Additive manufacturing systems and methods for using additive manufacturing systems

Abstract

SOLUTION: An additive manufacturing system comprises a powder material handling system comprising a virgin powder inlet. The virgin powder inlet is coupled to a virgin powder drum and configured to receive a virgin powder from the virgin powder drum. The additive manufacturing system further comprises a liquid material handling system comprising a binder inlet. The binder inlet is coupled to a binder drum and configured to receive a binder from the binder drum. The additive manufacturing system also comprises an additive manufacturing machine coupled to the powder material handling system and the liquid material handling system. The additive manufacturing machine receives the virgin powder and the binder from the powder material handling system and the liquid material handling system and is configured to produce a work product using the virgin powder and the binder.SELECTED DRAWING: Figure 1

Description

[Technical Field]

[0001] The present specification relates generally to additive manufacturing systems and methods of using the same. [Background technology]

[0002] Additive manufacturing devices often require building materials, such as powders and binders, to be loaded into the additive manufacturing machine. The additive manufacturing machine can then use the building materials to fabricate a work product. After the work product is fabricated, the work product and excess building materials may be removed from the additive manufacturing machine. In many conventional additive manufacturing systems, building materials can be manually loaded into the additive manufacturing machine. Similarly, in many conventional additive manufacturing systems, excess building materials can also be manually removed from the additive manufacturing machine. This is time-consuming and prone to material handling errors. Material handling errors can be particularly problematic when the building materials are reactive or contain solvent binders. Furthermore, such manual loading and unloading can expose the building materials and / or excess building materials to the open environment. This exposure can cause contamination with oxygen or debris, which can reduce the quality and effectiveness of the building materials. Summary of the Invention [Means for solving the problem]

[0003] One aspect of the present disclosure is an additive manufacturing system (100) including a powder material handling system (170) coupled to a virgin powder drum (182) and including a virgin powder inlet (174) configured to receive virgin powder from the virgin powder drum (182); a liquid material handling system (120) coupled to a binder drum (128) and including a binder inlet (124) configured to receive binder from the binder drum (128); and an additive manufacturing machine (110) coupled to the powder material handling system (170) and the liquid material handling system (120) and configured to receive the virgin powder from the powder material handling system (170) and the binder from the liquid material handling system (120), wherein the additive manufacturing machine (110) is configured to manufacture a work product using the virgin powder and the binder. [Brief explanation of the drawings]

[0004] [Figure 1] FIG. 1 schematically depicts an exemplary additive manufacturing system including a liquid material handling system, a powder material handling system, a de-powdering system, and an additive manufacturing machine. [Figure 2A] FIG. 2A depicts a perspective view of an exemplary additive manufacturing system including a liquid material handling system and an additive manufacturing machine according to one or more embodiments shown and described herein. [Figure 2B] FIG. 2B depicts a top view of the liquid materials handling system of FIG. 2A according to one or more embodiments shown and described herein. [Figure 3] FIG. 3 depicts a perspective view of an exemplary additive manufacturing system including a powder material handling system, a de-powdering system, and an additive manufacturing machine according to one or more embodiments shown and described herein. [Figure 4] FIG. 4 depicts a top view of the powder material handling system of FIG. 3 according to one or more embodiments shown and described herein. [Figure 5] FIG. 5 schematically illustrates example internal components of a control system for an additive manufacturing system according to one or more embodiments shown and described herein. [Figure 6] FIG. 6 illustrates a flow diagram of an exemplary operation of an additive manufacturing apparatus according to one or more embodiments shown and described herein. DETAILED DESCRIPTION OF THE INVENTION

[0005] The embodiments illustrated in the drawings are exemplary in nature and are not intended to limit the subject matter defined by the claims. The following detailed description of exemplary embodiments can be understood when read in conjunction with the following drawings, in which like structure is indicated with like reference numerals and in which:

[0006] Additional features and advantages of the present disclosure will be set forth in the detailed description which follows, and in part will be apparent to those skilled in the art from that description, or may be learned by practicing the embodiments described herein, including the detailed description which follows the claims and the accompanying drawings.

[0007] It is to be understood that both the foregoing general description and the following detailed description are intended to describe various embodiments and provide an overview or framework for understanding the nature and features of the claimed subject matter. The accompanying drawings are included to provide a further understanding of the various embodiments, and are incorporated into and constitute a part of this specification. The drawings illustrate various embodiments described herein, and together with the description, explain the principles and operation of the claimed subject matter.

[0008] Various embodiments of the apparatus, assemblies, and methods will now be described in detail, as illustrated in the accompanying drawings. Wherever possible, the same reference numbers will be used throughout the drawings to refer to the same or like parts. One embodiment of an additive manufacturing system 100 includes an additive manufacturing machine 110, shown generally in FIG. 1 . The additive manufacturing machine 110 includes a powder material handling system, a de-powdering system, and a liquid material handling system. The additive manufacturing machine 110 receives virgin powder from the powder handling system and a binder from the liquid handling system and produces a work product using the virgin powder and binder. Various embodiments of additive manufacturing apparatuses and methods of using the same will be described in further detail herein, with particular reference to the accompanying drawings.

[0009] Directional terms used herein, e.g., up, down, right, left, front, back, top, bottom, etc., refer only to the figures as drawn and are not intended to imply absolute orientation unless otherwise specified.

[0010] Unless otherwise expressly stated, it is never intended that any method described herein be construed as requiring that its steps be performed in a particular order or as requiring any particular orientation of any device. Thus, where a method claim does not actually recite the order in which its steps are to be followed, or an apparatus or assembly claim does not actually recite an order or orientation for individual components, or unless otherwise specifically stated in the claim or specification that the steps are to be limited to a particular order or no particular order or orientation for the components of the apparatus or assembly is recited, no order or orientation is intended to be inferred in any respect. This applies to any possible implicit basis for interpretation, including matters of logic regarding the arrangement of steps, operational flow, component order, or component orientation, plain meaning derived from grammatical organization or punctuation, and the number or type of embodiments described herein.

[0011] As used herein, the singular forms "a," "an," and the like include plural referents unless the context clearly dictates otherwise. Thus, for example, reference to "one" element includes aspects having two or more such elements unless the context clearly dictates otherwise.

