Additive manufacturing system with partially flexible build platform

Abstract

An additive manufacturing system is provided that includes a partially flexible build platform. [Solution] The additive manufacturing (AM) system (100) includes an adjustable base (110) and a building platform (104) including a peripheral region (142) and a periphery (143) of the peripheral region, the periphery being fixedly and rigidly connected to the base and intermediate region, and a metallurgical connection (190) fixedly and rigidly connecting the periphery (143) of the peripheral region (142) to the base (110), and a build material applicator (120) for depositing build material (122) above the building platform (104) to build an object (102).

Description

[Technical field]

[0001] The present disclosure relates generally to additive manufacturing, and more particularly, to an additive manufacturing system having a partially flexible build platform. [Background technology]

[0002] Additive manufacturing (AM) includes a wide variety of processes that build objects by successively depositing material onto a build platform rather than removing material from a block of material. Certain additive manufacturing processes can apply a stress to the build platform as the object is built. For example, in selective laser melting (SLM) AM processes, large parts with large weld areas compared to the area of ​​the build platform can cause the build platform to deform or warp due to thermal contraction. If the build platform is fully rigidly constrained to the base of the AM system, thermal stresses can remain in the part and cause defects. Alternatively, the connections between the build platform and the base can be damaged by the stress. One corrective approach is to add compliant supports to the object that allow deformation, but these supports are costly and time-consuming to fabricate, complicating the manufacture of the object. Other approaches implement complex spring systems between the base and the build platform, allowing the entire build platform to flex. Spring systems can become clogged with material accumulation and can disadvantageously require independent movement of the base relative to the build platform. [Prior art documents] [Patent documents]

[0003] [Patent Document 1] International Patent Application Publication No. WO2019 / 074827 Summary of the Invention

[0004] All aspects, embodiments and features described below can be combined in any manner that is technically possible.

[0005] One aspect of the present disclosure provides an additive manufacturing (AM) system comprising a build platform including an adjustable base and peripheral and intermediate regions fixedly and rigidly connected to the base, a metallurgical connection fixedly and rigidly connecting the peripheral region of the build platform to the base, and a build applicator for depositing a build object above the build platform to create the build object.

[0006] Another aspect of the present disclosure includes any of the preceding aspects, wherein the metallurgical connection includes at least one of a weld, solder, braze, or solid-state connection to fixedly and rigidly join the periphery of the peripheral intermediate region to the base.

[0007] Another aspect of the present disclosure includes any of the preceding aspects, wherein the metallurgical connection includes at least one weld for fixedly and rigidly joining the periphery of the peripheral region to the base.

[0008] Another aspect of the disclosure includes any of the preceding aspects, wherein the at least one weld is at least one of a fusion weld, a tack weld, a metal inert gas (MIG) weld, a gas metal arc weld (GMAW), a tungsten inert gas (TIG) weld, a gas tungsten arc weld (GTAW), a stick-shielded metal arc weld (SMAW), a flux-cored-flux weld, an energy beam weld (EBW), an atomic hydrogen weld (AHW), a plasma arc weld, and combinations thereof. ) fixedly and firmly connects the periphery of the peripheral region to the base.

[0009] Another aspect of the present disclosure includes any of the preceding aspects, wherein the at least one weld includes a tack weld.

[0010] Another aspect of the present disclosure includes any of the preceding aspects, wherein the metallurgical connection is provided by a build material applicator for fixedly and rigidly joining the periphery of the peripheral region to the base.

[0011] Another aspect of the present disclosure includes any of the preceding aspects, wherein the metallurgical connection includes a build material for fixedly and rigidly joining the periphery of the peripheral region to the base.

[0012] Another aspect of the present disclosure includes any of the preceding aspects, wherein the base is formed from a first material and the metallurgical connection includes said first material.

[0013] Another aspect of the present disclosure includes any of the preceding aspects, wherein the base directly contacts the build platform.

[0014] Another aspect of the present disclosure includes any of the preceding aspects and includes a build material applicator that deposits build material by at least one of direct metal laser melting; direct metal laser sintering; selective laser melting; and directed energy deposition.

[0015] Another aspect of the present disclosure includes any of the preceding aspects, wherein the perimeter of the peripheral region includes a first opposing perimeter transverse to an X-axis of the build platform and a second opposing perimeter transverse to a Y-axis of the build platform, and the metallurgical connection is positioned on at least one of the X-axis and the Y-axis.

[0016] Another aspect of the present disclosure includes any of the preceding aspects, wherein the metallurgical connections are disposed on an X-axis and a Y-axis.

[0017] One aspect of the present disclosure provides an additive manufacturing (AM) system comprising: a build platform including an adjustable base; a peripheral region including an intermediate region and a peripheral edge, the peripheral region fixedly and rigidly coupled to the base by a metallurgical connection configured to fixedly and rigidly couple the peripheral region to the base; and a build material applicator for depositing build material above the build platform to create an object.

[0018] Another aspect of the present disclosure includes any of the preceding aspects, wherein the metallurgical connection includes at least one of welding, soldering, brazing, or a solid connection to fixedly and securely join the periphery of the peripheral region to the base.

[0019] Another aspect of the present disclosure includes any of the preceding aspects, wherein the metallurgical connection includes at least one weld for fixedly and rigidly joining the periphery of the peripheral region to the base.

[0020] Another aspect of the present disclosure includes any of the preceding aspects, wherein the at least one weld includes at least one of a fusion weld, a tack weld, a metal inert gas (MIG) weld, a gas metal arc weld (GMAW), a tungsten inert gas (TIG) weld, a stick-shielded metal arc weld (SMAW), a flux-cored-flux weld, an energy beam weld (EBW), an atomic hydrogen weld (AHW), and a plasma arc weld.

[0021] Another aspect of the present disclosure includes any of the preceding aspects, wherein the at least one weld includes a tack weld.

[0022] Another aspect of the present disclosure includes any of the preceding aspects, wherein the metallurgical connection is provided by a build material applicator for fixedly and rigidly joining the periphery of the peripheral region to the base.

[0023] Another aspect of the present disclosure includes any of the preceding aspects, wherein the metallurgical connection includes a build material for fixedly and rigidly joining the periphery of the peripheral region to the base.

[0024] Another aspect of the present disclosure includes any of the preceding aspects, wherein the base is formed from a first material and the metallurgical connection includes the first material.

[0025] Another aspect of the present disclosure includes any of the preceding aspects, wherein the peripheral regions include first opposing peripheral regions transverse to an X-axis of the build platform and a second opposing peripheral region transverse to a Y-axis of the build platform, and the metallurgical connection is positioned on at least one of the X-axis and the Y-axis.

[0026] Two or more aspects described in this disclosure may be combined to form an embodiment not specifically described herein, including those described in this Summary.

