Direct metal laser printed gas manifold

Abstract

A gas manifold for a single-nozzle deposition chamber, comprising: a base having an upper and lower surface defining a thickness; a primary nozzle having an inlet and an outlet extending through the thickness of the base; and a secondary nozzle having an inlet extending partially through the upper surface of the base and at least one channel extending a certain distance from the side wall of the base, which is in fluid communication with the inlet of the secondary nozzle. The inlet of the primary nozzle has a hollow projection extending from the upper surface of the base into the gas supply section. The channel of the secondary nozzle includes a bend between the side wall of the base and the outlet, configured to pass between a first direct energy source and a second direct energy source, the first and second energy sources being located on the upper wall of the chamber.

Description

Technical Field

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

Background Art

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

[0003] The deposition process takes place within an inert deposition chamber that includes a direct energy source, a gas nozzle, and a build fixture. In a laser powder bed fusion (LPBF) system, powder is spread across a build fixture having a recoater assembly, a build platform, and a powder reservoir. During deposition of an additional layer onto the target object, the recoater assembly sweeps the powder across the target object and the build platform, while the gas nozzle supplies an inert sweep gas into the chamber to prevent weld spatter from redepositing onto the target object or the build plate. The inert sweep gas also reduces particulate interference with the laser path of the direct energy source when the direct energy source generates an energy beam that melts, sinters, or otherwise joins the feedstock material onto the target part. The target part is at least partially suspended or supported within the build fixture, and the energy beam is generated across the build fixture to join the powder material to the target part.

[0004] The deposition chamber may include a single direct energy source or multiple direct energy sources. The direct energy sources are positioned above the construction fixture and oriented to cover the target area of ​​the construction fixture. The deposition chamber may include a single gas nozzle or multiple gas nozzles to uniformly distribute gas over the construction fixture. In some embodiments, the deposition chamber includes a single centrally located gas nozzle. In other embodiments, the deposition chamber may include multiple gas nozzles to cover a larger target area. Single-nozzle configurations may suffer from variations in deposition or sweep uniformity and gas delivery. Multiple-nozzle configurations can provide better deposition or sweep uniformity and gas delivery than single-nozzle configurations, but multiple-nozzle configurations are generally more complex and have more failure modes. Therefore, there is a need to improve deposition and sweep uniformity, as well as gas delivery, in single-nozzle additive manufacturing system configurations. [Prior art documents] [Patent Documents]

[0005] [Patent Document 1] U.S. Patent Application Publication No. 2017 / 0087635 [Overview of the project]

[0006] In one embodiment, a gas manifold for use in an additive manufacturing system is disclosed. The gas manifold has a base whose thickness is defined between its top and bottom surfaces. The gas manifold further includes a primary nozzle having an inlet and an outlet extending through the thickness of the base. The inlet of the primary nozzle is in fluid communication with the inlet of the chamber of the additive manufacturing system. The gas manifold further includes a secondary nozzle having an inlet extending partially through the top surface of the base and at least one channel extending a certain distance from the side wall of the base. The channel includes an outlet, and the channel is in fluid communication with the inlet of the secondary nozzle. The inlet of the secondary nozzle is in fluid communication with the inlet of the chamber.

[0007] In another embodiment, an additive manufacturing system is disclosed. The additive manufacturing system includes a chamber having a top wall and a gas supply section extending through the top wall, and at least one direct energy source located in the top wall. The direct energy source guides an energy beam that bonds powder material to a target part placed in the chamber. The additive manufacturing system further includes a gas manifold having a base whose thickness is defined between its top and bottom surfaces. The gas manifold further includes a primary nozzle having an inlet and an outlet extending through the thickness of the base. The inlet of the primary nozzle is in fluid communication with the inlet of the chamber of the additive manufacturing system. The gas manifold further includes a secondary nozzle having an inlet extending partially through the top surface of the base and at least one channel extending a certain distance from the side wall of the base. The channel includes an outlet, and the channel is in fluid communication with the inlet of the secondary nozzle. The inlet of the secondary nozzle is in fluid communication with the inlet of the chamber. The upper surface of the base of the gas manifold abuts against the upper wall of the chamber, and the gas supply section is in fluid communication with the primary nozzle and the secondary nozzle.