[0012] Additive manufacturing devices utilize building materials, such as powders and binders, by loading the materials into an additive manufacturing machine for use in additive manufacturing. The additive manufacturing machine then uses the building materials to produce work products. Furthermore, large amounts of materials are utilized for additive manufacturing to run print cycles to build the work products, and even larger quantities are required to support rapid changeover for the production of multiple work products. In current additive manufacturing machines, these materials are pumped into intermediate containers to be manually filled into the machine reservoir. However, intermediate containers are not ideal for several reasons.

[0013] First, manual loading of building materials such as powders and binders is time-consuming and prone to material handling errors. Material handling errors can be particularly problematic when the building materials are reactive or contain solvent binders. Additionally, such manual loading and unloading can expose the building materials and / or excess building materials to the atmosphere. Furthermore, this exposure can cause contamination by oxygen or debris, potentially reducing the quality and effectiveness of the building materials.

[0014] The present invention relates to a powder material handling system, a de-powdering system, and a liquid material handling system, each coupled to an additive manufacturing machine so that the machine can receive powder and binder materials and manufacture work products using virgin powder and binder. Together, these systems reduce the duration required for the additive manufacturing process by enabling automated transfer of components such as binders and cleaners. Furthermore, the precision involved in additive manufacturing processes is improved by transferring these elements in a manner that avoids contamination. Safety is also improved by providing a closed system for reactive components such as solvents, reducing the potential for exposure.

[0015] Referring to FIG. 1 , an additive manufacturing system 100 is shown schematically. The additive manufacturing system 100 includes an additive manufacturing machine 110. The additive manufacturing machine 110 may be, but is not limited to, a binder jet printer, an electron beam manufacturing (EBM) system, a laser manufacturing system, or the like. For simplicity, the present invention discusses the additive manufacturing machine 110 as a binder jet printer, but it should be understood that any other device or system may be used. The additive manufacturing machine 110 may be configured to additively manufacture a workpiece by depositing powder and applying a binder. The additive manufacturing machine 110 may include a recoater arm (not shown) for depositing the powder and may include one or more nozzles (not shown) for depositing the binder onto the powder. The binder may interact with a portion of the powder, e.g., a portion of the powder in contact with the binder, to form a solid material. The powder not in contact with the binder may remain in powder form.

[0016] Additive manufacturing system 100 also includes a liquid material handling system 120, a powder material handling system 170, and may include a de-powdering system 200 in which loose powder is removed from the three-dimensional work product. Additive manufacturing machine 110 is fluidly coupled to liquid material handling system 120, powder material handling system 170, and may also be coupled to de-powdering system 200. In this manner, additive manufacturing machine 110 can transfer elements such as inert gases and waste liquids to liquid material handling system 120, while liquid material handling system 120 can transfer binders and cleaners to additive manufacturing machine 110.

[0017] Similarly, the additive manufacturing machine 110 can transfer the inert gas and recovered powder to the powder material handling system 170, which in turn transfers powder for the additive manufacturing machine 110 to build the work product. A de-powdering system 200 may also be fluidly coupled to the powder material handling system 170 and the additive manufacturing machine 110. In this manner, the de-powdering system 200 receives the work product from the additive manufacturing machine 110, and the de-powdering system 200 then transfers the recovered powder to the powder material handling system 170. Further details are provided in the following paragraphs.

[0018] Referring to FIG. 2A , a portion of an additive manufacturing system is shown, including a liquid material handling system 120 and an additive manufacturing machine 110. The liquid material handling system 120 can include a liquid station 122. Generally, the liquid station 122 is a self-contained environment that can include, for example, pipes, valves, meters, pressure regulators, flanges, and other components and equipment for performing additive manufacturing processes. The liquid station 122 includes a binder inlet 124 through which a binder can be received into the liquid station 122. The liquid station 122 can further include a binder outlet 126 through which the binder can exit the liquid station 122. The liquid station 122 can include at least one pump for delivery and at least one pump for extraction. For example, in the embodiment of FIG. 2A , a first pump 401 and a second pump 402 can provide delivery and extraction. Fluid station 122 also includes one or more valves 403 , which, along with first pump 401 and second pump 402 , can control the flow of binder through binder inlet 124 and binder outlet 126 .

[0019] The liquid material handling system 120 includes a binder drum 128 that can contain new or unused binder. The binder can be used in additive manufacturing processes to build work products. During the build process, the binder is selectively deposited onto a powder bed, binding areas together to form one layer at a time. The materials used can be metals, sand, and ceramics in granular form.

[0020] The binder drum 128 may be fluidly coupled to the binder inlet 124 via a first binder pipe 130. The binder outlet 126 may be fluidly coupled to the additive manufacturing machine 110 via a second binder pipe 132. Such couplings, the first pump 401, and / or the second pump 402 can enable flow from the binder drum 128, through the first binder pipe 130, into the liquid station 122, and through the second binder pipe 132 into the additive manufacturing machine 110. In this manner, the additive manufacturing machine 110 can receive binder from the liquid material handling system 120 at the inlet region 115. Within the additive manufacturing machine 110, the binder is delivered to one or more nozzles (not shown) of the additive manufacturing machine 110, which can deposit the binder onto the powder.

[0021] In some embodiments, the binder drum 128, the first binder pipe 130, the liquid station 122, the second binder pipe 132, and the additive manufacturing machine 110 may be connected in an airtight manner. As used herein, an "airtight manner" is a means of preventing gases (e.g., air) from escaping or passing through the drums, inlets, outlets, pipes, pumps, valves, and systems of an additive manufacturing system. For example, the liquid station 122 may include seals or other connections that prevent gases from leaking or entering the various pipes, valves, pumps, etc. This may be beneficial in some embodiments because it can reduce the risk of binder contamination (e.g., introduction of environmental contaminants into the binder). Furthermore, in embodiments in which the binder is flammable or chemically reactive, the use of sealing components can minimize interaction of the binder with any atmospheric or chemical materials external to the liquid material handling system 120, particularly materials that may cause combustion when combined with the binder.

[0022] 2A , the additive manufacturing machine 110 can receive a cleaner from the liquid material handling system 120. The cleaner may be a liquid cleaner for washing or flushing one or more nozzles of the additive manufacturing machine 110. In some embodiments, the liquid station 122 can include a cleaner inlet 134 through which the cleaner can be received within the liquid station 122 and a cleaner outlet 136 through which the binder can exit the liquid station 122. The liquid station 122 can include a first pump 401 and a second pump 402 and one or more valves 403 that can control the flow of the cleaner through the cleaner inlet 134 and the cleaner outlet 136.