[0027] The details of one or more embodiments are set forth in the accompanying drawings and the description below. Other features, objects, and advantages will become apparent from the description and drawings, and from the claims. [Brief description of the drawings]

[0028] These and other features of the present disclosure will be more readily understood from the following detailed description of the various aspects of the disclosure taken in conjunction with the accompanying drawings illustrating various embodiments of the present disclosure. [Figure 1] FIG. 1 illustrates a cross-sectional view of an additive manufacturing (AM) system including a partially flexible build platform in an unflexed state according to an embodiment of the present disclosure. [Diagram 2] FIG. 1 illustrates a top view of an AM system including a partially flexible build platform according to an embodiment of the present disclosure. [Diagram 3] FIG. 1 illustrates a top view of an additive manufacturing (AM) system including a partially flexible build platform according to another embodiment of the present disclosure. [Figure 4] FIG. 13 shows a top view of an AM system including a partially flexible build platform according to a further embodiment of the present disclosure. [Diagram 5] FIG. 13 shows a top view of an AM system including a partially flexible build platform according to a further embodiment of the present disclosure. [Figure 6] 1 illustrates a block diagram of a rectangular additively manufactured object on a build platform and a base with a metallurgical connection between the build platform and the base, according to an embodiment of the present disclosure. [Figure 7] FIG. 1 illustrates a block diagram of an AM system and method according to an embodiment of the present disclosure. [Figure 8A] 1 shows a schematic diagram of a front view of one or more isolation restrictors according to various embodiments of the present disclosure. [Figure 8B] 1 shows a schematic diagram of a top view of one or more isolation restrictors according to various embodiments of the present disclosure. [Figure 9] 1 illustrates a schematic front view of an alternative embodiment of a flexible base including at least one slot in the AM system base, according to an embodiment of the present disclosure. [Figure 10] 14A-14C show schematic front views of additional alternative embodiments of a flexible base including a reduced interface area between an object to be built and an AM system base in accordance with embodiments of the present disclosure. [Figure 11] 13 illustrates an alternative embodiment of a flexible base with an object constructed by an AM system, including a reduced area connection at the constructed object and the base, according to an embodiment of the present disclosure. [Figure 12] 1 illustrates a block diagram of an additional alternative embodiment of a build platform having an elongated metallurgical connection between the build platform and the base, and a flexible base having a rectangular additively manufactured object on the base, in accordance with an embodiment of the present disclosure. [Figure 13] FIG. 13 shows a further block diagram of an additional alternative embodiment of a flexible base having a build platform with a metallurgical connection disposed below and between the build platform and the base, according to an embodiment of the present disclosure, and a rectangular additively manufactured object on the base. [Figure 14]FIG. 13 shows a block diagram of an additional alternative embodiment of a build platform with a metallurgical connection between the build platform and the base and a flexible base with a rectangular additively manufactured object on the base in accordance with an embodiment of the present disclosure.

[0029] It should be noted that the drawings of the present disclosure are not necessarily to scale. The drawings are intended to depict only typical aspects of the present disclosure and therefore should not be considered as limiting the scope of the present disclosure. In the drawings, like numbering represents like elements between the drawings. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0030] As a first issue, in order to clearly explain the subject matter of this disclosure, it becomes necessary to select specific terms when referring to and describing the relevant machine objects in an additive manufacturing system. Wherever possible, common industry terms are used and adopted in a manner consistent with their accepted meaning. Unless otherwise specified, such terms should be given a broad interpretation consistent with the context of this application and the scope of the appended claims. Those skilled in the art will appreciate that a particular object is often referred to using several different or overlapping terms. Something described herein as being a single part may include and be referred to as being made up of several parts in another context. Alternatively, something described herein as including several parts may be referred to as a single part elsewhere.

[0031] In this specification, some descriptive terms may be used regularly, as explained below: The terms "first," "second," and "third" may be used interchangeably to distinguish one object from another, and are not intended to imply location or importance of the individual objects.

[0032] The terms used herein are for the purpose of describing particular embodiments only and are not intended to be limiting of the disclosure. As used herein, the singular forms "a," "an," and "the" are intended to include the plural unless the context clearly indicates otherwise. Furthermore, as used herein, it will be understood that the terms "comprises" and / or "comprising" specify the presence of the stated features, integers, steps, operations, elements, and / or objects, but do not preclude the presence or addition of one or more other features, integers, steps, operations, elements, objects, and / or groups thereof. "Optional" or "optionally" means that the subsequently described event or circumstance may or may not occur, or the subsequently described object or element may or may not be present, and that the description includes instances in which the event occurs or the object is present as well as instances in which it does not occur or is not present.

[0033] When an element or layer is referred to as "resting," "engaging," "connecting," or "bonded" to another element or layer, it may be directly resting, engaging, connecting, or bonding with the other element or layer, or there may be intervening elements or layers present. In contrast, when an element is referred to as being "directly resting," "directly engaged," "directly connected," or "directly bonded" on another element or layer, there may not be any intervening elements or layers present. Other words used to describe relationships between elements should be interpreted similarly (e.g., "between" vs. "directly between," "adjacent" vs. "directly adjacent," etc.). As used herein, the term "and / or" includes any and all combinations of one or more of the associated listed items.

[0034] As indicated above, the present disclosure provides an additive manufacturing (AM) system that includes a partially flexible build platform. More specifically, the AM system can include a build chamber (particularly for additive manufacturing processes where a controlled environment is desired), an adjustable base (coupled to the build chamber, if provided), and a build material applicator for depositing build material above the build platform to create objects. That is, one or more peripheral regions, e.g., one or more outer portions of the build platform, are provided with flexibility to flex or curl as one or more object(s) cool and "pull" the build platform. The partial flexibility allows deformation due to thermal distortion of the build platform during the printing process, reducing stress in the final object. A less restrictive build platform can reduce stress at least in the lower part of the object, reducing the risk of stress-induced defects. Thus, the AM system can produce larger additively manufactured objects from materials that are prone to cracking. Additionally, partial flexibility can prevent damage to the build platform and / or base without overly complex configurations.

[0035] The embodiments of the present disclosure can be applied to any type of additive manufacturing system. Additive manufacturing techniques typically involve taking a three-dimensional computer aided design (CAD) file of the object to be formed, electronically slicing the object into layers, e.g., 18-102 micrometers thick, and creating a file with a two-dimensional image of each layer, including vectors, images, or coordinates. This file can then be loaded into a preparation software system that can interpret the file and allow the object to be built in various types of additive manufacturing systems.

[0036] In 3D printing, directed energy deposition (DED) techniques include, but are not limited to, using a focused heat source such as a laser, electron beam, or gas-tungsten arc to form a molten pool and adding one or more filler materials in powder or wire form to the molten pool. The DED process can follow a toolpath created directly from a CAD shape and builds up the part in successive layers. In certain aspects of the embodiment, DED can direct energy to a tight, concentrated area to heat the substrate and the molten material simultaneously. Every pass of the DED head can form a track from the solidified material and layers can be created by a continuous line of material.