[0008] In yet another embodiment, a method for forming a gas manifold for use in an additive manufacturing system is disclosed. The method includes the step of forming a base having a thickness defined between its top and bottom surfaces. The method further includes the step of forming a primary nozzle having an inlet and an outlet extending through the thickness of the base. The inlet of the primary nozzle is in fluid communication with the inlet of the chamber. The method also includes the step of forming a secondary nozzle having an inlet extending partially through the top surface of the base. The secondary nozzle further has at least one channel extending a certain distance from the side wall of the base having an outlet. The channel is in fluid communication with the inlet of the secondary nozzle, and the inlet of the secondary nozzle is in fluid communication with the inlet of the chamber.

[0009] The subject matter of this disclosure is described in more detail below with reference to exemplary embodiments shown in the accompanying drawings. [Brief explanation of the drawing]

[0010] [Figure 1]This is a cross-sectional view of an exemplary additive manufacturing system including a gas manifold. [Figure 2] This is a bottom view of the additive manufacturing system shown in Figure 1, along the cross-sectional line A-A'. [Figure 3] This is an enlarged detailed cross-sectional view of detail B of the additive manufacturing system in Figure 1. [Figure 4] Figure 1 is a perspective view of the gas manifold. [Figure 5] Figure 1 is a perspective view of a secondary nozzle used with the gas manifold. [Modes for carrying out the invention]

[0011] The reference numerals used in the drawings and their meanings are listed in a summary format in the reference numeral list. As a general rule, identical parts are given the same reference numeral in the drawings.

[0012] In the following specification and claims, several terms are used with the following meanings:

[0013] As used herein, the singular forms “a,” “an,” and “the” include plural references unless the context specifically indicates otherwise. The terms “comprising,” “including,” and “having” are intended to be comprehensive and to mean that there may be additional elements other than those listed. The terms “any” or “optionally” mean that the event or situation described thereafter may or may not occur, and that the description includes both the case in which the event occurs and the case in which it does not.

[0014] Unless otherwise specified, approximate terms used herein, such as “generally,” “substantially,” and “about,” indicate that the terms thus modified may apply only to an approximate degree as recognized by those skilled in the art, and not to an absolute or complete degree. Therefore, values ​​modified with terms such as “approximately,” “about,” and “substantially” are not limited to the exact values ​​specified. In at least some examples, approximate terms may correspond to the precision of instruments used to measure values. Hereinafter, and throughout this specification and the claims, limits to the scope may be specified. Such scopes are combinatorial and / or interchangeable and include all sub-scopes contained herein unless otherwise indicated by context or wording.

[0015] Furthermore, unless otherwise indicated, terms such as “First,” “Second,” etc., are used solely as labels in this specification and do not impose any order, position, or hierarchical requirements on the items referred to by these terms. Moreover, a reference to an item “Second,” for example, does not require or exclude the existence of an item “First” or a lower-numbered item, or an item “Third” or a higher-numbered item.

[0016] The methods, systems, and apparatus described herein overcome at least some of the shortcomings of known additive manufacturing systems. More specifically, the systems and apparatus described herein improve the uniformity of gas flow delivery in a single-nozzle additive manufacturing system configuration by utilizing a gas manifold having a primary nozzle and a secondary nozzle without modifying the deposition chamber. The primary and secondary nozzles are oriented to supply gas from a single inlet and distribute the gas within the deposition chamber. The fluid channels of the gas manifold include one or more bends between the inlet and outlet so as not to interfere with the operation of the direct energy source of the deposition chamber.

[0017] Referring to Figure 1, in an exemplary embodiment, the additive manufacturing system 100 is a laser-powered bed fusion (LPBF) system. In an alternative embodiment, the additive manufacturing system 100 is any other suitable additive manufacturing system, but is not limited to, one of the following: direct metal laser melting (DMLM) systems, selective laser sintering (SLS) systems, direct metal laser deposition (DMLD) systems, powder coating additive manufacturing systems, and / or laser cususing systems. Figure 1 shows a cross-sectional view of the deposition chamber 110. Figure 2 shows a bottom view of the deposition chamber 110 along line A-A'.