[0023] The liquid material handling system 120 may include a cleaner drum 138 that can house a cleaner. The cleaner drum 138 may be fluidly coupled to a cleaner inlet 134 via a first cleaner pipe 140. The cleaner outlet 136 may be fluidly coupled to the additive manufacturing machine 110 via a second cleaner pipe 142. Such a coupling may allow a flow of cleaner from the cleaner drum 138, through the first cleaner pipe 140, into the liquid station 122, and through the second cleaner pipe 142 into the additive manufacturing machine 110. In this manner, the additive manufacturing machine 110 can receive the cleaner from the liquid material handling system 120. A cleaner may be provided to the additive manufacturing machine 110 so that the cleaner can clean or wash one or more nozzles within the additive manufacturing machine 110.

[0024] In some embodiments, the additive manufacturing machine 110 can purge used liquid cleaner. Accordingly, in some embodiments, the liquid station 122 can include a waste inlet 146 through which waste liquid can be received within the liquid station 122 and a waste outlet 144 through which waste liquid can exit the liquid station 122. The liquid material handling system 120 can include a waste drum 148 that can contain used liquid cleaner used to clean, flush, or prevent clogging or damage to one or more nozzles. The waste drum 148 can be fluidly coupled to the waste outlet 144 via a first waste pipe 150. The additive manufacturing machine 110 can be fluidly coupled to the waste inlet 146 via a second waste pipe 152. Such a coupling can allow used cleaner to flow from the additive manufacturing machine 110, through the second waste pipe 152, into the liquid station 122, through the first waste pipe 150, and into the waste drum 148. In this manner, the waste drum 148 can receive waste liquid from the additive manufacturing machine 110. The fluid station 122 can include a first pump 401 and a second pump 402 and one or more valves 403 that can control the flow of waste fluid through the waste inlet 146 and the waste outlet 144 .

[0025] In some embodiments, the additive manufacturing machine 110 may be coupled to a gas supply 300. Specifically, the additive manufacturing machine 110 may be airtightly coupled to the gas supply 300 such that no gas may enter the additive manufacturing machine 110 and gas from the gas supply 300 may be the only gas within the additive manufacturing machine 110. The gas supply 300 may include an inert gas, such as nitrogen. Thus, in some embodiments, the additive manufacturing machine 110 may not include air, but instead may include only an inert gas. This may be beneficial in some embodiments as it may prevent contamination of or reaction with the binder.

[0026] 2B , the additive manufacturing machine 110 may be coupled to the binder drum 128 via a binder pipe 302. Specifically, the binder pipe 302 may be airtightly fluidly coupled to the binder drum 128 and the liquid station 122 via a binder gas outlet 301. The additive manufacturing machine 110 may be fluidly coupled to a gas inlet 310 via a gas pipe 320. Such a coupling may allow gas to flow from the additive manufacturing machine 110, through the gas pipe 320, into the liquid station 122, and through the binder gas pipe 302 into the binder drum 128. In this manner, the binder drum 128 can receive gas from the additive manufacturing machine 110. The liquid station 122 may include a first pump 401 (not shown), a second pump 402 (not shown), and one or more valves 403 (not shown) that can control the flow of gas through the gas inlet 310 and the binder gas outlet 301. Thus, as binder is removed from binder drum 128 via first binder pipe 130, inert gas is drawn into binder drum 128 via binder pipe 302. In other words, the inert gas can fill the vacuum created by removing binder from binder drum 128.

[0027] As described above, the binder drum 128, the first binder pipe 130, the liquid Station 122, the second binder pipe 132, and the additive manufacturing machine 110 may be airtightly connected. Thus, in some embodiments, the binder can be transferred from the binder drum 128 to the additive manufacturing machine 110 without coming into contact with air and without air being introduced into the binder drum 128.

[0028] In some such embodiments, the additive manufacturing machine 110 may be coupled to the cleaner drum 138 via a cleaner gas pipe 304. Specifically, the cleaner gas pipe 304 may be airtightly fluidly coupled to the cleaner drum 138 and the liquid station 122 via a cleaner gas outlet 303. The additive manufacturing machine 110 may be fluidly coupled to a gas inlet 310 via a gas pipe 320. Such a coupling may allow gas to flow from the additive manufacturing machine 110, through the gas pipe 320, into the liquid station 122, through the cleaner gas pipe 304, and into the cleaner drum 138. In this manner, the cleaner drum 138 can receive gas from the additive manufacturing machine 110. The liquid station 122 may include a first pump 401 (not shown), a second pump 402 (not shown), and one or more valves 403 (not shown) that can control the flow of gas through the gas inlet 310 and the cleaner gas outlet 303. Therefore, when the cleaner is removed from the cleaner drum 138 through the first cleaner pipe 140, the inert gas is drawn into the cleaner drum 138 through the cleaner gas pipe 304. In other words, the inert gas can fill the vacuum created by removing the cleaner from the cleaner drum 138.

[0029] As mentioned above, the cleaner drum 138, the first cleaner pipe 140, the liquid station 122, the second cleaner pipe 142, and the additive manufacturing machine 110 may be airtightly connected. Thus, it will be appreciated that in some embodiments, the cleaner can be transferred from the cleaner drum 138 to the additive manufacturing machine 110 without coming into contact with air and without air being introduced into the cleaner drum 138.

[0030] 2B , the additive manufacturing machine 110 can be coupled to the waste drum 148 via a gas pipe 306. Specifically, the gas pipe 306 can be coupled to the waste drum 148 and the additive manufacturing machine 110 in an airtight manner using, for example, seals, valves, or other airtight connections. The gas pipe 306 can be configured and arranged to supply an inert gas from the additive manufacturing machine 110 to the waste drum 148. Thus, when cleaner is removed from the waste drum 148 via the first waste pipe 150, the inert gas can be drawn into the waste drum 148 via the gas pipe 306. In other words, the inert gas can fill the vacuum created by removing the cleaner from the waste drum 148.

