes, one or more laser beams are scanned over a thin layer of metal powder. If the various laser parameters, such as laser power, laser spot size, and / or laser scanning speed are in a regime in which the delivered energy is sufficient to melt the particles of metal powder, one or more melt pools may be established on a build surface. The laser beams are scanned along predefined trajectories such that solidified melt pool tracks create shapes corresponding to a two-dimensional slice of a three-dimensional printed part. After completion of a layer, the powder surface is indexed by a defined distance, the next layer of powder is spread onto the build surface, and the laser scanning process is repeated. In many applications, the layer thickness and laser power density may be set to provide partial re-melting of an underlying layer and fusion of consecutive layers. The layer indexing and scanning is repeated multiple times until a desired three-dimensional shape is fabricated.SUMMARY

[0004] In one aspect, a build plate assembly for an additive manufacturing system is provided. According to some embodiments, the build plate assembly comprises: a build plate; and one or more connectors configured to secure one or more intermediate parts to the build plate, wherein the one or more connectors are configured to receive the one or more intermediate parts in a plurality of possible poses relative to the build plate and lock a pose ofan associated intermediate part relative to the build plate in a desired pose relative to the build plate.

[0005] In another aspect, a method of additive manufacturing is provided. In some embodiments, the method comprises: orienting one or more intermediate parts relative to a build plate to align a corresponding one or more build surfaces of the one or more intermediate parts to be in a reference plane; and locking poses of the plurality of intermediate parts relative to the build plate to maintain the one or more build surfaces in alignment with the reference plane.

[0006] It should be appreciated that the foregoing concepts, and additional concepts discussed below, may be arranged in any suitable combination, as the present disclosure is not limited in this respect. Further, other advantages and novel features of the present disclosure will become apparent from the following detailed description of various nonlimiting embodiments when considered in conjunction with the accompanying figures.BRIEF DESCRIPTION OF DRAWINGS

[0007] The accompanying drawings are not intended to be drawn to scale. In the drawings, each identical or nearly identical component that is illustrated in various figures may be represented by a like numeral. For purposes of clarity, not every component may be labeled in every drawing. In the drawings:

[0008] FIG. 1 shows a schematic representation of an additive manufacturing system, according to some embodiments;

[0009] FIG. 2 shows an additive manufacturing system, according to some embodiments;

[0010] FIG. 3 shows a build plate assembly comprising a build plate and a connector, according to some embodiments;

[0011] FIG. 4 shows an intermediate part, according to some embodiments;

[0012] FIG. 5 shows a build plate assembly comprising a build plate, a connector, and an intermediate part, according to some embodiments;

[0013] FIG. 6 shows a build plate assembly comprising a build plate and a connector, according to some embodiments;

[0014] FIG. 7 shows a build plate assembly comprising a build plate and a connector, according to some embodiments;

[0015] FIG. 8A shows a build plate assembly comprising a build plate and a plurality of connectors, according to some embodiments;

[0016] FIG. 8B shows a build plate assembly comprising a build plate and a connector, according to some embodiments;

[0017] FIG. 9A shows a build plate assembly comprising a build plate and a connector, according to some embodiments;

[0018] FIG. 9B shows a build plate assembly comprising a build plate, a connector, and an intermediate part, according to some embodiments;

[0019] FIG. 10 shows a build plate assembly comprising a build plate, a connector, and an intermediate part, according to some embodiments;

[0020] FIG. 11 A shows a build plate assembly comprising a build plate, a plurality of connectors, and a plurality of intermediate parts, according to some embodiments;

[0021] FIG. 1 IB shows a build plate assembly comprising a build plate, a plurality of connectors, and a plurality of intermediate parts, according to some embodiments;

[0022] FIG. 12A shows a build plate assembly comprising a build plate, a plurality of connectors, and a plurality of intermediate parts aligned on a flat reference surface, according to some embodiments;

[0023] FIG. 12B shows a build plate assembly comprising a build plate, a plurality of connectors, and a plurality of intermediate parts aligned on a flat reference surface, according to some embodiments;

[0024] FIG. 12C shows a build plate assembly comprising a build plate, a plurality of connectors, and a plurality of intermediate parts aligned in a common plane according, to some embodiments;

[0025] FIG. 12D shows an additive manufacturing system comprising a build plate assembly comprising a build plate, a plurality of connectors, and a plurality of intermediate parts, according to some embodiments;

[0026] FIG. 12E shows an additive manufacturing system comprising powder and additively manufactured features on a build plate assembly comprising a build plate, a plurality of connectors, and a plurality of intermediate parts, according to some embodiments; and

[0027] FIG. 13 shows a method of additive manufacturing, according to some embodiments.DETAILED DESCRIPTION

[0028] As described above, some additive manufacturing processes, such as powder bed fusion processes, may use laser beams to melt metal powder. Forming all portions of a part using additive manufacturing can be expensive and time-consuming. Using additive manufacturing to form parts may be relatively expensive compared to other forms of manufacturing, and as such conventional manufacturing systems may be used to reduce cost. Even in cases where conventional manufacturing systems are used to supplement additive manufacturing systems to reduce cost, the cost related to the additive manufacturing may still be high. Additionally, additive manufacturing is slowed when parts must be manufactured one after another (e.g., serially), rather than in parallel (e.g., simultaneously). The present disclosure is directed, in some aspects, towards systems and methods that can accelerate additive manufacturing of parts (e.g., in the context of powder bed fusion processes and / or other appropriate types of additive manufacturing where parts are made on a build plate) by facilitating parallelized additive manufacturing and / or by facilitating additive manufacturing onto intermediate parts manufactured with a conventional machining technique. For example, in some embodiments, the disclosure is directed towards the alignment of a plurality of build surfaces with a common plane, in order to permit parallel processing on the build surfaces. The systems and methods herein are, in some embodiments, related to additive manufacturing onto intermediate parts secured to build plates.

[0029] Reliability of powder bed manufacturing can be improved by precisely maintaining the position and orientation of a build surface. For example, a build surface precisely aligned with a formation plane of an additive manufacturing process can improve the quality and precision of additive manufacturing (e.g., during a powder bed fusion process). Improved systems and methods for securing intermediate parts to build plates while precisely maintaining their position and orientation could improve the reliability and speed of manufacturing onto intermediate parts. However, providing accurate, repeatable, and cost effective positioning of build surfaces on an intermediate part, and certainly for an array of parts may be difficult. The Inventors have recognized these limitations interfere with the ability to form features on intermediate parts made using other manufacturing processes in both an accurate and repeatable fashion. Any of a variety of types of intermediate parts may be used in a build plate assembly as described herein. An intermediate part may comprise a build surface. For example, the intermediate part may comprise a flat referencesurface suitable for use as a build surface upon which additive manufacturing may be performed.

[0030] In view of the above, the inventors have recognized and appreciated that it may be advantageous to modify a build plate to include a connector that permits movement of an intermediate part into a desired pose, wherein the connector can then be used to lock the intermediate part into the desired pose. Accordingly, in some aspects, the disclosure is directed towards forming features on intermediate parts produced by another manufacturing process and subsequently secured to a build plate in a desired orientation and then using additive manufacturing to form the desired features. In some aspects, the disclosure is directed towards aligning one or more portions of one or more (e.g., a plurality of) intermediate parts with a reference plane to ensure an appropriate orientation of a build surface on the portions of the parts that the desired features are to be formed. Systems and methods provided herein may provide a number of advantages in the context of additive manufacturing, including the parallelized manufacturing of multiple parts on discrete intermediate parts, additive manufacturing onto intermediate parts produced by alternate manufacturing methods which may help reduce the time and cost associated with manufacturing a part, and / or printing onto disposable intermediate parts which may help avoid or reduce the amount of machining or post-processing work used to prepare a build plate for the next printing cycle.