[0018] In an exemplary embodiment, the additive manufacturing system 100 includes a construction fixture assembly 120, a direct energy source 130 located within the deposition chamber 110, and a gas delivery system 140. Furthermore, in an exemplary embodiment, the direct energy source 130 includes four heads 134 arranged in a matrix on the upper wall 112 of the deposition chamber. The four heads 134 are centrally located relative to the inlet 142 of the gas delivery system 140. In some embodiments, the direct energy source 130 includes at least two heads. In some embodiments, the direct energy source 130 includes four or more heads 134.

[0019] As shown in Figure 1, the construction fixture assembly 120 includes a construction plate 129 oriented within the construction fixture 120 and positioned to support one or more target parts 102. The construction fixture assembly 120 further includes a powder reservoir 122 that provides a continuous supply of powder material 124. During the deposition cycle, a powder platform 126 raises the powder material 124, and a recoater 128 scatters the raised powder material 124 over the target parts 102. As the layers are deposited, the construction plate 129 lowers the target parts 102, but there is excess powder material 124 above and in the adjacent volume of the construction plate 129.

[0020] The inert gas 106 (shown as a flow vector) is supplied into the deposition chamber 110 via the gas delivery system 140, supplied onto the build fixture 120, and sweeps welding spatter particles and soot particles during the deposition cycle. During the deposition cycle, the direct energy source 130 generates an energy beam 132 via a scanner system that selectively directs the energy beam 132 at a generally preselected scan speed across one or more target parts 102 and the build fixture 120 such that the direct energy beam 132 sinters or more generally joins the powder material 124 onto the build layer 104 of the target part 102. The direct energy beam 132 is sufficient to fuse a preselected area of the build layer 104 immediately below the build layer 104.

[0021] In an exemplary embodiment, the inlet 142 is a tube or cylindrical structure having a height H and a diameter D1 (shown in FIG. 3). The inert gas 106 is supplied into the deposition chamber 110 via a nozzle disposed within the deposition chamber 110. In at least some known embodiments, a single nozzle configuration can result in a non-uniform distribution of the inert gas 106 around the build fixture 120 such that welding spatter particles or soot particles remain, resulting in variations in deposition uniformity. The variations can result in an undesired level of porosity when additional layers are melted onto the build layer 104 over subsequent deposition cycles. As will be described in more detail below, the gas manifold 200 described herein can replace the single nozzle in a single nozzle configuration without the need to modify other components of the additive manufacturing system 100.

[0022] FIG. 4 shows a perspective view of the gas manifold 200, FIGS. 1 and 3 show side views of the gas manifold 200 disposed within the deposition chamber, and FIG. 2 shows the gas manifold 200 oriented with respect to the four heads 134 of the direct energy source 130. In an exemplary embodiment, the gas manifold 200 has both a primary nozzle 220 and a secondary nozzle 250 to which an inert gas 106 is supplied from an inlet 142 of the gas delivery system 140. The primary nozzle 220 and the secondary nozzle 250 are in fluid communication with the inlet 142 of the gas delivery system 140 and distribute the inert gas 106 across a plurality of outlets, as will be described in more detail below. As a result, the manifold 200 facilitates the uniformity of the deposition of the inert gas 106 and the improvement of gas delivery across the construction fixture assembly 120.

[0023] The gas manifold 200 includes a base 210 having a top surface 212 and a bottom surface 214. The top surface 212 and the bottom surface 214 define a thickness t1 of the base 210 (shown in FIG. 3). The primary nozzle 220 includes an inlet 222 and an outlet 224 that extend through the thickness t1 of the base 210. As shown in FIG. 2, in an exemplary embodiment, the outlet 224 of the primary nozzle 220 has an elliptical, slit-shaped, or substantially circular shape and is configured to supply the inert gas 106 across the construction fixture assembly (shown in FIG. 1). In an alternative embodiment, the outlet 224 can have any other shape that allows the nozzle 200 to function as described herein. In some embodiments, the inlet 222 of the primary nozzle includes a hollow protrusion 226 that extends from the top surface 212 of the base 210. The secondary nozzle 250 includes an inlet 252 that extends partially through the top surface 212 of the base 210 and at least one channel 260 that is in fluid communication with the inlet 252 and extends from the sidewall of the base 210. The at least one channel 260 includes an outlet 254 that is oriented to spray or distribute the inert gas 106 across the construction fixture assembly (shown in FIG. 1).