[0037] In 3D printing, rapid prototyping (RP), and direct digital manufacturing (DDM) forms of additive manufacturing, layers of material are selectively dispensed, sintered, formed, deposited, etc. to form an object. In metal powder additive manufacturing techniques such as direct metal laser melting (DMLM), also known as selective laser melting (SLM), layers of metal powder are melted sequentially to form an object. More specifically, fine layers of metal powder are uniformly distributed using an applicator onto a build platform in the form of a metal powder bed, and then melted sequentially.

[0038] Alternatively and in addition, additive manufacturing processes and systems include, for example, but are not limited to, vat photopolymerization, powder bed fusion, binder jetting, material jetting, sheet lamination, material extrusion, directed energy deposition and hybrid systems. These processes and systems include, for example, but are not limited to: stereolithography apparatus (SLA); digital light processing (DLP); scan, spin, and selectively photocure (3SP), liquid interface manufacturing (CLIP), selective laser sintering (SLS), direct metal laser melting (DMLM), selective laser melting (SLM), electron beam melting (EBM), selective thermal sintering (SHS), multi-jet fusion (MJF), 3D printing, voxeljet, polyjet, smooth surface printing (SCP), multi-jet modeling projet (MJM), additive manufacturing (LOM), selective deposition modeling (SDL), ultrasonic additive manufacturing (UAM), fused filament fabrication (FFF), fused deposition modeling (FDM), laser metal deposition (LMD), laser engineered net shaping (LENS), direct metal deposition (DMD), hybrid systems, combinations of these processes and systems, as well as other additive manufacturing systems and processes now known or hereafter developed. (3SP); liquid interface production (CLIP); selective laser sintering (SLS); direct metal laser melting (DMLM);, or direct metal laser sintering (DMLS); selective laser melting (SLM);Electron beam melting (EBM); selective heat sintering (SHS); multi-jet fusion (MJF); 3D printing, voxeljet, polyjet; smooth curvatures printing (SCP); multi-jet modeling projet (MJM); laminated object manufacture (LOM); selective deposition lamination (SDL); ultrasonic additive manufacturing (UAM); fused filament fabrication (FFF); fused deposition modeling (FDM); laser metal deposition (LMD); laser engineered net shaping (LENS); direct metal deposition (DMD); hybrid systems; combinations of these processes and systems; and other additive manufacturing systems and processes now known or hereinafter developed. These processes and systems may include, for example, but are not limited to, all forms of electromagnetic radiation, heating, sintering, melting, curing, binding, consolidating, pressing, embedding, and combinations thereof.

[0039] Figure 1 shows a schematic cross-sectional view and Figure 2 shows a plan view of an additive manufacturing system 100 for building one or more objects 102. For purposes of explanation, reference is made to the additive manufacturing system 100, such as, but not limited to, a DED additive manufacturing system in the form of a computerized metal powder additive manufacturing system (hereinafter "AM system 100").

[0040] 1 and 2, an AM system 100 is generating an object 102 on an intermediate plate or build platform 104 (hereafter "build platform 104"). The AM system 100 can generate the object 102, which can include one large object or multiple objects 102, of which only a single layer is shown in FIG. 2. Although the object 102 is illustrated as a rectangular element, it is understood that the additive manufacturing process can be readily adapted to produce objects of any shape, a wide variety of objects, and multiple objects on the build platform 104.

[0041] In any event, the AM system 100 can include a build chamber 108 (particularly for additive manufacturing processes where a controlled environment is desired), a base, and a base 110 adjustably coupled to the build chamber 108 (if a build chamber is provided). The build chamber 108, if provided, can be positioned such that the Y and X directions are substantially coplanar with the build platform 104 and base 110, and the Z direction is substantially perpendicular to the build platform 104 and base 110. The build chamber 108 can provide a controlled atmosphere for printing the object 102, e.g., a set pressure and temperature for a laser, or a vacuum for electron beam melting.

[0042] The AM system 100 may include a build material deposition system 119 for depositing a build material 122 above the build platform 104 to create the object(s) 102. The build material deposition system 119 may include any now known or later developed material delivery system. In the example of a directed energy deposition (DED) system, the system 119 may include a build material applicator or build material applicator head 120 ("applicator 120") for depositing the build material 122 above the build platform 104 to create the one or more objects 102. In a metal powder application, the applicator 120 deposits a layer of material 122, i.e., above an underlying layer of the one or more objects 102. The applicator 120 delivers and smooths a new layer of metal powder build material 122 (FIG. 1).

[0043] Once a layer is formed, a welding system 123 welds a portion of the layer of material 122. In the exemplary AM system 100, the welding system 123 includes one or more high power melting beams, such as one or more 100 watt Ytterbium lasers 124, to melt or sinter a portion of the layer of build material 122, which can later be solidified to form the object 102. The laser 124 and / or the build platform 104 move in the XY direction. Once a layer of the object 102 is formed, the base 110 is lowered by a vertical adjustment system 134, which can also vertically adjust the position of other parts of the AM system 100 to accommodate the addition of each new layer. For example, after each layer is formed, the build platform 104 may be lowered and / or the build chamber 108 and / or the applicator 120 may be raised.

[0044] The adjustment system 134, such as a vertical adjustment system, a horizontal adjustment system, a combined vertical and horizontal adjustment system, and / or a combined vertical and horizontal adjustment system with rotational capabilities, may include any now known or later developed linear actuator for providing such adjustment, under the control of an AM control system 200 (FIG. 7) described elsewhere herein. The adjustment system 134 may be provided in an additive manufacturing system if desired, although additive manufacturing systems including DEDs may not benefit from an adjustment system 134 as described herein. Once lowered, the process is then repeated, beginning with the applicator 120 directing a layer of build material 122 across the now lowered one or more objects 102. The build platform 104 on the base 110 may be lowered for each subsequent two-dimensional layer, and the process is repeated until the object 102 is fully formed.

[0045] During formation, thermal stresses may be generated in one or more objects 102 during a build, which may be retained in the one or more objects 102 and / or applied to the build platform 104. In accordance with an embodiment of the present disclosure, the build platform 104 includes an intermediate region 140 and a periphery 143 of a peripheral region 142 that is fixedly and rigidly coupled to the base 110. The retained stresses may cause undesired deflection of the build platform 104, including deflection of the periphery 143 of the peripheral region 142 of the build platform 104. FIG. 1 illustrates the object 102 and the build platform 104 prior to deflection prevention, as embodied by the present disclosure. The build platform 104 may be adjustably coupled to the base 110.

[0046] The build platform 104 may be coupled to the base 110 by at least one flexure or separation limiter (hereinafter "separation limiter") to, for example, prevent the periphery 143 of the peripheral region 142 from flexing or separating away from the base 110. In one aspect embodied by the present disclosure, the at least one separation limiter includes a metallurgical connection 190 or weld 191.