[0031] In some such embodiments, the additive manufacturing machine 110 may be coupled to the waste drum 148 via a waste gas pipe 306. Specifically, the waste gas pipe 306 may be fluidly coupled to the waste drum 148 and the liquid station 122 in an airtight manner via a waste gas inlet 305. The additive manufacturing machine 110 may be fluidly coupled to the gas outlet 312 via a gas pipe 322. Such a coupling may allow gas to flow from the waste drum 148, through the waste gas pipe 306, into the liquid station 122, and through the gas pipe 322 into the additive manufacturing machine 110. The liquid station 122 may include a first pump 401 (not shown), a second pump 402 (not shown), and one or more valves 403 (not shown), which may control the flow of gas through the waste gas inlet 305 and the gas outlet 312. Thus, the additive manufacturing machine 110 may be fluidly coupled to the gas outlet 312 via a gas pipe 322. Such a coupling may allow gas to flow from the waste drum 148, through the waste gas pipe 306, into the liquid station 122, and through the gas pipe 322 into the additive manufacturing machine 110. The liquid station 122 may include a first pump 401 (not shown), a second pump 402 (not shown), and one or more valves 403 (not shown), which may control the flow of gas through the waste gas inlet 305 and the gas outlet 312. waste liquid As waste liquid is added to the waste drum 148 via pipe 150, inert gas is drawn from the waste drum 148 via waste gas pipe 306. In other words, inert gas can be removed from the waste drum 148 as waste liquid is added to the waste drum 148 to maintain an inert environment.

[0032] As mentioned above, the waste drum 148, the first waste liquid Pipe 150, liquid Station 122, No. 2 waste liquidThe pipe 152 and the additive manufacturing machine 110 may be airtightly connected. Thus, it will be appreciated that in some embodiments, waste material can be transferred from the waste drum 148 to the additive manufacturing machine 110 without coming into contact with air and without introducing air into the waste drum 148.

[0033] Referring now to FIG. 3 , a portion of the additive manufacturing system 100 is shown, including a powder material handling system 170, an additive manufacturing machine 110, and a de-powdering system 200. The powder material handling system 170 may include a powder station 172. Generally, a powder station may be a self-contained environment containing pipes, valves, meters, pressure regulators, flanges, and other necessary components and equipment required to perform an additive manufacturing process. In some embodiments, the powder station 172 includes a unused powder inlet 174 through which unused powder is received into the powder station 172. The powder station 172 may also include a recovered powder inlet 176, through which recovered powder, or previously used powder, can be received into the powder station 172. In some embodiments, the additive manufacturing machine 110 may include a recovered powder outlet 112, which may be coupled to the recovered powder outlet 112 via a first recovered powder pipe 116.

[0034] Powder station 172 can include combining the recovered powder with the virgin powder, a sieve 178 that mixes the recovered powder and the virgin powder together to form a mixed powder, filtering virgin particles from the mixed powder using sieve 178, transferring the virgin particles to a powder outlet 179, and transferring the mixed powder to the additive manufacturing machine 110. Powder station 172 can include a powder outlet 180, through which the mixed powder can exit powder station 172. Powder station 172 can include a waste / oversized powder outlet 179, through which oversized powder can exit powder station 172. Powder station 172 can include one or more pumps (not shown) and one or more valves (not shown) that can control the flow of powder, e.g., virgin powder, recovered powder, and mixed powder, through powder station 172.

[0035] In some embodiments, powder material handling system 170 may not include recovered powder inlet 176 or sieve 178. In such embodiments, virgin powder enters powder station 172 through virgin powder inlet 174 and exits powder station 172 through powder outlet 180 without being combined with recovered powder. In this manner, additive manufacturing machine 110 can receive virgin powder from powder handling system 170 and manufacture a work product.

[0036] 4 , powder material handling system 170 includes a virgin powder drum 182 containing virgin powder. The virgin powder drum 182 may be coupled to a virgin powder inlet 174 via a virgin powder pipe 192. Powder material handling system 170 may also include a return powder drum 184, which may be coupled to a return powder inlet 176 through a second return powder pipe 194. The powder outlet 180 of powder station 172 may be coupled to additive manufacturing machine 110 via a powder transfer pipe 186. In this manner, additive manufacturing machine 110 can receive powder, for example, a mixed powder containing virgin powder and returned powder, from powder material handling system 170. Within additive manufacturing machine 110, the powder can be fed to a recoater arm (not shown) of additive manufacturing machine 110, which can deposit the powder within additive manufacturing machine 110.

[0037] In some embodiments, the powder material handling system 170 may be coupled to the unused powder drum 182 via a unused powder gas pipe 330. Specifically, the unused powder gas pipe 330 may be airtightly fluidly coupled to the unused powder drum 182 and the powder station 172 (not shown). The additive manufacturing machine 110 may be fluidly coupled to the powder station 172 via a gas pipe 324. Such a coupling may allow gas to flow from the additive manufacturing machine 110, through the gas pipe 324, into the powder station 172, and through the unused powder gas pipe 330 into the unused powder drum 182. In this manner, the unused powder drum 182 can receive gas from the powder material handling system 170. Thus, as unused powder is removed from the unused powder drum 182 and enters the powder station 172 via the unused powder inlet 174, inert gas may be drawn into the unused powder drum 182 via the unused powder gas pipe 330. In other words, the inert gas may fill the vacuum created by removing unused powder from the unused powder drum 182.

[0038] The powder material handling system 170 may be coupled to the collection powder drum 184 via a collected powder gas pipe 332. Specifically, the collected powder gas pipe 332 may be fluidly coupled to the collection powder drum 184 and the powder station 172 in an airtight manner (not shown). The additive manufacturing machine 110 may be fluidly coupled to the powder station 172 via a gas pipe 324. Such a coupling may allow gas to flow from the additive manufacturing machine 110, through the gas pipe 324, into the powder station 172, and through the collected powder gas pipe 332, into the collection powder drum 184. In this manner, the collection powder drum 184 can receive gas from the powder material handling system 170. Thus, as collected powder is removed from the collection powder drum 184 and enters the powder station 172 via the collected powder inlet 176, inert gas may be drawn into the collection powder drum 184 via the collected powder gas pipe 332. In other words, the inert gas can fill the vacuum created by removing the collected powder from the collection powder drum 184.

[0039] In some embodiments, the unused powder drum 182 and the returned powder drum 184 may each be airtightly coupled to the powder station 172. Similarly, the powder station 172, the powder delivery pipe 186, and the additive manufacturing machine 110 may be airtightly connected. For example, the additive manufacturing system 100 may include seals and / or other airtight connections. This may be beneficial in some embodiments as it may reduce the risk of powder contamination.