[0024] As best shown in Figures 3 and 4, the inlets 222 of the primary nozzle 220 and 252 of the secondary nozzle 250 are circular in shape and concentrically aligned with respect to each other. In alternative embodiments, the inlets 222 of the primary nozzle 220 and 252 of the secondary nozzle 250 may have any shape or orientation that allows them to function as described herein. On the upper surface 212 of the base, the inlet 222 of the primary nozzle 220 has a diameter D3 smaller than the diameter D4 of the inlet 252 of the secondary nozzle 250.

[0025] The upper surface 212 of the base 210 abuts against the upper wall 112 of the deposition chamber 110 so that both the inlet 222 of the primary nozzle 220 and the inlet 252 of the secondary nozzle 250 are in fluid communication with the inlet 142 of the gas delivery system 140. In embodiments in which the primary nozzle 220 includes a hollow projection 226 extending from the upper surface 212 of the base, the hollow projection 226 extends a certain distance into the inlet 142 of the gas delivery system 140 so that the hollow projection 226 captures a portion of the inert gas 106 as it is injected into the deposition chamber 110 through the inlet 142 of the gas delivery system 140. In some embodiments, the projection 226 tapers inward from the base 210. The projection 226 has an end 228 facing the base 210. The end portion 228 has a diameter D2 that is smaller than the diameter D3 of the inlet 222 of the primary nozzle 220 at the base 210. The diameter D2 of the end portion 228 of the projection 226 is smaller than the diameter D1 of the gas supply portion. The end portion 228 of the projection 226 is located at a distance L1 from the edge 141 of the inlet 142 of the gas delivery system 140. In an exemplary embodiment, the inlet 142 has a substantially cylindrical shape that can be coupled to a hose or coil.

[0026] This is because the diameter D2 of the end 228 of the projection 226 is smaller than the diameter D1 of the inlet 142. The inert gas 106 supplied by the inlet 142 can flow to both the primary nozzle 220 and the secondary nozzle 250. The ratio of the size of the end 228 of the projection 226 to the diameter D1 of the gas supply can vary depending on the desired amount of inert gas 106 to be delivered to the primary nozzle 220 and the secondary nozzle 250. In some embodiments, the ratio of the diameter D2 of the end 228 of the projection 226 to the diameter D1 of the inlet 142 is in the range of 1:10 to 9:10. In alternative embodiments, the ratio of the diameter D2 of the end 228 of the projection 226 to the diameter D1 of the inlet 142 can have any ratio that allows the primary nozzle 220 and the secondary nozzle 250 to function as described herein.

[0027] In some embodiments, the cross-sectional area of ​​the inlet 142 decreases from the upper surface 212 of the base 210 toward the end 228 of the projection 226 due to the taper of the projection 226. This reduction in cross-sectional area results in a higher static pressure of the inert gas 106 at the inlet 252 of the secondary nozzle compared to the static pressure at the end 228 of the projection 226. As will be described in more detail below, the inert gas 106 moving through the secondary nozzle 250 requires additional static pressure for at least one channel 260 between the inlet 252 and outlet 254 of the secondary nozzle 250. Similarly, in some embodiments, as best shown in Figure 3, the taper of the projection 226 also results in a decrease in the static pressure of the primary nozzle 220 to allow the primary nozzle 220 and the secondary nozzle 250 to move a desired amount of inert gas 106.