[0047] In certain aspects of the embodiment, the metallurgical connection 190 includes at least one of a weld 191, a solder, a braze, or a solid connection for fixedly and rigidly coupling the periphery 143 of the peripheral region 142 to the base 110. Alternatively, or in addition, the metallurgical connection 190 includes at least one weld 191 for fixedly and rigidly coupling the periphery 143 of the peripheral region 142 to the base 110. In certain aspects of the embodiment, the at least one weld 191 can be disposed at the periphery 143 of the peripheral region 142 of the build platform 104 and extend onto the base 110. Thus, as embodied by the present disclosure, a metallurgical connection such as the at least one weld 191 can fixedly and rigidly couple the build platform 104 to the base 110 that is fixed to the periphery 143 of the peripheral region 142. Thus, the build platform 104 is always in direct contact with the base 110 at the periphery 143 of the peripheral region 142. Thus, the periphery 143 of the peripheral region 142 cannot move completely independently of the base 110.

[0048] According to certain aspects of the present disclosure, the metallurgical connection may include at least one weld 191 . Each of the at least one welds 191 may include at least one of a fusion weld, a tack weld, a metal inert gas (MIG) weld, a gas metal arc weld (GMAW), a tungsten inert gas (TIG) weld, a gas tungsten arc weld (GTAW), a stick-shielded metal arc weld (SMAW), a flux-cored-flux weld, an energy beam weld (EBW), an atomic hydrogen weld (AHW), a plasma arc weld, and combinations thereof. At least one weld 191 fixedly and rigidly couples the build platform 104 to the base 110, which is secured to the periphery 143 of the peripheral region 142. Further, as embodied by the present disclosure, the metallurgical connection 190 can include any weld now known or later developed, as well as any combination of welds 191.

[0049] In a further aspect of the present disclosure, the metallurgical connection 190 is a tack weld 191. While not limited to a tack weld 191, at least one weld can be secured to at least one side or edge (hereinafter "edge") 143 of the peripheral region 142. Alternatively, or in addition, the tack weld 191 can be secured to multiple edges 143 of the peripheral region 142. As embodied by the present disclosure, one or more welds 191 can be secured to each edge 143 of the peripheral region 142.

[0050] A metallurgical connection, such as but not limited to a weld 191, may be provided by the build material applicator 120 to fixedly and rigidly couple the build platform 104 to the base 110 secured to the periphery 143 of the peripheral region 142. In this case, the AM system 100 may provide the object cord 204O to cause the applicator 120 to form the metallurgical connection 190 between the base 110 and the build platform 104, i.e., as part of the object 102.

[0051] In additional aspects embodied by the present disclosure, the metallurgical connection 190 can include build material 122 for fixedly and rigidly coupling the build platform 104 to the base 110 secured to the periphery 143 of the peripheral region 142. Additionally, in another aspect of the present disclosure, the base 110 can be formed from a first material and the metallurgical connection 190, which can be at least one weld 191, can include the first material.

[0052] In use, as shown in FIGS. 1 and 3, one or more objects 102 are built on the build platform 104 using any additive manufacturing process, for example but not limited to DED or other additive manufacturing systems or processes. The base 110 is in direct contact with the build platform 104. As shown in FIG. 1, if the one or more objects 102 do not exert a force on the build platform 104 sufficient to deflect, the build platform 104 remains substantially flush with the base 110. However, if the objects 102 exert a force (F) on the build platform 104 sufficient to deflect, the build platform 104 may deflect at one or more peripheral regions 142 and lose direct contact with the base 110. However, the intermediate region 140 of the build platform 104 may remain in direct contact with the base 110 while remaining substantially flush with the base 110, as the objects 102 impart sufficient weight to the build platform 104 to maintain the intermediate region 140 of the build platform 104 in contact with the base 110.

[0053] The force required to cause the deflection and the location of the force can be customized to address any challenge, such as a fragile object 102, breaking of a build platform-base connection, etc. More specifically, the location, shape, size and / or number of the periphery 143 of the intermediate region 140 and the peripheral region 142 can be adjusted to address the build challenge depending on many factors. For example, as shown in FIG. 2, the object 102 to be built can have a dimension (D). In the example shown in FIG. 2 and FIG. 3, the periphery 143 of the peripheral region 142 is located below the outer edge 148 of the object 102.

[0054] A larger or greater number of peripheral regions 142 may be desirable when a crack-prone material is used for the object 102. In the example shown in FIG. 2, an intermediate region 140 extends the entire length (L) of the build platform 104, and two longitudinal (L) peripheral regions 142 sandwich the intermediate region 140. Here, a periphery 143 of the peripheral region 142 includes first opposing peripheral sides 142A, 142B disposed across the Y-axis of the build platform 104.

[0055] As shown in the plan views of Figures 3-5, the location, shape, size and / or number of the periphery 143 of the intermediate region 140 and / or the peripheral region 142 may vary widely. In the example of Figure 3, the intermediate region 140 is centered widthwise (W) and lengthwise (L) on the build platform 104, surrounding one periphery 143 of the peripheral region 142. Here, the periphery 143 of the peripheral region 142 includes a first opposing periphery side that lies across the Y axis of the build platform 104 and a second opposing periphery side that lies across the X axis of the build platform 104. In the example of Figure 4, the intermediate region 140 extends diagonally on the build platform 104, with the periphery 143 of the peripheral region 142 having two sides on either side of the intermediate region 140. Although specific examples of arrangements of the intermediate region(s) 140 and peripheral region(s) 142 have been provided, it is emphasized that a wide variety of arrangements are possible.

[0056] In FIG. 5, the build platform 104 is configured and connected to the base 110 to relieve the stress and constraint imposed by the base 110 on the object 102. The build platform 104 and base 110 configuration can thus enhance the reduction of the risk of thermal cracking by mitigating the thermal contraction of the object 102. Thus, as embodied by one aspect of the present disclosure, one location for fastening the build platform 104 to the base 110 can be an area close to the center of gravity defined by the axes X and Y of the base of the object 102 as illustrated in FIG. 5. The location of this centroid can be within the interface between the build platform 104 and the base 110. Thus, in a further aspect of the embodiment, a further effective way of fastening the build platform 104 to the base 110 is to provide a metallurgical connection 190 and perform welding, clamping, or bolting close to the intersection between the edge and the main axis of the build platform 104. This intersection point on the build platform 104 can correspond to the maximum moment of inertia of the base region of the object 102, which is illustrated at points C and D in FIG. 5).

[0057] Due to thermal deformation of the object 102 during the additive manufacturing process, the build platform 104 may experience a moderate upward deflection relative to the base 110 during the additive manufacturing process. Such deflection is often not significant enough to affect the additive manufacturing process. As embodied by the present disclosure, to limit the upward deflection of the build platform 104 relative to the base 110, a metallurgical connection 190 (as one or more separation limiters) can be added to a region of the build platform 104 to limit separation from the base 110. In certain aspects of the embodiments of the present disclosure, such a location may be proximate to point A or point B in FIG. 5. Points A and B are located proximate to the edge of the build platform 104 at the intersection with the principal axis X that corresponds to the minimum moment of inertia of the base of the object 102.