[0040] Referring again to FIG. 3 , a portion of the additive manufacturing system 100 is shown, including the additive manufacturing machine 110 and the powder material handling system 170. The additive manufacturing system 100 can also include a de-powdering system 200, in which loose powder is removed from the three-dimensional work product. In some embodiments, the additive manufacturing machine 110 can transfer the work product (not shown) to the de-powdering system 200 via a conveyor system 190. Other means of transferring the work product are contemplated and are considered part of the present invention, such as manual transfer using a forklift or automated vehicle. In some embodiments, the de-powdering system 200 can be coupled to the powder material handling system 170. The de-powdering system 200 can include a recovered powder outlet 210, through which recovered powder, or previously used powder, can be transferred via a second recovered powder pipe 220 to a recovered powder inlet 176 of a powder station 172 in the powder material handling system 170.

[0041] The recovered powder supplied to powder station 172 from de-powdering system 200 can then be sieved through sieve 178 to combine the recovered powder with unused powder to create a mixed powder. The mixed powder can then flow from powder station 172 through powder outlet 180 and powder transfer pipe 186 to additive manufacturing machine 110. In this manner, additive manufacturing machine 110 can receive the recovered powder from de-powdering system 200.

[0042] In some embodiments, depowdering system 200 may be airtightly coupled to additive manufacturing machine 110 via depowdering gas pipe 350. In another embodiment, the depowdering station may have a depowdering gas pipe connected to its own source outside of additive manufacturing system 100. Regardless of the gas source within depowdering system 200, the airtight connection is maintained by using a seal or other airtight connection (not shown). This may be beneficial in some embodiments as it may reduce the risk of powder contamination.

[0043] Figure 5 illustrates a controller 500 that may be included in the additive manufacturing system 100. In the embodiment of Figure 5, the additive manufacturing system 100 includes one or more processors 502, a communication path 504, one or more memory modules 506, network interface hardware 508, and a data storage component 510, the details of which are described in the following paragraphs.

[0044] Each of the one or more processors 502 may be any device capable of executing machine-readable and executable instructions. Thus, each of the one or more processors 502 may be a controller, an integrated circuit, a microchip, a computer, or any other computing device.

[0045] One or more processors 502 are connected to communication paths 504, which provide interconnectivity between the various devices of the additive manufacturing system 100. Thus, the communication paths 504 can communicatively couple any number of processors 502 to one another, allowing the modules coupled to the communication paths 504 to operate in a distributed computing environment. Specifically, each of the modules can operate as a node that can send and / or receive data. As used herein, the term "communicatively coupled" refers to coupled components that can exchange data signals with one another, such as, for example, electrical signals over a conductive medium, electromagnetic signals over the air, optical signals over an optical waveguide, etc.

[0046] Thus, communication path 504 may be formed from any medium capable of transmitting a signal, such as, for example, a conductive wire, a conductive trace, an optical waveguide, etc. In some embodiments, communication path 504 may facilitate the transmission of wireless signals, such as Wi-Fi, Bluetooth, or Near Field Communication (NFC). Communication path 504 may also be comprised of a combination of media capable of transmitting a signal. In one embodiment, communication path 504 comprises a combination of conductive traces, conductive wires, connectors, and buses that cooperate to enable the transmission of electrical data signals to components such as processors, memories, sensors, input devices, output devices, and communication devices. Furthermore, it should be noted that the term "signal" refers to a waveform (e.g., electrical, optical, magnetic, mechanical, or electromagnetic), such as direct current, alternating current, sine wave, triangular wave, square wave, vibration, etc., that can pass through a medium.

[0047] The additive manufacturing system 100 includes one or more memory modules 506 coupled to the communication path 504. The one or more memory modules 506 may comprise RAM, ROM, flash memory, a hard drive, or any device capable of storing machine-readable and executable instructions such that they can be accessed by the one or more processors 502. The machine-readable and executable instructions may comprise, for example, logic or algorithms written in a machine language that can be executed directly by a processor, or in any programming language of any generation (e.g., 1GL, 2GL, 3GL, 4GL, or 5GL), such as assembly language, object-oriented programming (OOP), scripting language, microcode, etc., that can be compiled or assembled into machine-readable and executable instructions and stored on the one or more memory modules 506. Alternatively, the machine-readable and executable instructions may be written in a hardware description language (HDL), such as logic implemented via either a field-programmable gate array (FPGA) configuration or an application-specific integrated circuit (ASIC), or the like. Thus, the methods described herein may be implemented in any conventional computer programming language, as pre-programmed hardware elements, or as a combination of hardware and software components.

[0048] 5 , the additive manufacturing system 100 includes network interface hardware 508. In some embodiments, the network interface hardware 508 may also couple the additive manufacturing system 100 to one or more other external devices, such as a remote computing device (e.g., a cloud server or an edge server) or another vehicle. The network interface hardware 508 may be any device that can be communicatively coupled to the communication path 504 and that can transmit and / or receive data over a network or over a wired connection (e.g., a cable connection). In some embodiments, the network interface hardware 508 may include a communications transceiver for transmitting and / or receiving any wired or wireless communications. For example, the network interface hardware 508 may include an antenna, a modem, a LAN port, a Wi-Fi card, a WiMax card, cellular communications hardware, near-field communications hardware, satellite communications hardware, and / or any wired or wireless hardware for communicating with other networks and / or devices.

[0049] The additive manufacturing system 100 also includes a data storage component 510. The data storage component 510 can store data used by various components of the additive manufacturing system 100. The control system 500 can be utilized to perform various processes, such as the process described below with respect to FIG.

[0050] FIG. 6 shows a flow diagram of an exemplary method 600 of operating the additive manufacturing system 100. In block 602, the controller determines whether recovered powder is available to manufacture a work product. If the controller does not detect recovered powder, the controller directs the system to block 604, where unused powder is transferred from the unused powder drum 182 to the powder material handling system 170. For example, the unused powder is transferred along the unused powder pipe 192 to the unused powder inlet 174 on the powder station 172. In step 606, the unused powder is transferred to the additive manufacturing machine. Referring again to FIG. 3, the powder station 172 includes a powder outlet 180 coupled to the additive manufacturing machine 110 via a powder transfer pipe 186. For example, the unused powder is transferred from the powder station 172 to the powder outlet 180 and then transferred through the powder transfer pipe 186 to the additive manufacturing machine 110.