[0028] As shown in Figures 1 to 4, the inlet 252 of the secondary nozzle 250 is in fluid communication with at least one channel 260 extending from the side wall 216 of the base 210. In some embodiments, the gas manifold 200 includes two channels 260a and 260b, each having the same characteristics as channel 260. Channel 260 is located between two heads 134 and extends over a length L3 (shown in Figure 2) defining the X-X' axis. Furthermore, channel 260 extends by length L3 so that a first bend 262 of channel 260 does not interfere with the operation of the heads 134. In exemplary embodiments, the first bend 262 extends substantially perpendicular to the X-X' axis and substantially parallel to the Y-Y' axis. At the base 210, the Y-Y' axis is perpendicular to X-X'. In exemplary embodiments, the first bend 262 extends by a length L4 to the second bend 264 such that the first bend 262, the second bend 264, and the channel 260 do not generally interfere with the operation of the head 134. The second bend 264 extends substantially perpendicular to the first bend 262 and substantially parallel to the Y-Y' axis. In some embodiments, the outlet 254 of the secondary nozzle 250 extends by at least a length L3 from the second bend 264 such that the outlet 254 of the secondary nozzle 250 lies on the same axis X-X' as the outlet 224 of the primary nozzle 220. The first bend 262 is substantially perpendicular to at least one channel 260 extending from the base 210, and the second bend 264 is substantially perpendicular to the first bend 262. In other words, at least one channel 260 forms a U-shape or semicircle such that the outlet 254 of the secondary nozzle 250 lies on the same axis X-X' as the outlet 224 of the primary nozzle 220. Alternatively, in some embodiments, at least one channel 260 does not have a bend. Furthermore, in some embodiments, the outlet 254 of the secondary nozzle 250 extends from the base 210 by a length L3. In alternative embodiments, the first bend 262 and the second bend 264 may have any shape or orientation that allows the channel 260 to function as described herein.

[0029] As best shown in Figures 2 and 5, the outlet 254 of the secondary nozzle 250 includes a plurality of flow expansion channels 270, each flow expansion channel 270 having a first end 272 and a second end 274. The flow expansion channels 270 are oriented as gas diffusers, and the first end 272 has a cross-sectional area 278 smaller than the cross-sectional area 279 of the second end 274. The first end 272 of each flow expansion channel 270 is in fluid communication with channel 260, and the second end 274 of each expansion channel 270 is oriented as the outlet 254 of the secondary nozzle 250.

[0030] As shown in Figure 4, in some embodiments, the gas manifold 200 includes a support structure 202 that connects the outlet 254 of the secondary nozzle 250 to the base 210. In some embodiments, the upper surface 261 of the channel 260 includes a plurality of standoffs 266 extending from the upper surface 261. The standoffs 266 abut against the upper wall 112 of the deposition chamber 110 and provide structural rigidity to at least one channel 260.

[0031] The embodiments described above overcome at least some of the shortcomings of known methods for repairing parts. Specifically, the embodiments improve the uniformity of gas delivery in a single-nozzle additive manufacturing system configuration by utilizing a gas manifold having a primary nozzle and a secondary nozzle without modifying the deposition chamber to distribute the gas. The primary and secondary nozzles are oriented to supply gas from a single inlet and distribute the gas within the deposition chamber. The fluid channels of the gas manifold include one or more bends between the inlet and outlet so as not to interfere with the operation of the direct energy source of the deposition chamber. The gas manifold described herein can replace a single nozzle in a single-nozzle configuration without requiring modification of other components of the additive manufacturing system.

[0032] The methods, systems, and compositions disclosed herein are not limited to the specific embodiments described herein. Rather, steps of the methods, elements of the systems, and / or elements of the compositions can be used independently of other steps and / or elements described herein. For example, the methods, systems, and compositions are not limited to implementation in the rotating machinery described herein. Rather, the methods, systems, and compositions can be implemented and used in connection with many other applications.

[0033] Specific features of various embodiments are shown in some drawings, and not in others, but this is merely for convenience. Furthermore, the reference to “one embodiment” in the above description is not intended to be construed as excluding the existence of additional embodiments that also incorporate the described features. According to the principles of this disclosure, any feature in the drawings may be referenced and / or claimed in combination with any feature in any other drawing.

[0034] This specification uses several embodiments, including best modes, to enable those skilled in the art to carry out the disclosure, including the manufacture and use of any apparatus or system and the execution of any related methods. The patentable scope of this disclosure is defined by the claims and may include other embodiments that a person skilled in the art could conceive. Such other embodiments are intended to be within the claims if they have structural elements that do not differ from the language of the claims, or if they include equivalent structural elements that do not substantially differ from the language of the claims.

[0035] Further aspects of the present invention are provided by the subject matter of the following clauses.