[0058] 6 illustrates a case where the base shape of the object 102 is rectangular. According to the method described above, the midpoint of the long side of the build platform 104 can be fixed to eliminate rigid body motion of the base 110 and eliminate thermal cracking due to deflection of the object 102. According to certain aspects of the embodiment, the midpoint of the long side of the build platform 104 can be fixed to the base 110. Fixing the build platform 104 to the base 110 can reduce or eliminate movement of the build platform 104 relative to the base 110. Alternatively or in addition, fixing the build platform 104 to the base 110 can reduce or eliminate thermal cracking of the object 102. The build platform 104 can be fixed to the base 110 at two or more points, for example, but not limited to, by a metallurgical connection 190 such as a weld.

[0059] Thus, in the embodiment of FIGS. 1-6, the peripheral region 142 is not permitted to flex to any significant degree due to the metallurgical connection 190 between the build platform 104 and the base 110.

[0060] Embodiments of the present disclosure may also include a method of additively manufacturing an object using the AM system 100 as described herein.

[0061] FIG. 7 is a schematic block diagram of an exemplary AM system 100. The AM system 100 of FIG. 7 generally includes a metal powder additive manufacturing control system 200 ("control system") and an AM printer 202. The control system 200 executes an object code 204O to generate the object 102 using one or more melt beam sources, e.g., lasers 124. The teachings of this disclosure are applicable to any melt beam source, e.g., electron beam, laser, etc. The control system 200 is shown implemented on a computer 206 as computer program code. To this extent, the computer 206 is shown including a memory 208 and / or storage system (storage system) 210, a processor unit (PU) 212, an input / output (I / O) interface 214, and a bus 216. Further, computer 206 is shown to communicate with external I / O devices / resources 220 and storage system 210. In general, processor unit (PU) 212 executes computer program code 204 stored in memory 208 and / or storage system 210. While executing computer program code 204, processor unit (PU) 212 can read and write data to memory 208, storage system 210, I / O devices 220 and / or AM printer 202. Bus 216 provides a communication link between each object in computer 206, and I / O devices 220 can comprise any device (e.g., keyboard, pointing device, display, etc.) that allows a user to interact with computer 206. Computer 206 is merely representative of various possible combinations of hardware and software. For example, processor unit (PU) 212 may be comprised of a single processing unit or may be distributed across one or more processing units on one or more locations, e.g., a client and a server. Similarly, memory 208 and / or storage system 210 may reside in one or more physical locations. Memory 208 and / or storage system 210 may be comprised of any combination of various types of non-transitory computer-readable storage media including magnetic media, optical media, random access memory (RAM), read-only memory (ROM), etc. Computer 206 may comprise any type of computing device, such as an industrial controller, a network server, a desktop computer, a laptop, a handheld device, etc.

[0062] As previously discussed, the AM system 100, and in particular the control system 200, executes the program code 204 to generate one or more objects 102, and in certain aspects of the embodiment, the program code 204 may include code to generate at least one metallurgical connection 190 between the build platform 104 and the base 110. The system 100 and the program code 204 direct the applicator 120 to create the at least one metallurgical connection 190 between the build platform 104 and the base 110. The creation of the at least one metallurgical connection 190 between the build platform 104 and the base 110 may occur prior to the start of additive manufacturing of the object 102. The at least one metallurgical connection 190 between the build platform 104 and the base 110 may be created by the applicator 120 during a step of additive manufacturing of the object 102, before deflection of the build platform 104 occurs and / or before stress occurs in the object 102 from being additively manufactured.

[0063] The program code 204 may include, among other things, a set of computer-executable instructions for operating the AM printer 202 or other system portions (referred to herein as "system code 204S"), and a set of computer-executable instructions defining one or more objects 102 to be physically produced by the AM printer 202 (referred to herein as "object code 204O"). As described herein, the additive manufacturing method begins with a non-transitory computer-readable storage medium (e.g., memory 208, storage system 210, etc.) that stores the program code 204. The system code 204S for operating the AM printer 202 may include any now known or later developed software code capable of operating the AM printer 202.

[0064] The object code 204O defining one or more objects 102 may include a precisely defined 3D model of the object and may be generated from any of a wide variety of well-known computer-aided design (CAD) software systems, such as AutoCAD®, TurboCAD®, DesignCAD 3D Max (AutoCAD®, TurboCAD®, DesignCAD 3D Max). In this regard, the object code 204O may include any file format now known or later developed. Furthermore, the object code 204O representing one or more objects 102 may be converted between different formats. For example, the object code 204O may include a Standard Tessellation Language (STL) file created for 3D Systems' stereolithography CAD program, or an Additive Manufacturing File (AMF), an American Society of Mechanical Engineers (ASME) standard that is an Extensible Markup Language (XML)-based format designed to allow any CAD software to describe the shape and configuration of any three-dimensional object to be manufactured by any AM printer. An object code 204O, representative of one or more objects 102, may also be converted to a set of data signals and transmitted, or received as a set of data signals and converted to code and stored, as desired. In either case, the object code 204O may be an input to the AM system 100 and may come from a part designer, an intellectual property (IP) provider, a design company, the operator, or owner of the AM system 100, or from other sources. In either case, the control system 200 executes the system code 204S and the object code 204O to divide the one or more objects 102 into a series of thin slices that are assembled using the AM printer 202 with successive layers of material.

[0065] One or more melt beam sources, such as lasers 124 , are configured to melt a layer of metal powder on the build platform 104 to produce the build 102 .

[0066] 7, the applicator 120 can create at least one metallurgical connection 190 between the build platform 104 and the base 110. The creation of the at least one metallurgical connection 190 between the build platform 104 and the base 110 can occur before the start of additive manufacturing of the object 102. The at least one metallurgical connection 190 between the build platform 104 and the base 110 can be created by the applicator 120 during a step of additive manufacturing of the object 102, but before deflection of the build platform 104 occurs and / or stress occurs in the object 102 from being additively manufactured.

[0067] The applicator 120 may also create a thin layer of material 122 that spreads as a blank canvas on which each successive slice of the final object is created. The applicator 120 may move under the control of a linear transport system 230. The linear transport system 230 may include any now known or later developed arrangement for moving the applicator 120. In one embodiment, the linear transport system 230 may include a pair of opposing rails 232, 234 that extend on opposite sides of the build platform 104 and a linear actuator 236, such as an electric motor, coupled to the applicator 120 for moving the applicator 120 along the rails 232, 234. The linear actuator 236 is controlled by the control system 200 to move the applicator 120. Other forms of linear transport systems may also be employed.

[0068] The applicator 120 may take a variety of forms. In one embodiment, the applicator 120 may include a body 238 configured to move along opposing rails 232, 234 and an actuator element (not shown in FIG. 7) in the form of a tip, blade or brush configured to spread metal powder evenly onto a previously formed layer of the build platform 104, i.e., the build platform 104 or one or more objects 102 to form a layer of raw material. The actuator element may be coupled to the body 238 using a holder (not shown) in any number of ways. The process may use different raw materials in the form of metal powder. The raw material may be supplied to the applicator 120 in a number of ways. In one embodiment shown in FIG. 7, a stock of raw material may be held in a raw material source 240 in the form of a chamber accessible by the applicator 120. In other arrangements, the material 122 may be delivered through the applicator 120, for example, through the body 238 in front of the applicator element and onto the build platform 104. In any event, an overflow chamber 241 may be provided on the far side of the applicator 120 to capture any overflow of feedstock that was not deposited onto the build platform 104.