[0031] In some embodiments, one or more intermediate parts are connected to a build plate assembly in a desired pose. For example, the build plate may be configured to permit reorientation of the one or more intermediate parts relative to the build plate and to secure the one or more intermediate parts in the desired corresponding poses to oriented the individual build surfaces of the one or more intermediate parts in a desired pose for forming corresponding features on the intermediate parts.

[0032] A build plate may be configured to allow one or more intermediate parts to be secured thereto in any appropriate fashion. For example, the build plate may be configured to admit a connector capable of mechanically coupling (e.g., rigidly coupling) an intermediate part to the build plate. An intermediate part of a build plate assembly, when present, may have any of a variety of suitable dispositions with respect to the build plate. For example, the build plate may be configured such that the intermediate part may be connected to any appropriate portion of the build plate including above or below an upper surface of the build plate. According to some embodiments, the build plate comprises a recess formed in thebuild plate. The recess may be configured to receive the intermediate part (e.g., such that at least a portion of the intermediate part is disposed within the recess when disposed therein). Regardless of the type of arrangement or connectors used, in some embodiments, a build plate may include a plurality connectors and associated features configured to receive a corresponding plurality of intermediate parts in a desired pose and to maintain that plurality of intermediate parts in the desired pose.

[0033] A build plate is, according to some embodiments, configured to be coupled to a vertical motion stage, as described in greater detail below. The vertical motion stage may be configured to move the build plate assembly (e.g., in a vertical direction relative to a direction of gravity). In some embodiments, the vertical motion stage is configured to align the build plate assembly within an additive manufacturing system (e.g., it is a multiple degree of freedom vertical motion stage that is configured to control both a vertical position and orientation of the build plate using multiple vertical actuators, a vertical actuator and one or more rotational actuators, and / or any other appropriate arrangement). In such an embodiment, a coupling between the build plate assembly and the vertical motion stage may include one or more kinematic couplings. However, other sorts of mechanical couplings (e.g., fasteners, adhesives, welds, solder connections) may also be used to couple the build plate assembly to the vertical motion stage as the disclosure is not so limited.

[0034] Any of a variety of suitable connectors may be used in a build plate assembly. According to some embodiments the connector is a discrete part. The connector may be mechanically coupled to the build plate. The connector may mechanically couple to the build plate without a coupling to an intermediate part. For example, the connector may be adhered to, welded to, or fastened to (e.g., screwed into, riveted to, bolted to, pinned to, or clamped to) the build plate. In some embodiments, the connector is designed to secure the intermediate part to the build plate by mechanically coupling with both. For example, the build plate may comprise a through hole or a blind hole that extends partially through a build plate. The connector and / or an associated intermediate part may extend into or through the hole such that the intermediate part may be positioned in a desired pose on the build plate. In some embodiments, by connecting an intermediate part to the connector, both the connector and the intermediate part are secured to the build plate. For example, the intermediate part may have a wider cross-section than a connector passing through a hole in a build plate, such that the intermediate part blocks the removal of the connector from the hole. Otherembodiments, where the connector is mechanically coupled with or integrally formed with an intermediate part are also possible, as the disclosure is not so limited.

[0035] Any of a variety of suitable types of connectors may be used in a build plate assembly. For example, A build plate assembly may comprise a connector that is a collet (e.g., an expansion collet), a clamp, a clip, a post (e.g., a post configured to be secured to an intermediate part by compression), pins extending through corresponding matched holes in the intermediate part and build plate, and / or any other appropriate type of connector capable of permitting an intermediate part to be moved between different poses and locked in a desired pose relative to a build plate. Examples of suitable connectors are described in greater detail below, with reference to the figures.

[0036] According to some embodiments, an intermediate part is capable of being secured to a build plate via a connector. For example, the intermediate part may include one or more features complementary to a feature of a connector, as discussed above. In some embodiments, for example, the intermediate part may include: a hole configured to receive an expandable connector; a threaded bore; a hole configured to receive a pin; a surface sized and shaped to complement the geometry of a clip or clamp; and / or any other appropriate feature capable of being engaged by a connector. Of course, the intermediate part might comprise no such features, and embodiments where the intermediate part is not complementary to the connector are also contemplated. For example, in some embodiments, an intermediate part is mechanically coupled to and or is integrally formed with a connector. In some such embodiments, the connector is configured to receive the intermediate part in a plurality of possible poses relative to the build plate by allowing the connector to connect to the build plate in any of a plurality of possible poses. In other words, the current application includes embodiments in which the connector is part of the build plate, is part of the intermediate part, and / or is separate from the intermediate part and build plate.

[0037] A connector may be at least partially disposed in the build plate, according to some embodiments. For example, the connector extends through or bolts into the build plate in some embodiments. According to other embodiments, the connector is not disposed in the build plate. For example, the connector could engaged with a surface feature of the build plate such as a clip, support surface, or other structure. Examples of each type are described in greater detail with reference to the figures below.

[0038] One advantage of the connectors described herein is that they may, in some embodiments, be selectively engageable. A selectively engageable connector is, in someembodiments, able to receive an intermediate part in any of a plurality of poses relative to the build plate and to permit the intermediate part to be moved between these different poses while the connector is in an unlocked configuration. As used herein, a pose refers to a particular position of a component (e.g., an intermediate part) in three dimensional space in combination with a particular orientation of the component (which may include an angular orientation) relative to the build plate. Accordingly, moving a component such as an intermediate part between two poses (e.g., a first pose and a second pose) may comprise translating the component, rotating the component, or both translating and rotating the component. In some embodiments, until a connector is engaged with the build plate and part in a locked configuration, the connector may freely permit the intermediate part to move between different poses of the plurality of poses. For example, in some embodiments, a pose of an intermediate part received by a connector can be changed until a desired pose is reached. A connector can then, according to some embodiments, be moved to an engaged configuration where motion of the intermediate part is prevented to maintain an associated intermediate part in a particular pose (e.g., a desired pose) relative to the build plate. An engaged connecter may then maintain the pose of the intermediate part until the connector is disengaged.

[0039] According to some embodiments, a connector described herein is designed to be complementary to (e.g., to interlock with) an intermediate part and / or a build plate. Two plate assembly components (e.g., a connector, a build plate, or an intermediate part) are complementary if the first plate assembly component comprises one or more features (e.g., geometric features) constructed and arranged such that the one or more features can rigidly couple the first plate assembly component to the second plate assembly component via an interaction with one or more features of the second plate assembly component (e.g., such that the interaction between the one or more features of the first plate assembly component locks the pose of the first plate assembly component with respect to the second plate assembly component. For example, a connector may be configured to expand to form an interference or compression lock with an intermediate part. In one such embodiment, a threaded shaft may be used to bias an expandable structure in an outward radial direction to compress against a corresponding bore formed in an intermediate part. As another example, a connector may comprise a clip configured to compliment a curve or other surface feature of an intermediate part. Other embodiments are also possible, as the disclosure is not so limited. In some embodiments, it may be advantageous for a connector to comprise a featurecomplementary to a feature of a build plate, such that the connector is locked into a fixed position with respect to the build plate. Rigid coupling of the build plate to the connector may, for example, mean that changes in the pose of an intermediate part with respect to a build plate can be mediated without displacement of the connector, which can simplify selection of a desired pose.