[0036] A gas manifold for use in an additive manufacturing system, comprising: a primary nozzle having a base whose thickness is defined between its top and bottom surfaces, and an inlet and outlet extending through the thickness of the base, the inlet of the primary nozzle being in fluid communication with the inlet of a chamber; and a secondary nozzle having at least one channel extending a certain distance from the side wall of the base, having an inlet that partially extends through the top surface of the base, and an outlet, the channel being in fluid communication with the inlet of the secondary nozzle, the inlet of the secondary nozzle being in fluid communication with the inlet of a chamber.

[0037] 2.1 The gas manifold described in the preceding paragraph, wherein the outlet of the primary nozzle has one of the shapes of elliptical, slit, and circular.

[0038] 3. A gas manifold according to any one of Clauses 1 to 2, wherein the inlet of the secondary nozzle has a substantially circular shape and is substantially concentrically oriented with respect to the inlet of the primary nozzle, the inlet of the secondary nozzle has a substantially circular shape, and the diameter of the inlet of the primary nozzle is smaller than the diameter of the inlet of the secondary nozzle.

[0039] 4.1 The gas manifold according to any one of clauses 1 to 3, wherein the inlet of the primary nozzle has a projection extending from the upper surface of the base.

[0040] 5. A gas manifold according to any one of clauses 1 to 4, wherein the projection tapers inward from the base such that the end of the projection is smaller than the diameter of the inlet of the primary nozzle at the base.

[0041] 6. The gas manifold according to any one of Clauses 1 to 5, wherein the upper surface of the base is in contact with the upper wall of the chamber, and the chamber has a gas supply section extending through the upper wall of the chamber that is in fluid communication with a primary nozzle and a secondary nozzle, and the projection extends a certain distance into the gas supply section.

[0042] 7. A gas manifold as described in any one of clauses 1 to 6, wherein the diameter of the end of the protruding part is smaller than the diameter of the gas supply part.

[0043] 8. A gas manifold as described in any one of clauses 1 to 7, wherein the ratio of the diameter of the end of the projection to the diameter of the gas supply section is in the range of 1:10 to 9:10.

[0044] 9.2 A gas manifold according to any one of the clauses 1 to 8, wherein at least one channel of the secondary nozzle includes at least one bend defined between the base side wall and the outlet.

[0045] 10. A gas manifold according to any one of the clauses 1 to 9, wherein at least one bend is one of a U-shape and a semicircle.

[0046] 11. A gas manifold according to any one of clauses 1 to 10, wherein at least one bend extends between a first direct energy source and a second direct energy source, and the first and second energy sources are located on the upper wall of the chamber.

[0047] 12.2 A gas manifold according to any one of the clauses 1 to 11, wherein at least one channel of the secondary nozzle includes a first bend and a second bend, the first bend being perpendicular to at least one channel, the second bend being perpendicular to the first bend, and the outlet of the secondary nozzle extends a certain distance from the second bend.

[0048] 13.2 The gas manifold according to any one of Clauses 1 to 12, wherein the outlet of the secondary nozzle includes a plurality of flow channels, each of which has a first end and a second end, the first end having a smaller cross-sectional area than the second end.

[0049] 14. A additive manufacturing system comprising: a chamber comprising an upper wall, a gas supply unit extending through the upper wall, and at least one direct energy source located in the upper wall, the direct energy source guiding an energy beam for bonding powder material onto a target part located in the chamber; a gas manifold comprising a secondary nozzle comprising a base having an upper and lower surface defining a thickness, a primary nozzle having an inlet and an outlet extending through the thickness of the base, and at least one channel extending a certain distance from the side wall of the base having an inlet that partially penetrates the upper surface of the base, and an outlet, the at least one channel being in fluid communication with the inlet of the secondary nozzle, wherein the upper surface of the base abuts against the upper wall of the chamber, and the gas supply unit is in fluid communication with the primary nozzle and the secondary nozzle.

[0050] 15.1 The system described in the preceding paragraph, wherein the inlet of the primary nozzle has a hollow projection extending from the upper surface of the base.

[0051] 16. The system according to any one of clauses 14 to 15, wherein the projection tapers inward from the base, and the projection has an end opposite the base, the end having a diameter smaller than the diameter of the inlet of the primary nozzle at the base.

[0052] 17. The system described in any one of clauses 14 to 16, wherein the projection extends a certain distance into the gas supply section.