[0069] In one embodiment, one or more objects 102 may be made of a metal, including a pure metal or an alloy. In one example, the metal may include substantially any non-reactive metal powder, i.e., a non-explosive or non-conductive powder, such as, for example, a cobalt chromium molybdenum (CoCrMo) alloy, stainless steel, a nickel-chromium-molybdenum-niobium alloy (NiCrMoNb) (e.g., Inconel 625 or Inconel 718), a nickel-chromium-iron-molybdenum alloy (NiCrFeMo) (e.g., Hastelloy X® available from Haynes International, Inc.), or a nickel-chromium-cobalt-molybdenum alloy (NiCrCoMo) (e.g., Haynes 282 available from Haynes International, Inc.). In another example, the metal may include virtually any metal, such as, but not limited to, tool steel (e.g., H13), titanium alloys (e.g., Ti6Al4V), stainless steel (e.g., 316L), cobalt chromium alloys (e.g., CoCrMo), and aluminum alloys (e.g., AlSi10Mg).

[0070] The atmosphere in the build chamber 108 can be controlled for the particular type of additive manufacturing and / or melt beam source used. For example, in the case of a laser 124, the build chamber 108 can be filled with an inert gas, such as argon or nitrogen, and controlled to minimize or eliminate oxygen. Here, the control system 200 is configured to control the flow of an inert gas mixture 242 in the build chamber 108 from an inert gas source 244 (if provided). In this case, the control system 200 can control a pump 246 and / or a flow valve system 248 for the inert gas to control the content of the gas mixture 242. The flow valve system 248 can include one or more computer-controllable valves, flow sensors, temperature sensors, pressure sensors, etc., that can precisely control the flow of a particular gas. The pump 246 can be provided with or without the valve system 248. If the pump 246 is omitted, the inert gas can simply enter a conduit or manifold before being introduced into the build chamber 108. The source of inert gas 244 may take the form of any conventional source for the materials contained therein, such as a tank, reservoir, or other source. Any sensors (not shown) necessary to measure the gas mixture 242 may be provided. The gas mixture 242 may be filtered using a filter 250 in a conventional manner. Alternatively, in the case of an electron beam, the build chamber 108 may be controlled to maintain a vacuum. Here, the control system 200 may control a pump 246 to maintain the vacuum, and the flow valve system 248, the inert gas source 244, and / or the filter 250 may be omitted. Any sensors (not shown) necessary to maintain the vacuum may be employed.

[0071] An adjustment system 134 may be provided to adjust the position of various parts of the AM printer 202 to accommodate the addition of each new layer, for example, the build platform 104 may lower after each layer and / or the chamber 108 and / or the applicator 120 may rise. The adjustment system may provide vertical adjustment, horizontal adjustment, a combination of vertical and horizontal adjustment, and rotational adjustment with vertical adjustment, horizontal adjustment, and / or a combination of vertical and horizontal. The adjustment system 134 may include any linear actuator now known or later developed to provide such adjustment under the control of the control system 200.

[0072] In operation, the build platform 104 having metal powder thereon is provided within the build chamber 108 (if provided, as described above), and the control system 200 controls the atmosphere within the build chamber 108. The control system 200 also controls the AM printer 202, and in particular the applicator 120 (e.g., linear actuator 236) and the melt beam source (e.g., laser 124), to sequentially melt layers of metal powder on the build platform 104 to produce one or more objects 102, in accordance with an embodiment of the present disclosure.

[0073] As previously mentioned, various parts of the AM printer 202 may move vertically via adjustment system 134 to accommodate the addition of each new layer, e.g., the build platform 104 may lower and / or the chamber 108 and / or applicator 120 may rise after each layer. When one or more objects 102 tend to exert a force F on one or more peripheral regions 142 of the build platform 104 (FIG. 1), the one or more peripheral regions 142 of the build platform 104 are restrained from deflecting upward by metallurgical connections 190 configured to fixedly and rigidly couple the periphery 143 of the peripheral regions 142 to the base 110. Meanwhile, the intermediate regions 140 remain in direct contact with the base 110 due in part to the weight of the objects 102 on the build platform. It is emphasized that although a particular AM system is described herein, the teachings of the present disclosure are applicable to a wide variety of additive manufacturing processes other than DMLM.

[0074] The embodiments of the AM system 100 allow the development of large additive objects that may have high thermal stress during the additive manufacturing process and by reducing the stress, may normally crack, thus improving productivity and / or part yield. The system embodied by the present disclosure also allows the production of larger additively manufactured objects with one or more materials that are possibly more prone to cracking. The flex limiters provided are located in the build platform, i.e., in a protected manner, rather than above, below, or between the build platform and the base. The build platform 104 and / or base 110 of the AM system 100 of FIGS. 8-11 provide flex limiting and restricting features that reduce the stress in the additively manufactured object 102, thus improving productivity and / or part yield by reducing the stress therein.

[0075] As embodied by the present disclosure, the metallurgical connections 190 may be provided to limit upward deflection and / or separation of the build platform 104 relative to the base 110. In a further aspect of an embodiment of the present disclosure, one or more separation limiters may be added to a region of the build platform 104 to limit deflection and / or separation of the build platform 104 relative to the base 110.

[0076] 8A and 8B show schematic front and top views of one or more separation restrictor(s) 290. In one aspect of the embodiment, the separation restrictor(s) 290 is integrated into the base 110. The separation restrictor 290 includes a first leg 292 that extends a first distance d from the base 110. The distance d is greater than the height of the build platform 104. The separation restrictor 290 also includes a second leg 294 that extends from the first leg 292, parallel to the base 110, and above the build platform 104. Thus, the second leg 294 limits the deflection, deflection, and / or separation of the build platform 104 relative to the base 110 as the build platform 104 flexes, deflects, and / or separates from the base 110 during an additive manufacturing process.

[0077] 9 shows a schematic front view of an alternative embodiment of a flexible base having a restrictor configuration 390 for restricting separation. The restrictor configuration 390 can be incorporated to restrict deflection and / or separation of the build platform 104 relative to the base 110. The separation restrictor 390 includes at least one slot 392 formed in the base 110, thus forming the build platform 104'. The at least one slot 392 may be cut into the base 110 such that the stiffness of the base 110 is reduced. Thus, over-constraints that induce cracks in the object 102 are substantially alleviated during manufacturing purchasing the at least one slot 392 that deflects as described herein.