[0040] It may be advantageous, according to some embodiments, to secure an intermediate part using more than one connector. Securing an intermediate part using a plurality of connectors may give the intermediate part more stability than could be achieved using a single connector. For example, in some embodiments, the use of a plurality of connectors provides greater stability against rotation of an intermediate part. One advantage of the systems and methods described herein is that a plurality of connectors can be used without requiring high connector precision. For example, a build plate assembly comprising a first connector capable of engaging the intermediate part in a first plurality of poses may also include a second connector capable of engaging the intermediate part in a second plurality of poses where at least some of the first and second plurality of poses are the same such that the intermediate part may be engaged with both the first and second connectors within a desired range of poses. Thus, in some embodiments, the advantages of securing an intermediate part using more than one connector can be more easily achieved using connectors capable of receiving the intermediate part in more than one pose.

[0041] As discussed above, in some embodiments, a build plate assembly may comprise a plurality of connectors configured to connect to a plurality of intermediate parts. For example, the build plate assembly may comprise one or more connectors per intermediate part. As discussed herein, one advantage of connectors configured to receive an intermediate part in a plurality of poses is that the connectors may be configured to align the intermediate parts in an overall desired arrangement on the build plate. For example, the plurality of intermediate parts may be arranged in an array of intermediate parts on the build plate with a desired layout and overall pose of the intermediate parts on the build plate. Thus, a plurality of connectors of a build plate assembly may be configured such that they are capable of locking a plurality of intermediate into a plurality of aligned poses with respect to the build plate. For example, a plurality of connectors may be configured to lock one or more (e.g., a plurality of) intermediate parts into a plurality of desired poses such that each intermediate part of the one or more intermediate parts is approximately aligned in a reference plane after an alignment operation is performed as described herein. In some embodiments, for example,a plurality of connectors is configured to lock a plurality of intermediate parts into a plurality of desired poses such that the one or more intermediate parts are mutually approximately aligned in a common reference plane.

[0042] A build plate assembly may include any of a variety of suitable numbers of connectors. For example, in some embodiments, a build plate assembly comprises greater than or equal to 1, greater than or equal to 2, greater than or equal to 3, greater than or equal to 5, greater than or equal to 10, greater than or equal to 20, greater than or equal to 30, greater than or equal to 50, or more connectors. In some embodiments, a build plate assembly comprises less than or equal to 100, less than or equal to 50, less than or equal to 40, less than or equal to 30, less than or equal to 20, less than or equal to 10, less than or equal to 5, less than or equal to 3, or less than or equal to 2 connectors or less. Combinations of these ranges are possible. For example, in some embodiments, a build plate assembly comprises greater than or equal to 1 connector and less than or equal to 100 connectors. Other ranges, higher than those described above, are also possible, as the disclosure is not so limited.

[0043] Any of a variety of appropriate numbers of connectors maybe used to secure an intermediate part. For example, in some embodiments, 1, 2, 3, 4, 5, 6, or more connectors are used to secure an intermediate part.

[0044] A connector described herein may have a desired compliance to accommodate distortion of the intermediate parts and / or build plate during a printing process (e.g., resulting from thermal variation). For example, the connector may have a desired compliance with respect to displacement in the x / y directions of a formation plane (i.e., parallel to the upper surface of the build plate oriented towards an optics assembly of the system). In some embodiments, a connector has a compliance in the x / y directions of a formation plane of greater than or equal to 50 N / micron, greater than or equal to 100 N / micron, greater than or equal to 150 N / micron, greater than or equal to 200 N / micron, or greater than or equal to 250 N / micron, or greater. In some embodiments, a connector has a compliance in the x / y directions of a formation plane of less than or equal to 300 N / micron, less than or equal to 250 N / micron, less than or equal to 200 N / micron, less than or equal to 150 N / micron, less than or equal to 100 N / micron, or less. Combinations of these ranges are possible. For example, in some embodiments, a connector has a compliance in the x / y directions of a formation plane of greater than or equal to 50 N / micron and less than or equal to 50 N / micron. Other ranges, both higher and lower than those described above, are also possible,as the disclosure is not so limited. In some embodiments, connectors associated with larger parts which may undergo larger thermal distortions during printing may have lower compliances as compared to smaller parts.

[0045] A plurality of intermediate parts may be aligned using connectors of the build plate assembly, according to some embodiments. For example, a plurality of intermediate parts may each be locked into a desired pose using connectors of the build plate assembly, wherein the desired pose of each intermediate part approximately aligns each build surface of the intermediate part with a common reference plane. Such a configuration may be advantageous in the context of additive manufacturing because a build plate assembly comprising intermediate parts with approximately co-planar build surfaces can permit additive manufacturing onto the approximately co-planar build surfaces by aligning the approximately co-planar build surfaces with the plane of formation of the additive manufacturing system.

[0046] An intermediate part, or plurality of intermediate parts, may include one or more build surfaces formed thereon that may be approximately aligned with a reference plane such that a plane-normal direction of the reference plane differs by less than or equal to less than or equal to 5°, less than or equal to 2°, less than or equal to 1°, or less than or equal to 0.5° from a normal direction of the one or more build surfaces of the intermediate part. Preferably, the alignment between the normal directions may be less than or equal to 1°. Ranges higher than those described above are also possible, as the disclosure is not so limited.

[0047] An intermediate part, or a plurality of intermediate parts, can be approximately aligned with a reference plane such that an average maximum distance between the build surface of an intermediate part and the common plane is less than or equal to 1000 microns, less than or equal to 800 microns, less than or equal to 500 microns, less than or equal to 200 microns, less than or equal to 100 microns, less than or equal to 50 microns, less than or equal to 30 microns, less than or equal to 15 microns, or less. Ranges higher than those described above are also possible, as the disclosure is not so limited. It should be understood that the specific desired distance range will be dependent on the focal range and / or type of additive manufacturing system being used.

[0048] The intermediate parts may be aligned with one or more planes (e.g., a common plane for all intermediate parts, or multiple planes for different intermediate parts) by any of a variety of suitable methods. For example, in some embodiments, a plurality ofintermediate parts are aligned with a common plane by placing the build surfaces of the intermediate parts on a flat reference surface. The intermediate parts may be placed on the flat reference surface such that a build plate, placed on a side of the plurality of intermediate parts opposite the build surfaces of the plurality of intermediate parts, can be connected to the intermediate parts via connectors. Thus, in some embodiments, the flat reference surface may be used to maintain the desired poses of the intermediate parts while the build plate is aligned with the intermediate parts. Connectors may be used to secure the intermediate parts to the build plate. Once the intermediate parts are locked into their desired poses relative to the build plate, the build plate assembly comprising the secured intermediate parts can be repositioned while maintaining the alignment of the intermediate parts with a common reference plane. The build plate assembly can then be positioned such that the common plane corresponds to a formation plane of an additive manufacturing system (e.g., a powder fusion manufacturing system).

[0049] Material may be additively manufactured onto some or all of the intermediate parts of the build plate assembly. For example, in some embodiments, an additive manufacturing method comprises manufacturing one or more features on one or more build surfaces of the build plate assembly. In some embodiments, one or more features are manufactured on a plurality of build surfaces of the build plate assembly. Features may be manufactured on the build surfaces in any of a variety of suitable orders. For example, in some embodiments, a first feature is manufactured on a first build surface of the build plate assembly, a second feature is manufactured on a second build surface of the build plate assembly, and a third feature is manufactured on the first build surface of the build plate assembly. The first, second, and third features may be formed consecutively as part of a sequential additive manufacturing process or as part of a parallelized additive manufacturing process that manufactures material onto the build surfaces via iterative steps. Other manufacturing processes are also possible, as the disclosure is not so limited.