[0053] 18. The system according to any one of the clauses 14 to 17, wherein at least one channel of the secondary nozzle includes a first bend and a second bend, the first bend being perpendicular to at least one channel, the second bend being perpendicular to the first bend, and the outlet of the secondary nozzle extends a certain distance from the second bend.

[0054] 19. The system according to any one of clauses 14 to 18, wherein the first bend and the second bend are arranged to pass between the first direct energy source and the second direct energy source.

[0055] 20. A method for forming a gas manifold for use in an additive manufacturing system, comprising: forming a base having a top and bottom surface that define its thickness between them; forming a primary nozzle having an inlet and an outlet extending through the thickness of the base, the inlet of the primary nozzle being in fluid communication with the inlet of a chamber; and forming a secondary nozzle having at least one channel extending a certain distance from the side wall of the base having an inlet and an outlet that partially extends through the top surface of the base, the channel being in fluid communication with the inlet of the secondary nozzle, the inlet of the secondary nozzle being in fluid communication with the inlet of a chamber. [Explanation of Symbols]

[0056] 100 Additive Manufacturing Systems 102 Target parts 104 Construction Layer 106 Inert gas 110 Deposition Chamber 112 Upper wall 120 Construction Fixture Assembly 120 Construction Fixtures 122 Powder Reservoir 124 Powder materials 126 Powder Platform 128 Ricohta 129 Construction Plate 130 Energy Sources 132 Energy beams 134 heads 140 Gas Delivery Systems 141 Edge 142 Entrance 200 Gas Manifold 200 Manifold 202 Support structure 210 base 212 Top surface 214 Bottom 216 Side wall 220 Primary Nozzle 222 Entrance 224 Exit 226 Protrusion 226 Hollow protrusion 228 End 250 Secondary Nozzle 252 Entrance 254 Exit 260 channels 260a channel 261 Top surface 262 First bending section 264 Second bend 266 Standoff 270 Expansion Channels 272 First end 274 Second end 278 Cross-sectional area 279 Cross-sectional area

Claims

1. A gas manifold (200) for use in an additive manufacturing system (100), A base (210) whose thickness is defined between the upper surface (212) and the bottom surface (214), A primary nozzle (220) having an inlet (222) and an outlet (224) extending through the thickness of the base (210), wherein the inlet (222) of the primary nozzle (220) is in fluid communication with the inlet (142) of the chamber (110), A gas manifold (200) comprising a secondary nozzle (250), the secondary nozzle (250) having an inlet (252) that extends partially through the upper surface (212) of the base (210) and an outlet (254), the secondary nozzle (250) having at least one channel (260) that extends a certain distance from the side wall (216) of the base (210), the channel (260) being in fluid communication with the inlet (252) of the secondary nozzle (250), and the inlet (252) of the secondary nozzle (250) being in fluid communication with the inlet (142) of the chamber (110).

2. The gas manifold (200) according to claim 1, wherein the outlet (224) of the primary nozzle (220) has one of the shapes of an ellipse, a slit, and a circle.

3. The gas manifold (200) according to claim 1, wherein the inlet (252) of the secondary nozzle (250) has a substantially circular shape that is substantially concentrically oriented with respect to the inlet (222) of the primary nozzle (220), the inlet (252) of the secondary nozzle (250) has a substantially circular shape, and the diameter of the inlet (222) of the primary nozzle (220) is smaller than the diameter of the inlet (252) of the secondary nozzle (250).

4. The gas manifold (200) according to claim 1, wherein the inlet (222) of the primary nozzle (220) has a projection (226) extending from the upper surface (212) of the base (210).

5. The gas manifold (200) according to claim 4, wherein the projection (226) tapers inward from the base (210) such that the end (228) of the projection (226) is smaller than the diameter of the inlet (222) of the primary nozzle (220) of the base (210).

6. The gas manifold (200) according to claim 5, wherein the upper surface (212) of the base (210) is in contact with the upper wall (112) of the chamber (110), the chamber (110) has a gas supply section extending through the upper wall (112) of the chamber (110) that is in fluid communication with the primary nozzle (220) and the secondary nozzle (250), and the protrusion (226) extends a certain distance into the gas supply section.