[0051] Then, at block 620, the work product is transferred from the additive manufacturing machine to a de-powdering system. For example, the work product may exit the additive manufacturing machine 110 and be transported along the conveyor system 190 until it reaches the de-powdering system 200. At block 622, recovered powder from the de-powdering system is transferred to a powder material handling system for use in future builds. For example, the de-powdering system 200 may recover powder from the work product, and the recovered powder may be transported along a second recovered powder pipe 220 to a recovered powder inlet 176 of a powder station 172 in the powder material handling system 170.

[0052] At block 652, the recovered powder and virgin powder can be mixed through a sieve 178 to form a mixed powder. For example, the recovered powder and virgin powder can be transported along the powder station 172, and both the recovered powder and virgin powder can be directed through the sieve 178 to form a mixed powder. At block 654, the mixed powder can be filtered through the sieve 178 to remove oversized particles from the mixed powder. For example, the sieve can allow powder of a certain size from both the recovered powder and virgin powder to fall through the sieve 178 to form the mixed powder below.

[0053] In block 656, the oversized particles may be transferred from the powder material handling system 170 via the outlet 179. For example, the oversized particles can be transferred along the powder station 172 to the outlet 179 and exit the powder station 172. In step 658, the sieved mixed powder may be transferred to the additive manufacturing machine 110 via the powder transfer pipe 186. For example, the mixed powder may be transferred along the powder station 172 or through the powder outlet 180. The mixed powder can continue to be transferred through the powder transfer pipe 186 until it reaches the additive manufacturing machine 110.

[0054] However, if in block 602 the controller determines that there is recovered powder to produce the work product, the controller directs the system to block 608, where the recovered powder is transferred from the drum to a powder material handling system. For example, the recovered powder is transferred along recovered powder pipe 194 to recovered powder inlet 176 on powder station 172.

[0055] In block 610, the controller determines whether virgin powder is also needed to produce the work product. If virgin powder is not needed, the controller instructs the system to remove oversized particles from the recovered powder through a sieve in block 630. For example, the sieve can allow powder of a desired size from the recovered powder to fall through sieve 178 to form sieved recovered powder below.

[0056] In block 632, the oversized particles are transferred from the powder material handling system. For example, the oversized particles can be transferred along the powder station 172 to the outlet 179 and exit the powder station 172. In step 634, the sieved recovered powder is transferred to the additive manufacturing machine. In step 640, the binder can be transferred to the additive manufacturing machine 110. For example, the binder can be transferred from the binder drum 128 to the liquid material handling system 120 via the first binder pipe 130. That is, the binder can travel along the first binder pipe 130 and enter the liquid station 122 at the binder inlet 124. The binder can be transferred to the additive manufacturing machine 110 via the second binder pipe 132. For example, the binder can exit the liquid station 122 at the binder outlet 126, and the binder can be transferred along the second binder pipe 132 to the additive manufacturing machine 110.

[0057] Although blocks 640, 642, and 644 are shown serially in FIG. 6 , these steps may occur in any order or substantially simultaneously. The ability to occur substantially simultaneously is limited by the number of pumps in the system. In block 630, cleaner may be transferred from the cleaner drum 138 to the liquid material handling system 120 via the first cleaner pipe 140. For example, the cleaner may travel along the first cleaner pipe 140 and enter the liquid station 122 at the cleaner inlet 134. In step 632, the cleaner may be transferred from the liquid material handling system 120 to the additive manufacturing machine 110 via the second cleaner pipe 142. For example, the cleaner may exit the liquid station 122 at the cleaner outlet 136, and the binder may be transferred along the second cleaner pipe 142 to the additive manufacturing machine 110.

[0058] In step 644, the waste liquid may be transported from the additive manufacturing machine 110 to a waste drum 148 via the second waste pipe 152 and the first waste pipe 150. For example, the waste liquid may be transported along the second waste pipe 152 to the waste inlet 146 on the liquid station 122. The waste liquid then exits the liquid station 122 at the waste outlet 144 and is transported to the first waste drum 148. waste liquid It can be transported along pipe 150 into waste drum 148 .

[0059] If virgin powder is needed in block 610, the controller directs the system to block 650 to transfer the virgin powder from the drum to the powder material handling system. For example, the virgin powder is transferred along virgin powder pipe 194 to recovered powder inlet 176 on powder station 172. The controller then directs the system to block 652, where the recovered powder and virgin powder can be mixed via sieve 178 to form a mixed powder. Blocks 654, 656, 658, 640, and 644 can follow as well. Details of such blocks are described above.

[0060] In view of the foregoing, it should be understood that the powder used to form the article can be derived from virgin powder, recycled powder, or a combination of virgin and recycled powder (e.g., mixed powder).

[0061] In view of the above, it should be appreciated that at least some embodiments of the present invention are directed to an additive manufacturing system including a powder material handling system including a virgin powder inlet. The virgin powder inlet is coupled to a powder drum and configured to receive virgin powder from the powder drum. The additive manufacturing system further includes a liquid material handling system including a binder inlet. The binder inlet is coupled to the binder drum and configured to receive binder from the binder drum. The additive manufacturing system also includes an additive manufacturing machine coupled to the powder material handling system and the liquid material handling system. The additive manufacturing machine receives virgin powder from the powder material handling system and receives binder from the liquid material handling system. The additive manufacturing machine is also configured to fabricate a workpiece using the virgin powder and the binder. As described above, this system provides advantages over the prior art, such as time savings, improved process efficiency, and increased safety due to its automated nature and airtight design.

[0062] It should be noted that the terms "substantially" and "about" may be utilized herein to express the inherent degree of uncertainty that may result from any quantitative comparison, value, measurement, or other representation. These terms are also utilized herein to express the degree to which a quantitative representation may vary from the stated reference without resulting in a change in the basic functionality of the subject matter in question.

[0063] While particular embodiments have been illustrated and described herein, it should be understood that various other changes and modifications can be made without departing from the spirit and scope of the claimed subject matter. Moreover, although various aspects of the claimed subject matter have been described herein, such aspects need not be utilized in combination. It is therefore intended that the appended claims cover all such changes and modifications that are within the scope of the claimed subject matter.

[0064] Further aspects are provided by the subject matter of the appendices below.