[0050] An additive manufacturing system may comprise one or more laser energy sources. For example, the additive manufacturing system may comprise a plurality of laser energy sources. A laser energy source may be configured to produce an incident laser spot or a plurality of incident laser spots on a build surface. In some embodiments, a plurality of incident laser spots on a build surface may be arranged in a line with a long dimension and a short dimension, or in an array. In either case, according to some aspects, a line, or array, of incident laser energy consists of multiple individual laser energy pixels arranged adjacent toeach other that can have their respective power levels individually controlled. Each laser energy pixel may be turned on or turned off independently and the power of each pixel can be independently controlled. The resulting pixel-based line or array may then be scanned across a build surface to form a desired pattern thereon by controlling the individual pixels during translation of the optics assembly.

[0051] Depending on the particular embodiment, an additive manufacturing system according to the current disclosure may include any suitable number of laser energy sources. For example, in some embodiments, the number of laser energy sources may be at least 5, at least 10, at least 50, at least 100, at least 500, at least 1,000, at least 1,500, or more. In some embodiments, the number of laser energy sources may be less than 2,000, less than 1,500, less than 1,000, less than 500, less than 100, less than 50, or less than 10. Additionally, combinations of the above-noted ranges may be suitable. Ranges both greater and less than those noted above are also contemplated as the disclosure is not so limited.

[0052] Depending on the application, output of the optics assembly may be scanned across a build surface of an additive manufacturing system in any appropriate fashion. For example, in one embodiment, one or more galvo scanners may be associated with one or more laser energy sources to scan the resulting one or more laser pixels across the build surface. Alternatively, in other embodiments, an optics assembly may include an optics head that is associated with one or more appropriate actuators configured to translate the optics head in a direction parallel to a plane of the one or more build surfaces present on the one or more intermediate parts disposed on a build plate to scan the one or more laser pixels across the one or more build surface. In either case, it should be understood that the disclosed systems and methods are not limited to any particular construction for scanning the laser energy across a build surface of the additive manufacturing system.

[0053] While the present disclosure is primarily described in the context of additive manufacturing, and in particular, towards laser powder bed fusion (EPBF), it should of course be understood that the techniques described herein could be used for any of a variety of machining or additive manufacturing processes as the disclosure is not so limited. For example, in some embodiments, the systems and methods described herein are appropriate for use with fused filament additive manufacturing, selective deposition lamination, stereolithography, or any of a variety of other additive manufacturing techniques wherein it might be desirable to manufacture features on one or more intermediate parts locked relative to a build plate assembly. Moreover, it should be understood that the systems and methodsdescribed herein may be used for conventional machining techniques such as surface finishing (e.g., grinding, polishing, coating) where it may be desirable to align one or more surfaces with a reference plane, and that such machining techniques may be used along with additive manufacturing techniques (e.g., by first preparing a surface of the intermediate part and by subsequently additively manufacturing features on the surface of the intermediate part), as the disclosure is not so limited.

[0054] It will be appreciated that any embodiments of the systems, components, methods, and / or programs disclosed herein, or any portion(s) thereof, may be used to form any part suitable for production using additive manufacturing. For example, a method for additively manufacturing one or more parts may, in addition to any other method steps disclosed herein, include the steps of selectively fusing one or more portions of a plurality of layers of precursor material deposited onto the build surface to form the one or more parts. This may be performed in a sequential manner where each layer of precursor material is deposited on the build surface and selected portions of the upper most layer of precursor material is fused to form the individual layers of the one or more parts. This process may be continued until the one or more parts are fully formed.

[0055] Turning to the figures, specific non-limiting embodiments are described in further detail. It should be understood that the various systems, components, features, and methods described relative to these embodiments may be used either individually and / or in any desired combination as the disclosure is not limited to only the specific embodiments described herein.

[0056] FIG. 1 shows, according to some embodiments, a schematic representation of an additive manufacturing system 100, including a plurality of laser energy sources 102 that deliver laser energy to an optics assembly 104 positioned within a machine enclosure 106. For example, the machine enclosure may define a build volume in which an additive manufacturing process may be carried out. In particular, the optics assembly may direct laser energy 108 towards a build surface 110 of an intermediate part of a build plate assembly positioned within the machine enclosure to selectively fuse powdered material on the build surface. As described in more detail below, the optics assembly 104 may include a plurality of optics defining an optical path within the optics assembly that may transform, shape, and / or direct laser energy within the optics assembly such that the laser energy is directed onto the build surface as an array of laser energy pixels. In some embodiments, the optics assembly may be movable within machine enclosure 106 to scan laser energy 108 acrossbuild surface 110 during a manufacturing process. For example, the optics assembly may be associated with appropriate actuators, rails, motors, and / or any other appropriate structure capable of optics assembly relative to the surface. Alternatively, embodiments in which the optics assembly includes galvomirrors or other appropriate components that are configured to scan the laser energy 108 across the build surface while the optics assembly is held stationary relative to the build surface are also contemplated.

[0057] In some embodiments, the additive manufacturing system 100 further includes one or more optical fiber connectors 112 positioned between the laser energy sources 102 and the optics assembly 104. As illustrated, a first plurality of optical fibers 114 may extend between the plurality of laser energy sources 102 and the optical fiber connector 112. In particular, each laser energy source 102 may be coupled to the optical fiber connector 112 via a respective optical fiber 116 of the first plurality of optical fibers 114. Similarly, a second plurality of optical fibers 118 extends between the optical fiber connector 112 and the optics assembly 104. Each optical fiber 116 of the first plurality of optical fibers 114 is coupled to a corresponding optical fiber 120 of the second plurality of optical fibers 118 within the optical fiber connector. In this manner, laser energy from each of the laser energy sources 102 is delivered to the optics assembly 104 such that laser energy 108 can be directed onto the build surface 110 during an additive manufacturing process (i.e., a build process). Of course other methods of connecting the laser energy sources 100 due to the optics assembly 104 are also contemplated.

[0058] FIG. 2 depicts one embodiment of an additive manufacturing system at the beginning of a build process. The additive manufacturing system includes a build plate assembly 202 mounted on a fixed plate 204, which is in turn mounted on one or more vertical supports 206 that attach to a base 208 of the additive manufacturing system. In the depicted embodiment, the one or more vertical supports may correspond to one, two, and / or any other appropriate number of supports configured to support the build plate assembly, and the corresponding build surface(s) of the intermediate part(s), at a desired position and orientation. For example, the supports depicted in the figure may correspond to one or more vertical motion stages configured to control a vertical position and orientation of the build plate assembly. A powder containment shroud 210 may at least partially, and in some embodiments completely, surround a perimeter of the build plate assembly 202 to support a volume of precursor material 202a, such as a volume of powder, disposed on the build plateassembly and contained within the shroud. The shroud may be supported on the base 208 or by any other appropriate portion of the system.

[0059] The additive manufacturing system may include a powder deposition system in the form of a recoater 212 that is mounted on a horizontal motion stage 214 that allows the recoater to be moved back and forth across either a portion, an entire, or a plurality of, build surface(s) of the intermediate part(s) of the build plate assembly 202. As the recoater traverses the build surface(s) of the build plate assembly, it deposits a precursor material 202a, such as a powder, onto the build plate assembly and smooths the surface to provide a layer of precursor material with a predetermined thickness on top of the underlying volume of fused and / or unfused precursor material deposited during prior formation steps.