[0078] The at least one slot 392 includes a first slot 394 and a second slot 396. The first slot 304 extends generally parallel to the base 110 from beneath the object 102 being formed by additive manufacturing. The second slot 396 extends from the first slot 394 to a surface of the base 110 on which the object 102 is built. Thus, as embodied by this aspect of the disclosure, the first slot 394 and the second slot 396 combine to form a build platform 104' from the base 110. The build platform 104' thus includes cantilevered portions 105 extending from a central support portion 107. 9 having a build platform 104′ including a cantilevered portion 105 and a central support portion 107 may allow deflection of the build platform 104′ due to the mass of the object 102 in a “downward” direction CF opposite to the deflection caused by additive manufacturing induced forces F (FIG. 1). Thus, in accordance with this aspect of the embodiment, the deflection-limiting configuration of FIG. 9 may avoid or reduce stresses in the object 102.

[0079] As illustrated in FIG. 10, the object 102 can be formed with a reduced interface area 492 between the object 102 and an underlying portion of the base 110. As embodied by the present disclosure, FIG. 10 illustrates a further alternative embodiment of a flexible base having a restrictor feature 490 for limiting separation. The restrictor feature 490 can be incorporated into the object 102 during additive manufacturing to limit deflection and / or separation relative to the base 110. In accordance with FIG. 10, the control system 200 executes the object code 204O (FIG. 7) to generate the one or more objects 102 having a base 102' of the object 102 with reduced solid connections at the reduced interface area 492. In certain non-limiting aspects of the embodiments, the base 102 of the one or more objects 102 can be formed in any programmable shape to provide reduced solid connection areas. In certain aspects, the reduced solid connection areas 492 can be a uniform shape. The reduced solid connection regions 492 can include a variety of configurations. For example, and not intended to be limiting of embodiments, the reduced solid connection regions 492 of the object 102 can include arched or curved voids, triangular reduced solid connection regions 494, polygonal reduced solid connection regions 495, and / or other configurations of reduced solid connection regions now known or hereafter developed.

[0080] Another further approach for additively manufacturing an object 102 and suppressing flexing, deflection, and / or separation of the object 102 relative to the base 110 is illustrated in FIG. 11. As illustrated in FIG. 11, manufacturing the object 102 includes a sequential formation of the object 102. The first manufacturing step is additively manufacturing a vertical strip 1 of the object 102 on the base 110. With reference to FIG. 11, a control system 200 executes the object code 204O (FIG. 7) to generate the part (FIGS. 1-8, 11). The control system 200 executes the object code 204O (see FIG. 7) to rotate the base 110 by 90° or 180°. Manufacturing of the object 102 continues by additively manufacturing and depositing material on the lateral surfaces of the vertical strip 1 in a sequential manner.

[0081] In FIG. 11, the numbers on the portions of object 102 indicate the order of manufacture of the corresponding portions of object 102. As shown, the portions of object 102 in FIG. 11 are on opposite sides of vertical elongated portion 1. Thus, a 180° rotation of base 110 occurs after each portion (1-5) of object 102 has been deposited in the desired portion to create object 102. Additionally, portion 6 may be added after a 90° rotation of base 110 to allow for the desired construction of object 102, as indicated by object code 204O.

[0082] This additive manufacturing process of FIG. 11 can provide relief of the crack-inducing over-constraint between the base 110 and the object 102 as a single vertical, elongated portion 1 of the object 102 in contact with the base 110. As embodied by the present disclosure, the object 102 can be formed in multiple configurations enabled by the additive manufacturing process. Additionally, the additive manufacturing process of FIG. 11 takes advantage of the advantages of DED AM. For example, the DED AM additive manufacturing process allows for rotation of the base 110 during additive manufacturing. In other additive manufacturing processes, including but not limited to powder-bed additive manufacturing, it is difficult or impossible to enable rotation of the additive manufacturing system, including the build plate or base.

[0083] FIG. 12 shows a block diagram of a rectangular additively manufactured object on a build platform and base with an elongated metallurgical connection between the build platform and the base according to an embodiment of the present disclosure. In FIG. 12, the base shape of the object 102 is rectangular. According to the method described above, the midpoint of the long side of the build platform 104 should be fixed to eliminate rigid body motion of the base 110 and eliminate thermal cracking due to deflection of the object 102. According to certain aspects of the embodiment, the midpoint of the long side of the build platform 104 can be fixed to the base 110. The build platform 104 can be fixed to the base 110 at two or more points by elongated metallurgical connections 190, for example, but not limited to welding. Fixing the build platform 104 to the base 110 can reduce or eliminate movement of the build platform 104 relative to the base 110. Alternatively or additionally, fixing the build platform 104 to the base 110 can reduce or eliminate thermal cracking of the object 102.

[0084] FIG. 13 shows a further block diagram of a rectangular additively manufactured object on a build platform and a base with metallurgical connections disposed below the build platform and between the build platform and the base according to an embodiment of the present disclosure. In FIG. 13, the base shape of the object 102 is rectangular. According to the method described above, the midpoint of the long side of the build platform 104 should be fixed to remove rigid body motion of the base 110 and to eliminate thermal cracking due to deflection of the object 102. According to the FIG. 13 aspect of the embodiment, a slot 199 can be formed in the build platform 104. The slot 199 is illustrated in FIG. 13 as being located in the center of the build platform 104. However, as embodied by the present disclosure, the slot 199 can be located anywhere on the build platform 104 where the weld 191 can hold and secure the object 102 to the build platform 104 to reduce or eliminate movement.

[0085] FIG. 14 illustrates a block diagram of a rectangular additively manufactured object on a build platform and base with a metallurgical connection between the build platform and the base, according to an embodiment of the present disclosure. FIG. 14 illustrates the case where the base shape of the object 102 is rectangular. According to the method described above, the midpoint of the long side of the build platform 104 can be fixed to eliminate rigid body motion of the base 110 and eliminate thermal cracking due to deflection of the object 102. According to an aspect of the embodiment, a slot 199 can be formed in the build platform 104 in the FIG. 14 aspect of the embodiment. The slot 199 is illustrated in FIG. 14 as being located in the center of the build platform 104. However, as embodied by the present disclosure, the slot 199 can be located anywhere on the build platform 104. As embodied by the present disclosure, the embodiment of FIG. 14 includes at least one peg or protrusion 195 located on the build platform 104. At least one protrusion 195 is configured in a shape and orientation to prevent rotation of object 102 on build platform 104 as object 102 is formed and undergoes any thermal deformation in the additive manufacturing process.

[0086] 14 , the at least one protrusion 195 can be disposed on the build platform 104, and the object 102 can be additively manufactured around the at least one protrusion 195. In accordance with another aspect of the disclosure, the at least one protrusion 195 can be disposed within a slot 199 provided in the build platform 104. In accordance with another aspect of the disclosure, the at least one protrusion 195 can be formed by an additive manufacturing process prior to the formation of the object. Alternatively, the at least one protrusion 195 can be formed and attached to the build platform 104 separate from the additive manufacturing process of the embodiments.

[0087] 14, the at least one protrusion 195 is illustrated as an ellipsoid and a polygonal (triangle) peg or protrusion. These configurations will prevent rotation of the object 102 relative to the build platform 104. As embodied by the present disclosure, the at least one protrusion 195 as a polygon can be formed as any polygon having any number of sides.