[0065] 1. An additive manufacturing system comprising: a powder material handling system coupled to a powder drum, the powder material handling system comprising a virgin powder inlet configured to receive virgin powder from the powder drum; a liquid material handling system coupled to a binder drum, the binder inlet configured to receive binder from the binder drum; and an additive manufacturing machine coupled to the powder material handling system and the liquid material handling system, the additive manufacturing machine receiving the virgin powder from the powder material handling system and receiving the binder from the liquid material handling system, wherein the additive manufacturing machine is configured to manufacture a work product using the virgin powder and the binder.

[0066] 10. The additive manufacturing system as defined above, wherein the additive manufacturing system is coupled to the powder handling system via an airtight coupling.

[0067] 10. The additive manufacturing system as defined above, wherein the additive manufacturing system is coupled to the liquid material handling system via an airtight coupling.

[0068] 10. The additive manufacturing system, wherein the additive manufacturing machine comprises a recovered powder outlet, and wherein the powder material handling system comprises a recovered powder inlet coupled to the recovered powder outlet such that the powder material handling system receives recovered powder from the additive manufacturing machine.

[0069] The additive manufacturing system, further comprising a de-powdering system coupled to the powder material handling system, the powder material handling system receiving recovered powder from the de-powdering system.

[0070] 10. The additive manufacturing system of claim 9, wherein the powder material handling system comprises a sieve configured to mix recovered powder and virgin powder to form a mixed powder output.

[0071] 10. The additive manufacturing system of claim 9, wherein the liquid material handling system further includes a cleaner inlet, the cleaner inlet coupled to the cleaner drum such that the cleaner inlet receives cleaner from the cleaner drum.

[0072] 10. The additive manufacturing system, wherein the additive manufacturing machine is fluidly coupled to the liquid material handling system such that the additive manufacturing machine receives the cleaner from the liquid material handling system.

[0073] The additive manufacturing system, wherein the additive manufacturing machine includes a waste outlet coupled to a waste drum, and waste is discharged from the additive manufacturing machine via the waste outlet into the waste drum.

[0074] 1. An additive manufacturing system comprising: a powder material handling system comprising: a virgin powder inlet coupled to a powder drum such that the virgin powder inlet receives virgin powder from the powder drum; a first recovered powder inlet configured to receive a first recovered powder; and a sieve configured to mix the first recovered powder and the virgin powder to form a mixed powder output; a liquid material handling system having a binder; and an additive manufacturing machine coupled to the powder material handling system and to the liquid material handling system such that the additive manufacturing machine receives the mixed powder output from the powder material handling system and receives the binder from the liquid material handling system, wherein the additive manufacturing machine is configured to manufacture a work product using the mixed powder and the binder.

[0075] The additive manufacturing system, further comprising a de-powdering system coupled to the powder material handling system, the powder material handling system receiving recovered powder from the de-powdering system.

[0076] 10. The additive manufacturing system, wherein the additive manufacturing machine includes a recovered powder outlet, and wherein the powder material handling system includes a recovered powder inlet coupled to the recovered powder outlet of the additive manufacturing machine, and wherein the powder material handling system receives recovered powder from the additive manufacturing machine.

[0077] 1. A method of using an additive manufacturing system, hermetically transferring virgin powder from a virgin powder drum to a powder material handling system, the powder material handling system including a virgin powder inlet coupled to a powder drum such that the virgin powder inlet receives the virgin powder from the virgin powder drum, and the powder material handling system hermetically transferring the virgin powder from the powder material handling system to an additive manufacturing machine.

[0078] 10. A method of using the additive manufacturing system described above, further comprising: transferring the binder from the binder drum to a liquid material handling system in an airtight manner, the liquid material handling system including a binder inlet coupled to the binder drum such that the binder inlet receives the binder from the binder drum, and transferring the binder from the liquid material handling system to the additive manufacturing machine in an airtight manner.

[0079] 10. A method of using the additive manufacturing system described above, further comprising airtightly transferring the cleaner from the cleaner drum to a liquid material handling system, the liquid material handling system including a cleaner inlet coupled to the cleaner drum such that the cleaner inlet receives the cleaner from the cleaner drum, and airtightly transferring the cleaner from the liquid material handling system to the additive manufacturing machine.

[0080] A method of using the additive manufacturing system described above, further comprising transferring waste liquid to a waste drum via a waste liquid outlet coupled to the additive manufacturing system.

[0081] 10. A method of using the additive manufacturing system described above, further comprising transferring recovered powder via a recovered powder outlet coupled to the additive manufacturing machine to a recovered powder inlet coupled to the powder material handling system.

[0082] A method of using the additive manufacturing system described above, mixing the recovered powder and the unused powder together using a sieve in the powder material handling system to form a mixed powder output, removing oversized particles from the mixed powder using the sieve, transferring the oversized particles to an outlet, and transferring the mixed powder to an additive manufacturing machine.

[0083] 10. A method of using the additive manufacturing system described above, comprising transferring a work product from the additive manufacturing machine to a de-powdering system, transferring recovered powder from the de-powdering system to the powder material handling system, mixing the recovered powder and the unused powder using a sieve in the powder material handling system to form a mixed powder output, removing oversized particles from the mixed powder using the sieve, transferring the oversized particles to an outlet, and transferring the mixed powder to the additive manufacturing machine.

[0084] 10. A method of using the additive manufacturing system described above, further comprising: transferring a cleaner to the liquid material handling system via a cleaner inlet coupled to a cleaner drum; and wherein the additive manufacturing machine is coupled to the liquid material handling system, and transferring waste liquid to a waste drum via a waste outlet coupled to the additive manufacturing machine.

[0085] 1. A method of assembling an additive manufacturing system comprising coupling a powder drum to a virgin powder inlet of an additive manufacturing system and coupling a binder drum to a binder inlet of the additive manufacturing system, the additive manufacturing system comprising a powder material handling system including the virgin powder inlet configured to receive virgin powder from the powder drum, and a liquid material handling system including a binder inlet configured to receive binder from the binder drum, the additive manufacturing machine coupled to the powder material handling system and the liquid material handling system, the additive manufacturing machine configured to manufacture a work product using the virgin powder and the binder.

[0086] 10. A powder material handling system comprising: a powder station including a virgin powder inlet, the virgin powder inlet coupled to the virgin powder drum such that the virgin powder inlet receives virgin powder from the virgin powder drum; and an additive manufacturing machine coupled to the powder material handling system.

[0087] 11. The powder material handling system of claim 10, further comprising: a first recovered powder inlet coupled to the powder station and configured to receive a first recovered powder; and a sieve, wherein the first recovered powder and the virgin powder are mixed together using the sieve to form a mixed powder output.