[0060] In some embodiments, the supports 206 of the build plate assembly 202 may be used to index the build surface(s) of the build plate assembly 202 in a vertical downwards direction relative to a local direction of gravity. In such an embodiment, the recoater 212 may be held vertically stationary for dispensing precursor material 202a, such as a precursor powder, onto the exposed build surface(s) of the build plate assembly as the recoater is moved across the build plate assembly each time the build plate assembly is indexed downwards.

[0061] In some embodiments, the additive manufacturing system may also include an optics assembly 218 that is supported vertically above and oriented towards the build plate assembly 202. As detailed above, the optics assembly may be optically coupled to one or more laser energy sources, not depicted, to direct laser energy in the form or one or more laser energy pixels onto the build surface(s) of the build plate assembly 202. To facilitate movement of the laser energy pixels across the build surface(s), the optics assembly may be configured to move in one, two, or any number of directions in a plane parallel to the build surface(s) of the build plate assembly. To provide this functionality, the optics assembly may be mounted on a gantry 220, or other actuated structure, that allows the optics unit to be scanned in plane parallel to the build surface(s) of the build plate assembly.

[0062] In the above embodiment, the build plate assembly is indexed vertically while the remaining active portions of the system are held vertically stationary. However, embodiments, in which the build plate assembly is held vertically stationary and the shroud 210, recoater 212, and optics assembly 218 are indexed vertically upwards relative to a local direction of gravity during formation of successive layers are also contemplated. In such an embodiment, the recoater horizontal motion stage 214 may be supported by vertical motionstages 216 that are configured to provide vertical movement of the recoater relative to the build plate assembly. Corresponding vertical motion stages may also be provided for the shroud 210, not depicted, to index the shroud vertically upward relative to the build plate assembly in such an embodiment. In some embodiments, the additive manufacturing system may also include an optics assembly 218 that is supported on a vertical motion stage 220 that is in turn mounted on the gantry 220 that allows the optics unit to be scanned in the plane of the build plate assembly 202.

[0063] In the above embodiment, the vertical motion stages, horizontal motion stages, and gantry may correspond to any appropriate type of system that is configured to provide the desired vertical and / or horizontal motion. This may include supporting structures such as: rails; linear bearings, wheels, threaded shafts, and / or any other appropriate structure capable of supporting the various components during the desired movement. Movement of the components may also be provided using any appropriate type of actuator including, but not limited to, electric motors, stepper motors, hydraulic actuators, pneumatic actuators, electric actuators, and / or any other appropriate type of actuator as the disclosure is not so limited.

[0064] In addition to the above, in some embodiments, the depicted additive manufacturing system may include one or more controllers 224 that is operatively coupled to the various actively controlled components of the additive manufacturing system. For example, the one or more controllers may be operatively coupled to the one or more supports 206, recoater 212, optics assembly 218, the various motion stages, and / or any other appropriate component of the system. In some embodiments, the controller may include one or more processors and associated non-transitory computer readable memory. The non- transitory computer readable memory may include processor executable instructions that when executed by the one or more processors cause the additive manufacturing system to perform any of the methods disclosed herein.

[0065] FIG. 3 presents a cross-sectional schematic illustration of a non-limiting build plate assembly 301, according to some embodiments. The build plate assembly generally comprises a build plate 309 that may comprise a build surface 303, as shown. Of course, the build plate need not comprise a build surface and the build plate assembly may instead be configured to provide one or more build surfaces of intermediate parts. The build plate assembly may further comprise a connector 305, represented in FIG. 3 as an expansion collet.

[0066] In the depicted embodiment, a connector may be an expandable connector configured to secure an intermediate part to the build plate via expansion. A connector maybe configured such that it can be expanded to engage an intermediate part by interacting a complementary feature (e.g., a hole) of the intermediate part, securing the intermediate part via friction. For example, expansion collet 305 is an expandable connector that may be engaged as shown in FIG. 3, by actuating a flared bolt 307 to drive the flared bold 307 in the downwards direction 313 against the collet 305 to cause expansion 315 of the collet 305. Thus, in some embodiments, an intermediate part receives a portion of connector 305 while in a first, unexpanded configuration that allows the intermediate part to be received in multiple poses. The connector may receive the intermediate part into a desired pose. As elaborated on below, in some embodiments, the connector may be expanded to lock the intermediate part into the desired pose after the intermediate part is properly oriented in a desired plane. Of course, while a specific connector is shown in the figure, other types of connectors may also be used as detailed previously.

[0067] As shown in FIG. 3, connector 305 may be a discrete component. However, it should, of course, be understood that the connector could instead be integrally formed with a build plate or with an intermediate part, as the disclosure is not so limited. Furthermore, it should be understood that while connector 305 of build plate assembly 301 protrudes from build plate 309, connectors may generally have any of a variety of appropriate dispositions with respect to the build plate, as the disclosure is not so limited. For example, in some embodiments, the connectors may be within a recess of the build plate, such that an intermediate part may be secured into the recess of the build plate using the connector.

[0068] A connector of a build plate assembly may be engaged using any of a variety of appropriate methods. For example, connector 305 is configured to be engaged using flared bolt 307. In some embodiments, the build plate assembly is configured to permit engagement of a connector that has received an intermediate part. A build plate assembly may be configured to permit the connector to be accessed via a side of the build plate opposite the intermediate part, in some embodiments. For example, connector 305 is configured to secure an intermediate part above build surface 303 of build plate 309, and flared bolt 307 is configured to access connector 305 by passing through side 323 of build plate 309 opposite the upper surface 303 of the build plate oriented towards an optics assembly or other printer head of a system. It should, of course, be understood that in some embodiments the connector may be accessed via a side of the build plate. Additionally, in some embodiments, access to the connector may be unnecessary (e.g., the connector may be configured to beactuated between the engaged and unengaged configurations using an actuator configured to actuate the connector as the disclosure is not so limited.

[0069] FIG. 4 presents a cross-sectional schematic illustration of a non-limiting intermediate part 451 suitable for use in a build plate assembly, according to some embodiments. The intermediate part could have any of a variety of appropriate geometries. An intermediate part may be a part that has been manufactured without additive manufacturing, onto which additive manufacturing may be used to provide a final geometry. The intermediate part may, in some embodiments, be a disposable puck configured to provide a build surface for additive manufacturing of a part and subsequently discarded. For example, intermediate part 451 of FIG. 4 is presented as a puck comprising a build surface 453. However, other embodiments are also possible, as the disclosure is not so limited. For example, the intermediate part may be a part produced by conventional manufacturing, on to which additive manufacturing of one or more additional features is desirable. For example, the intermediate part may be an unfinished component that, by the additive manufacturing of one or more additional features onto the intermediate part, may be manufactured into a finished component suitable for subsequent use.

[0070] According to some embodiments, an intermediate part comprises a feature configured to help a connector lock the intermediate part into a pose. For example, intermediate part 451 comprises hole 455 which is configured to receive an expandable connector as discussed in the context of FIG. 3. In other embodiments, the feature may be a curve of the intermediate part that is configured to match a clip connector in order to secure the intermediate part. Of course, embodiments where the connector is part of (e.g., integrally formed with) the intermediate part, or wherein the connector is configured such that it can engage with the intermediate part without engaging a particular geometry of the intermediate part are also contemplated, as the disclosure is not so limited.