7. The gas manifold (200) according to claim 6, wherein the diameter of the end portion (228) of the protruding portion (226) is smaller than the diameter of the gas supply portion.

8. The gas manifold (200) according to claim 7, wherein the ratio of the diameter of the end portion (228) of the projection (226) to the diameter of the gas supply portion is in the range of 1:10 to 9:

10.

9. The gas manifold (200) according to claim 1, wherein the at least one channel (260) of the secondary nozzle (250) includes at least one bend defined between the side wall (216) of the base (210) and the outlet (254).

10. The gas manifold (200) according to claim 9, wherein the at least one bent portion is one of a U-shape and a semicircle.

11. The gas manifold (200) according to claim 9, wherein the at least one bent portion extends between a first direct energy source and a second direct energy source, and the first and second energy sources are located on the upper wall (112) of the chamber (110).

12. The gas manifold (200) according to claim 1, wherein the at least one channel (260) of the secondary nozzle (250) includes a first bend (262) and a second bend (264), the first bend (262) being perpendicular to the at least one channel (260), the second bend (264) being perpendicular to the first bend (262), and the outlet (254) of the secondary nozzle (250) extending a certain distance from the second bend (264).

13. The gas manifold (200) according to claim 1, wherein the outlet (254) of the secondary nozzle (250) includes a plurality of flow channels (260), each of the flow channels (260) having a first end (272) and a second end (274), the first end (272) having a smaller cross-sectional area than the second end (274).

14. Additive manufacturing system (100), A chamber (110) comprising an upper wall (112), a gas supply section extending through the upper wall (112), and at least one direct energy source (130) disposed on the upper wall (112), wherein the direct energy source (130) guides an energy beam for bonding powder material onto a target component (102) disposed within the chamber (110), A gas manifold (200), A base portion (210) having an upper surface (212) and a lower surface (214) that define the thickness, A primary nozzle (220) having an inlet (222) and an outlet (224) extending through the thickness of the base (210), A secondary nozzle (250) comprising: an inlet (252) extending partially through the upper surface (212) of the base (210); and at least one channel (260) extending a certain distance from the side wall (216) of the base (210) having an outlet (254), the channel (260) being in fluid communication with the inlet (252) of the secondary nozzle (250), wherein the secondary nozzle (250) comprises: A system (100) comprising a gas manifold (200), the upper surface (212) of the base (210) abuts against the upper wall (112) of the chamber (110), and the gas supply unit is in fluid communication with the primary nozzle (220) and the secondary nozzle (250).

15. The system (100) according to claim 14, wherein the inlet (222) of the primary nozzle (220) has a hollow projection (226) extending from the upper surface (212) of the base (210).

16. The system (100) according to claim 15, wherein the projection (226) tapers inward from the base (210), the projection (226) has an end (228) opposite to the base (210), and the end (228) has a diameter smaller than the diameter of the inlet (222) of the primary nozzle (220) at the base (210).

17. The system (100) according to claim 15, wherein the protruding portion (226) extends a certain distance into the gas supply section.

18. The system (100) according to claim 14, wherein the at least one channel (260) of the secondary nozzle (250) includes a first bend (262) and a second bend (264), the first bend (262) being perpendicular to the at least one channel (260), the second bend (264) being perpendicular to the first bend (262), and the outlet (254) of the secondary nozzle (250) extending a certain distance from the second bend (264).

19. The system according to claim 19, wherein the first bend (262) and the second bend (264) are arranged to pass between the first direct energy source and the second direct energy source.

20. A method for forming a gas manifold (200) for use in an additive manufacturing system (100), The steps include forming a base (210) whose thickness is defined between the upper surface (212) and the bottom surface (214), A primary nozzle (220) having an inlet (222) and an outlet (224) extending through the thickness of the base (210), wherein the inlet (222) of the primary nozzle (220) is in fluid communication with the inlet (142) of the chamber (110), A method comprising the step of forming a secondary nozzle (250), the secondary nozzle (250) having an inlet (252) extending partially through the upper surface (212) of the base (210) and an outlet (254), wherein the channel (260) is in fluid communication with the inlet (252) of the secondary nozzle (250) and the inlet (252) of the secondary nozzle (250) is in fluid communication with the inlet (142) of the chamber (110).

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