[0088] With respect to the protrusion 195, multiple protrusions 195 can be provided to prevent rotation of the object 102 on the build platform 104 as the object 102 is formed and undergoes any thermal deformation in the additive manufacturing process. If multiple protrusions 195 are provided, the protrusions 195 can be formed as a circular protrusion, as two or more circular protrusions will prevent rotation of the object 102 relative to the build platform 104.

[0089] The aforementioned figures show some of the processes involved according to some embodiments of the present disclosure. The acts indicated in the figures or description may occur out of the order indicated, or may in fact be performed substantially simultaneously or in reverse order, depending, for example, on the acts involved. Approximate terms used throughout this specification and claims may be applied to modify any quantitative expression that may be permissibly changed without resulting in a change in the basic function to which it relates. Thus, values ​​modified by terms such as "about," "approximately," "substantially," and the like are not limited to the exact values ​​specified. In at least some instances, approximating expressions may correspond to the precision of an instrument for measuring the value. Throughout this specification and claims, range limitations may be combined and / or interchanged. Such ranges are specified and include all subranges contained therein, unless the context or language indicates otherwise. "Substantially" as applied to a particular value in a range applies to both end values ​​and may indicate ±5% of the stated value, unless dependent on the precision of the instrument for measuring the value.

[0090] Corresponding structures, materials, acts, and equivalents of all means or step-plus-function elements in the following claims are intended to include any structure, material, or act for performing a function in combination with other claimed elements as specifically claimed. The description of the present disclosure has been presented for purposes of illustration and description, but is not intended to be exhaustive or limiting of the disclosure in the disclosed form. Many modifications and variations will be apparent to those skilled in the art without departing from the scope and spirit of the present disclosure. The embodiments were chosen and described in order to best explain the principles and practical application of the disclosure, and to enable those skilled in the art to understand the disclosure in various embodiments with various modifications as suited to the particular use contemplated. [Explanation of symbols]

[0091] 100: Additive manufacturing system 102: Object 104: Intermediate plate / build platform 105: Cantilever section 107: Central support section 108: Build chamber 110: Base 119: Build material deposition system 120: Applicator 122: Metal powder build material 123: Welding system 124: Ytterbium laser 134: Adjustment system 140: Intermediate region 142: Peripheral region 143: Peripheral region periphery 190: Metallurgical connection 191: Weld 195: Peg / protrusion 199: Slot 200: AM control system 202: AM printer 204: Computer program code 204S: System code 204O: Object code 206: Computer 208: Memory 210: Storage system 212: Processor unit 214: Input / output (I / O) interface 216: Bus 220: Input / Output (I / O) device 230: Linear transport system 232, 234: Rail 236: Linear actuator 238: Body 240: Feed source 241: Overflow chamber 242: Inert gas mixture 244: Inert gas 246: Pump 248: Flow valve system 250: Filter 290: Separation restrictor 292: First leg 294: Second leg 390, 490: Separation restrictor arrangement 392: Slot 394: First slot 396: Second slot 492: Interface region 494, 495: Solid connection region

Claims

1. An additive manufacturing (AM) system (100), comprising an adjustable base (110), a shaping platform (104) including a peripheral region (142) and a periphery (143) of the peripheral region, wherein the peripheral portion is fixedly and rigidly coupled to the base and an intermediate region, and a metallurgical connection (190) fixedly and rigidly couples the periphery (143) of the peripheral region (142) to the base (110), the shaping platform (104); a build material applicator (120) for depositing a build material (122) above the shaping platform (104) for shaping an object (102); An AM system comprising the above.

2. The AM system according to claim 1, wherein the metallurgical connection (190) includes at least one of welding (191), soldering, brazing, or solid connection for fixedly and rigidly coupling the periphery (143) of the peripheral region (142) to the base (110).

3. The AM system according to claim 1, wherein the metallurgical connection (190) includes at least one weld (191) for fixedly and rigidly coupling the periphery (143) of the peripheral region (142) to the base (110).

4. The at least one weld (191) is at least one of fusion welding, tack welding, metal inert gas (MIG) welding, gas metal arc welding (GMAW), tungsten inert gas (TIG) welding, stick shielded metal arc welding (SMAW), flux-cored flux welding, energy beam welding (EBW), atomic hydrogen welding (AHW), plasma arc welding, and combinations thereof, for fixedly and rigidly coupling the periphery (143) of the peripheral region (142) to the base (110). The AM system according to claim 3.

5. The AM system according to claim 3, wherein the at least one weld (191) includes tack welding.

6. The AM system according to claim 1, wherein the metallurgical connection (190) is provided by the build material applicator (120) for fixedly and rigidly coupling the periphery (143) of the peripheral region (142) to the base (110).

7. The AM system according to claim 6, wherein the metallurgical connection part (120) includes a build material (122) for fixedly and rigidly connecting the periphery (143) of the peripheral region (142) to the base (110).

8. The AM system according to claim 1, wherein the base (110) includes a first material and the metallurgical connection part (190) includes the first material.

9. The AM system according to claim 1, wherein the build material applicator (120) for depositing the build material (122) deposits the build material (122) by at least one of direct metal laser melting, direct metal laser sintering, selective laser melting, and directed energy deposition.

10. The AM system according to claim 1, wherein the periphery (143) of the peripheral region (142) includes a first opposing periphery crossing the X-axis of the shaping platform (104) and a second opposing periphery crossing the Y-axis of the shaping platform (104), and the metallurgical connection part (190) is arranged on at least one of the X-axis and the Y-axis.

11. The AM system according to claim 10, wherein the metallurgical connection part (190) is arranged on the X-axis and the Y-axis.

12. An additive manufacturing (AM) system (100), an adjustable base (110), a shaping platform (104) including a peripheral region (142) and a periphery (143) of the peripheral region, wherein the periphery is fixedly and rigidly connected to the base by a metallurgical connection part (190) configured to fixedly and rigidly connect the periphery (143) of the peripheral region (142) to the base (110), the shaping platform (104), a build material applicator (120) for depositing a build material (122) above the shaping platform (104) to shape an object (102), and an AM system comprising the same.

13. The AM system according to claim 12, wherein the metallurgical connection part (190) includes at least one of welding (190), soldering, brazing, or solid connection for fixedly and firmly connecting the periphery (143) of the peripheral region (142) to the base (110).

14. The AM system according to claim 12, wherein the metallurgical connection part (190) includes at least one welding part (191) for fixedly and rigidly connecting the periphery (143) of the peripheral region (142) to the base (110).

15. The AM system according to claim 14, wherein the at least one welding part (190) includes at least one of fusion welding, tack welding, metal inert gas (MIG) welding, gas metal arc welding (GMAW), tungsten inert gas (TIG) welding, stick shielded metal arc welding (SMAW), AM system, flux-cored flux welding, energy beam welding (EBW), atomic hydrogen welding (AHW), plasma arc welding, and is for fixedly and rigidly connecting the periphery (143) of the peripheral region (142) to the base (110).

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