[0071] FIG. 5 presents a cross-sectional schematic illustration of a non-limiting build plate assembly 501 formed by receiving intermediate part 451 of FIG. 4 onto connector 305 of build plate assembly 301 shown in FIG. 3. As shown in FIG. 5, connector 305 has been configured to receive to build plate 309 via the protrusion of connector 305 into hole 455 of the intermediate part. In some embodiments, the received intermediate part is able to be received into a plurality of poses relative to the build plate. The intermediate part may be received by the connector such that it can be freely moved between poses. In some embodiments, the connector may be engaged (e.g., expanded, as illustrated in FIG. 3) suchthat intermediate part 451 is locked into a particular pose (e.g., a desired pose) relative to the build plate.

[0072] The connector may directly contact the intermediate part as shown in FIG. 5, or may contact the intermediate part indirectly via one or more intervening components. For example, in some embodiments, the build plate assembly includes a sealing component (e.g., a soft or elastic component such as a gasket, not shown) that wraps around the exterior of the connector or the interior of the intermediate part. Such a sealing component may increase the friction between the connector and the intermediate part, helping to lock the intermediate part in position, when compressed. However, direct contact between the connector and the intermediate part may also be advantageous and may be used, in some embodiments. For example, in some embodiments, direct contact between the intermediate part and the connector reduces the freedom of motion of the intermediate part, improving the accuracy of positioning of the intermediate part.

[0073] It should, of course, be understood that any of a variety of suitable connectors may be used, and that the connector need not be an expansion collet. For example, FIG. 6 presents a cross-sectional schematic illustration of a non-limiting build plate assembly 601 comprising a connector 605 and a build plate 609. Connector 605 is an expandable connector that is configured to be expanded by driving sphere 641 against one or more appropriately shaped surfaces, such as curves 643a and 643b, of connector 605, e.g., through the use of bolt 607. A sphere may be configured to cause radial expansion of the connector. In some embodiments, connector 605 is configured to fill a hole of the intermediate part, much like connector 405 as shown in FIG. 5.

[0074] FIG. 7 presents a cross-sectional schematic illustration of a non-limiting build plate assembly 701 comprising a connector 705 disposed in a build plate 709. Like connector 605 of FIG. 6, connector 705 comprises a sphere 741 configured to expand connector 705. However, connector 705 is configured to be engaged by displacing a pusher 745, which may be a solid intermediate structure capable of transmitting force from the bolt to the sphere into sphere 741, using bolt 707. In some embodiments, the connector has an adjustable position within the build plate assembly. For example, connector 705 of build plate assembly 701 comprises threading 752 that interlocks with threading 754 of build plate 709 in order to control a height h of the connector above the build plate. In some embodiments, the build plate assembly includes one or more components configured to bias the transverse position of a connector (e.g., to help stabilize the transverse position of the connector by increasing thefrictional forces holding the connector in position relative to the plate). For example, build plate assembly 701 comprises springs 756 which are configured to maintain a height h of a portion of the connector 705 extending above the build plate at a predetermined height. If springs are used, any of a variety of appropriate springs may be used, as the disclosure is not so limited. However, it should of course be understood that in some embodiments no springs are used, and the position of the connector is controlled without any bias forces.

[0075] An intermediate part may, in some embodiments, be received and secured using a plurality of pins. FIG. 8 A presents a top view schematic illustration of a non-limiting build plate assembly 801 comprising connectors 805a, 805b, and 805c, configured to receive build plate 809 into a space indicated by dashed boundary 862. As shown, connector 805a comprises a split pin with an unbiased cross section encompassing the split pin that is larger than a corresponding hole formed in an intermediate part. Thus, the split pin may be compressed to fit within a hole formed in the intermediate part and provide a friction fit that may help to maintain the part in a desired pose. Thus, the pins may secure an x-y position of the intermediate part while leaving it free to move between various poses. Connector 805b comprises a large cylindrical extension, or other appropriately shaped protrusion, configured to contact an edge of the intermediate part. Connector 805c comprises a small cylindrical pin configured to insert into the intermediate part. Simultaneous use of pin connectors 805a, 805b, and 805c can thereby secure an intermediate part into a pose indicated by boundary 862 when simultaneously engaged, while allowing the intermediate part to move between different poses to permit the intermediate part to be properly aligned with a desired predetermined reference plane.

[0076] Pin connectors may generally be engaged by any of a variety of suitable methods. In some embodiments, the pin is statically positioned such that a base of the pin is fixed relative to the build plate. FIG. 8B presents a cross-sectional schematic illustration of build plate assembly 801 and pin connector 805c comprising pin 807 configured to extend into an intermediate part. Pin connector 805c is illustrated as configured to bolt into build plate 809 such that its position can be adjusted relative to build plate 809. It should of course be understood that in some embodiments, pin connector 805c is integrally formed with build plate 809 or is otherwise secured such that it is unable to move relative to build plate 809, as the disclosure is not so limited. Pin connectors such as pin connector 805c may be flexible, and may be statically mounted but configured to engage an intermediate part by undergoing elastic deformation in order to extend into an intermediate part. An advantage of such aconfiguration is that, in some embodiments, flexibility of the pin connector may allow the intermediate part to be retained despite dimensional changes of the intermediate part (e.g., as a result of thermal expansion of the intermediate part). In some embodiments, pin connector 805c may be engaged or disengaged via movement through build plate 809 (e.g., to change an extent of pin connector 805c into the intermediate part). Statically mounted pins may be mechanically coupled to a build plate by any of a variety of suitable methods. For example, statically mounted pins may be configured to screw into the build plate from above or below; may be configured to press-fit into the build plate (e.g., using a snap fitting); may be welded, soldered, or adhered to the build plate; may be fastened to the build plate using a fastener (e.g., a bolt, a clamp, a rivet); or may be integrally formed with the build plate. Other embodiments are also possible as the disclosure is not so limited.

[0077] FIGS. 9A-9B provide another example of connectors that may be used to secure an intermediate part in a desired pose relative to an underlying build plate. FIG. 9A presents a cross-sectional schematic illustration of a non-limiting build plate assembly 901 comprising multiple connectors 905 in the form of flexible clips, or rigid appropriately shaped protrusions, configured to secure an intermediate part to build plate 909. Dashed box 962 indicates a position where the intermediate part may be secured, to help illustrate the action of clips 905. Clips 905 are sized and shaped to compliment a portion of an intermediate part received by the clips such that the clips may maintain the intermediate part in a desired pose. In some embodiments, the complementary portions of the clips and intermediate part may be curved to facilitate reorientation of the intermediate part while it is engaged by the clips. It should, of course, be understood that other types of clips, including non-curved clips, may also be used, as the disclosure is not so limited.

[0078] FIG. 9B presents a schematic, top-view illustration of a portion of build plate assembly 901 comprising intermediate part 951 secured to build plate 909 by clips 905. As shown, multiple clips may be used to bias the position of intermediate part 951 towards central position 960. The bias of the intermediate part towards central position 960 may be advantageous for providing consistent positioning of intermediate part 951, and provides one illustration of a situation in which the use of multiple connectors to lock the position of an intermediate part provides a mechanical advantage over the use of a single connector.

[0079] FIG. 10 provides another example of a build plate assembly wherein multiple connectors are used to secure a single intermediate part. As shown, FIG. 10 presents a cross- sectional schematic illustration of a non-limiting build plate assembly 1001 comprisingmultiple connectors 1005 configured to secure intermediate part 1051 to build plate 1009. As discussed above, the use of multiple connectors may be advantageous, according to some embodiments, to provide the intermediate part with more stability than could be achieved using a single connector, e.g., by providing improved resistance to rotation of intermediate part 1051. Of course, it should be understood that although both connectors 1005 are represented as connectors of the same type, in general the intermediate part may be secured using more than one type of connector and / or different types of connectors from those shown in the figure, as the disclosure is not so limited.