[0088] The powder material handling system further comprising a de-powdering system coupled to the powder material handling system, the powder material handling system receiving recovered powder from the de-powdering system.

[0089] 1. A liquid material handling system comprising: a liquid station including a binder inlet, the binder inlet coupled to a binder drum to receive binder from the binder drum; and an additive manufacturing machine coupled to the liquid material handling system.

[0090] The liquid materials handling system as described above, further comprising a cleaner inlet coupled to the liquid station, the cleaner inlet coupled to the cleaner drum such that the cleaner inlet receives cleaner from the cleaner drum.

[0091] the liquid material handling system including a waste inlet coupled to the liquid station, the waste inlet coupled to the additive manufacturing machine such that the waste inlet receives waste liquid from the additive manufacturing machine, and a waste drum coupled to the liquid station such that the waste drum receives waste liquid from the liquid station.

[0092] 1. A method of using an additive manufacturing system, comprising: airtightly transferring recovered powder from a recovery powder drum to a powder material handling system, the powder material handling system including a recovered powder inlet coupled to the recovery powder drum to receive the recovered powder from the recovery powder drum, the recovered powder inlet being coupled to the recovery powder drum to receive the recovered powder from the recovery powder drum, and transferring the recovered powder from the powder material handling system to an additive manufacturing machine.

Claims

1. a powder material handling system (170) including a fresh powder inlet (174) coupled to a fresh powder drum (182) and configured to receive fresh powder from said fresh powder drum (182); a liquid materials handling system (120) including a binder inlet (124) coupled to a binder drum (128) and configured to receive binder from the binder drum (128); an additive manufacturing machine (110) coupled to the powder material handling system (170) and the liquid material handling system (120), the additive manufacturing machine receiving the virgin powder from the powder material handling system (170) and the binder from the liquid material handling system (120); Including, the additive manufacturing machine (110) is configured to manufacture a work product using the virgin powder and the binder; The liquid material handling system (120) includes a liquid station (122); The liquid station (122) includes a first pump (401) for delivering liquid, a second pump (402) for extracting liquid, a valve (403) for controlling the flow of liquid, a waste liquid inlet (146) for receiving waste liquid into the liquid station (122), and a waste liquid outlet (144) for discharging waste liquid from the liquid station (122); The waste outlet (144) is fluidly coupled to a waste drum (148) via a first waste pipe (150); the waste inlet (146) is fluidly coupled to the additive manufacturing machine (110) via a second waste pipe (152); waste liquid passes from the additive manufacturing machine (110) through the second waste pipe (152) into the liquid station (122) and is discharged through the first waste pipe (150) into the waste drum (148); An additive manufacturing system (100).

2. coupled to the powder material handling system (170) via at least one airtight coupling; The additive manufacturing system (100) of claim 1.

3. coupled to the liquid material handling system (120) via at least one airtight coupling; The additive manufacturing system (100) of claim 1 or claim 2.

4. the additive manufacturing machine (110) includes a collected powder outlet (112); the powder material handling system (170) includes a recovered powder inlet (176) coupled to the recovered powder outlet (112) such that the powder material handling system (170) receives recovered powder from the additive manufacturing machine (110); The additive manufacturing system (100) of claim 1 or claim 2.

5. further comprising a de-powdering system (200) coupled to the powder material handling system (170); The powder material handling system (170) receives recovered powder from the de-powdering system (200); the powder material handling system (170) including a sieve (178) configured to mix the recovered powder and the virgin powder to form a mixed powder output (180); The additive manufacturing system (100) of claim 1 or claim 2.

6. The liquid material handling system (120) further includes a cleaner inlet (134); the cleaner inlet (134) is coupled to the cleaner drum (138) such that the cleaner inlet (134) receives cleaner from the cleaner drum (138); the additive manufacturing machine (110) is fluidly coupled to the liquid material handling system (120) such that the additive manufacturing machine (110) receives the cleaner from the liquid material handling system (120); The additive manufacturing system (100) of claim 1 or claim 2.

7. Hermetically transferring the virgin powder from the virgin powder drum (182) to the powder material handling system (170); transferring the virgin powder from the powder material handling system (170) to an additive manufacturing machine (110) in an airtight manner; 10. A method of using the additive manufacturing system (100) of claim 1.

8. transferring the binder from the binder drum (128) to the liquid material handling system (120) in an airtight manner; transferring the binder from the liquid material handling system (120) to the additive manufacturing machine (110) in an airtight manner; 10. A method of using the additive manufacturing system (100) of claim 7.

9. Hermetically transferring the cleaner from the cleaner drum (138) to the liquid material handling system (120); transferring the cleaner from the liquid material handling system (120) to the additive manufacturing machine (110) in an airtight manner; 7. A method of using the additive manufacturing system (100) of claim 6.

10. transferring the waste liquid to the waste drum (148) via the waste liquid outlet (144) coupled to the additive manufacturing machine (110); 10. A method of using the additive manufacturing system (100) of claim 9.

11. transferring recovered powder via the recovered powder outlet (112) coupled to the additive manufacturing machine (110) to the recovered powder inlet (176) coupled to the powder material handling system (170); 5. A method of using the additive manufacturing system (100) of claim 4.

12. mixing the recovered powder and the virgin powder using the sieve (178) of the powder material handling system (170) to form the mixed powder output (180); using said sieve (178) to remove oversized particles from the mixed powder; transferring said oversized particles to an outlet (179); transferring the mixed powder to the additive manufacturing machine (110); 6. A method of using the additive manufacturing system (100) of claim 5.

13. transferring a work product from the additive manufacturing machine (110) to the de-powdering system (200); transferring recovered powder from said de-powdering system (200) to said powder material handling system (170); mixing the recovered powder and the virgin powder using the sieve (178) of the powder material handling system (170) to form the mixed powder output (180); removing oversized particles from the mixed powder using the sieve (178); transferring said oversized particles to an outlet (179); transferring the mixed powder to the additive manufacturing machine (110); 6. A method of using the additive manufacturing system (100) of claim 5.

14. Transferring the cleaner to the liquid material handling system (120) via the cleaner inlet (134) coupled to the cleaner drum (138); transferring the waste liquid to the waste drum (148) via the waste liquid outlet (144) coupled to the additive manufacturing machine (110); 7. A method of using the additive manufacturing system (100) of claim 6.

Images