[0080] FIGS. 11A-11B presents schematic illustrations of various perspectives of a non-limiting build plate assembly 1101 comprising a plurality of intermediate parts 1151 configured to be secured to build plate 1109 using connectors 1105. Connectors 1105 are clamps configured to be engaged using bolts 1107 which are accessible from the side of build plate 1109, and which are configured to tighten clamps 1105 around intermediate parts 1151 in order to lock intermediate parts 1151 into a desired pose relative to the build plate 1109. While FIGS. 11A-1 IB show clamps locked by bolts 1107, it should of course be understood that any of a variety of appropriate methods of locking the clamp may be employed. For example, in some embodiments, the clamp may be locked using welding, friction fitting, adhesive, riveting, or any of a variety of other suitable methods to secure the clamp in a given position. As illustrated, intermediate parts 1151 extend through build plate 1109, rather than being secured above build plate 1109 like the intermediate parts shown in earlier figures. It should, of course, be understood that while build plate assembly 1101 includes 6 intermediate parts, a build plate assembly may generally include any appropriate number of intermediate parts, as previously described.

[0081] As discussed herein, the use of a plurality of intermediate parts can be particularly advantageous, particularly for the parallelized manufacture of multiple components. In embodiments with multiple intermediate parts, aligning the parts can improve the consistency of additive manufacturing. For example, when performing powder bed fusion methods, manufacturing using a plurality of intermediate parts may be improved when the intermediate parts are aligned to within a tolerance comparable to an interaction zone of a laser with powder of the powder bed.

[0082] FIGS. 12A-12E present cross-sectional schematic illustrations showing how, according to some embodiments, one or more intermediate parts can be locked into a desired pose and used for additive manufacturing. FIG. 12A presents a cross-sectional schematicillustration of a non-limiting build plate assembly 1201 comprising multiple connectors 1205 disposed in build plate 1209. Below the build plate assembly is a flat reference surface 1281 on which two intermediate parts 1251 have been placed such that build surfaces 1253 formed on the separate intermediate parts are approximately aligned with a common plane defined by flat reference surface 1281. By lowering the build plate assembly to the intermediate parts, connectors 1205 can receive intermediate parts 1251 by inserting the connectors into holes 1255 while the intermediate parts are maintained in the desired poses.

[0083] FIG. 12B shows build plate assembly 1201 lowered such that connectors 1205 have received intermediate parts 1251 in a desired pose with respect to build plate 1209. While only a single pose of each intermediate part is shown, it should, of course, be understood that each intermediate part is capable of being received by connectors 1205 in any of a variety of poses, but that the pose of the intermediate parts are being maintained in a desired pose using the flat reference surface. Specifically, in some embodiments, flat reference surface 1281 retains intermediate parts 1251 in a desired pose relative to the build surface by maintaining their alignment with a common plane while connectors 1205 are positioned and engaged.

[0084] It should, of course, be understood that while FIGS. 12A-12B show flat reference surface 1281 positioned vertically below build plate assembly 1201, any of a variety of suitable methods for biasing a reference surface against the one or more build surfaces of one or more corresponding intermediate parts may be used. For example, in some embodiments, the build plate assembly may be disposed below a reference surface. Then, the reference surface may be lowered towards the intermediate parts and build plate and / or the build plate and associated intermediate parts may be raised towards the reference surface. In either case, the reference surface may be pressed against the one or more build surfaces of the one or more intermediate parts to move the intermediate parts into a desired pose. Finally, the connectors can be engaged and the flat reference surface may be removed. Other embodiments are also possible. It should be understood that the reference surface may either be flat or may include another appropriate shape to orient the one or more build surfaces of the intermediate parts into a desired reference plane.

[0085] After positioning the build surfaces of the intermediate parts 1251 and positioning the connectors 1205, the connectors 1205 may be engaged to secure intermediate parts 1251, locking them into a desired pose (e.g., into a desired pose wherein the intermediate parts are aligned with a common plane) relative to the build plate. As shown inFIG. 12C, the secured intermediate parts can form part of build plate assembly 1201, which may be removed from the flat reference surface. Connectors 1205 can, during movement of the build plate assembly, maintain secured intermediate parts 1251 in their desired poses relative to the build plate. For example, in FIG. 12C, intermediate parts 1251 are locked in alignment with reference plane 1283, originally defined by flat reference surface 1281 but now separated from flat reference surface 1281 by motion of build plate assembly 1201.

[0086] The build plate assembly can then be used in an additive manufacturing system. For example, FIG. 12D shows a cross-sectional schematic illustration of build plate assembly 1201, which has been vertically inverted relative to its orientation in FIGS. 12A- 12C, and which has been added to additive manufacturing system 1200 via mechanical coupling to vertical motion stage 1291.

[0087] Build plate assembly 1201 may be mechanically coupled to vertical motion stage 1291 using any of a variety of suitable types of mechanical couplings. According to some embodiments, for example, build plate assembly 1201 is mechanically coupled to vertical motion stage 1291 via one or more kinematic couplings 1293 as shown in FIG. 12D. A kinematic coupling may allow the build plate assembly to reach a desired position and orientation by creating a plurality of contact points between the build plate assembly that constrain its three-dimensional position and orientation when the build plate assembly sits at rest on the vertical motion stage while avoiding binding or otherwise over constraining the build plate assembly on the vertical motion stage. For example, the coupling between the vertical motion stage and the build plate assembly can be a Kelvin coupling (e.g., the build plate assembly may comprise a plurality of spherical portions configured to rest in tetrahedral recesses of the vertical motion stage). As another example, the coupling between the vertical motion stage and the build plate assembly can be Maxwell coupling (e.g., the build plate assembly may comprise a plurality of spherical portions configured to rest in extended V- grooves of the vertical motion stage). It should, of course, be understood that although all three spherical portions of kinematic coupling 1293 are represented schematically in FIG.12D, the spherical portions and associated recesses are not co-linear. Rather, the representation of all three spherical portions of kinematic coupling 1293 represent a distortion for the sake of visualization of the kinematic coupling. In some embodiments, the build plate assembly is coupled to the vertical motion stage by a method other than use of a kinematic coupling. For example, the build plate assembly may couple to the vertical motion stageusing an adhesive or a fastener such as a bolt, a pin, a clamp, or a nail, as the disclosure is not so limited.

[0088] FIG. 12E shows additive manufacturing system 1200 during performance of a non-limiting additive manufacturing process. Although the systems and methods provided herein may be compatible with a variety of additive manufacturing processes, FIG. 12E shows a powder bed fusion additive manufacturing process where a plurality of layers of powder 1292 have been deposited on top of build plate 1209 and intermediate parts 1251 of build plate assembly 1201. The layers of powder have been selectively fused using one or more laser energy sources to additively manufacture features 1294 on the build surfaces of 1253 of the intermediate parts 1251, as illustrated. It should, of course, be understood that although features 1294 are depicted as having the same geometry, in general the geometry of the features deposited on separate intermediate parts can differ, as the disclosure is not limited to embodiments where intermediate parts are used to additively manufacture identical features. It should be understood that the powder bed fusion process presented in FIG. 12E could be used in concert with any of the build plate assemblies and intermediate parts described with reference to FIGS. 3-1 IB, or with any of a variety of other build plate assemblies described herein.

[0089] FIG. 13 presents a schematic illustration of a non-limiting additive manufacturing method 1301, according to some embodiments. As shown, the method comprises step 1303 of receiving one or more intermediate parts onto corresponding connectors of a build plate assembly. The connectors and intermediate parts may be any of the types discussed herein. The method further comprises a step 1305 of aligning one or more build surfaces of the one or more intermediate parts with a reference surface, which may optionally be a flat reference surface, by biasing the one or more build surfaces against the reference surface. It should, of course, be understood that while method 1301 represents step 1303 as being performed prior to step 1305, in some embodiments step 1305 may be performed first, as the disclosure is not limited with respect to the order of the method steps of method 1301. For example, FIGS. 12A-12E illustrate an embodiment wherein a plurality of intermediate parts are aligned with a flat reference surface first, followed by receipt of the intermediate parts onto the connectors.

[0090] Method 1301 comprises an additional step 1307 of maintaining a pose of the one or more intermediate parts relative to the build plate. For example, method 1307 may comprise engaging connectors of the build plate assembly in order to secure the intermediateparts to the build plate assembly in the previously set pose during step 1305. In step 1309, the method comprises additively manufacturing one or more features on the one or more intermediate parts (e.g., on the build surfaces of the one or more intermediate parts) to form one or more corresponding parts including a portion manufactured with typical manufacturing processes and one or more portions formed thereon with additive manufacturing. The one or more features may be manufactured serially or in parallel, as the disclosure is not so limited. In some embodiments, step 1309 comprises forming exactly one part, while in others, step 1309 comprises forming a plurality of parts. Finally, method 1301 comprises step 1311 of removing the part from the build plate assembly. The part may be removed from the build plate assembly by removing the intermediate part from the build plate assembly, or by removing the part from the intermediate part. In some embodiments, the method does not comprise removing the part from the intermediate part at all. For example, as discussed above, the additive manufacturing method could be used to additively manufacture features onto intermediate parts prepared without additive manufacturing, such that the additively manufactured part produced by method 1301 and the intermediate part together form a finished part. In some embodiments, the method comprises the additional, optional step of removing the finished part from the intermediate part. Embodiments where some additively manufactured parts are not removed from intermediate parts while others are removed from intermediate parts are also contemplated, as the disclosure is not so limited.

[0091] The above method may be implemented by one or more controllers including at least one processor operatively coupled to the various controllable portions of an additive manufacturing system as disclosed herein. The method may be embodied as computer readable instructions stored on non-transitory computer readable memory associated with the at least one processor such that when executed by the at least one processor the additive manufacturing system may perform any of the actions related to the methods disclosed herein. Additionally, it should be understood that the disclosed order of the steps is exemplary and that the disclosed steps may be performed in a different order, simultaneously, and / or may include one or more additional intermediate steps not shown as the disclosure is not so limited.

[0092] While several embodiments of the present invention have been described and illustrated herein, those of ordinary skill in the art will readily envision a variety of other means and / or structures for performing the functions and / or obtaining the results and / or one or more of the advantages described herein, and each of such variations and / or modificationsis deemed to be within the scope of the present invention. More generally, those skilled in the art will readily appreciate that all parameters, dimensions, materials, and configurations described herein are meant to be exemplary and that the actual parameters, dimensions, materials, and / or configurations will depend upon the specific application or applications for which the teachings of the present invention is / are used. Those skilled in the art will recognize, or be able to ascertain using no more than routine experimentation, many equivalents to the specific embodiments of the invention described herein. It is, therefore, to be understood that the foregoing embodiments are presented by way of example only and that, within the scope of the appended claims and equivalents thereto, the invention may be practiced otherwise than as specifically described and claimed. The present invention is directed to each individual feature, system, article, material, kit, and / or method described herein. In addition, any combination of two or more such features, systems, articles, materials, kits, and / or methods, if such features, systems, articles, materials, kits, and / or methods are not mutually inconsistent, is included within the scope of the present invention.

Claims

CLAIMS1. A build plate assembly for an additive manufacturing system, the build plate assembly comprising: a build plate; and one or more connectors configured to secure one or more intermediate parts to the build plate, wherein the one or more connectors are configured to receive the one or more intermediate parts in a plurality of possible poses relative to the build plate and lock a pose of an associated intermediate part relative to the build plate in a desired pose relative to the build plate.

2. The build plate assembly of claim 1, wherein the plurality of possible poses include a plurality of possible angles of the one or more intermediate parts relative to the build plate.

3. The build plate assembly of any one of the preceding claims, further comprising the one or more intermediate parts.

4. The build plate assembly of any one of the preceding claims, wherein the one or more intermediate parts are a plurality of intermediate parts.

5. The build plate assembly of any one of the preceding claims, wherein each intermediate part of the one or more intermediate parts comprises one or more build surfaces, and wherein the one or more build surfaces are approximately aligned in a reference plane when the one or more intermediate parts are locked in the desired pose.

6. The build plate assembly of any one of the preceding claims, wherein the build plate assembly comprises a plurality of connectors for each of the one or more intermediate parts.

7. The build plate assembly of any one of the preceding claims, mechanically coupled to a vertical motion stage of an additive manufacturing system.

8. The build plate assembly of any one of the preceding claims, wherein the build plate includes one or more kinematic couplings.

9. The build plate assembly of any one of the preceding claims, wherein the one or more connectors include one or more selected from an expanding collet, a clip, a clamp, and a pin.

10. The build plate assembly of any one of the preceding claims, further comprising one or more recesses configured to receive the one or more intermediate parts are disposed in the build plate.

11. The build plate assembly of any one of the preceding claims, wherein at least some of the one or more connectors are selectively engageable with the one or more intermediate parts.

12. The build plate assembly of any one of the preceding claims, wherein the build plate assembly is configured to secure the one or more intermediate parts above the build plate.

13. An additive manufacturing system, comprising: the build plate assembly of any one of the preceding claims, one or more laser energy sources; and an optics assembly movable relative to the build plate assembly and configured to direct laser energy from the one or more laser energy sources toward the build plate assembly to melt at least a portion of a layer of material disposed on the build plate assembly.

14. A method of additive manufacturing, the method comprising: orienting one or more intermediate parts relative to a build plate to align a corresponding one or more build surfaces of the one or more intermediate parts to be in a reference plane; and locking a pose for at least one intermediate part of the one or more intermediate parts relative to the build plate to maintain the one or more build surfaces in alignment with the reference plane.

15. The method of claim 14, wherein orienting the one or more intermediate parts includes biasing a reference surface against the one or more build surfaces of the one or more intermediate parts.

16. The method of any one of claims 14-15, wherein the reference surface is a flat reference surface.

17. The method of any one of claims 14-16, further comprising locking the poses of the one or more intermediate parts using one or more corresponding connectors.

18. The method of any one of claims 14-17, further comprising locking the pose of at least one of the one or more intermediate parts using a plurality of connectors.

19. The method of any one of claims 14-18, further comprising aligning the reference plane with a formation plane of an additive manufacturing system.

20. The method of any one of claims 14-19, wherein the one or more intermediate parts are a plurality of intermediate parts.

21. The method of any one of claims 14-20, further comprising additively manufacturing one or more features on the one or more build surfaces.

22. The method of any one of claims 14-21, further comprising manufacturing one or more features on each build surface of the one or more build surfaces.

23. The method of any one of claims 14-22, further comprising depositing a precursor material onto at least one of the one or more build surfaces, and selectively fusing at least a portion of the precursor material with one or more laser energy pixels to form one or more parts on the build surface.

24. A part manufactured using the method of any one of claims 14-23.

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