Modular configuration for additive manufacturing

Abstract

The print engine of the additive manufacturing system includes a print station configured to hold a removable cartridge. The laser engine including a frame can be arranged to hold at least one removable field-replaceable unit including at least some laser optics or patterning optics. An optical alignment system can be attached to at least one of the print station or the laser engine to align the field-replaceable unit with the removable cartridge.

Description

[Technical Field]

[0001] Related Applications This disclosure is part of a non-provisional patent application which claims the benefit of priority to U.S. Patent Application No. 63 / 030,757, filed May 27, 2020, and which is incorporated by reference in its entirety.

[0002] FIELD OF THE DISCLOSURE This disclosure relates generally to systems and methods for high-throughput additive manufacturing. In one embodiment, high-speed manufacturing is supported through the use of removable print cartridges and removable laser print engines. [Background technology]

[0003] Traditional component machining often relies on the removal of material by drilling, cutting, or grinding to form a part. In contrast, additive manufacturing, also known as 3D printing, typically adds material sequentially, layer by layer, to build a part. Starting with a 3D computer model, additive manufacturing systems can be used to create complex parts from a wide variety of materials.

[0004] One additive manufacturing technique, known as powder bed fusion (PBF), uses one or more focused energy sources, such as a laser or electron beam, to imprint patterns on thin layers of powder, gradually forming a 3D-printed part by melting the powder and bonding it to the layer below. The powders can be plastic, metal, glass, ceramic, crystalline, or other fusible materials, or a combination of fusible and infusible materials (i.e., plastic and wood, or metal and ceramic). This technique is highly precise and can achieve small feature sizes, typically 150–300 μm. However, industrial additive manufacturing systems can be cumbersome to operate, often requiring workers to wear protective equipment (e.g., safety masks, eye protection, specialized uniforms) when performing normal daily tasks such as removing 3D-printed parts, cleaning the print chamber, or repairing wear items.

[0005] Some additive manufacturing systems have attempted to improve ease of maintenance and safety by enclosing the 3D print in a box. This box can be removed from the machine after the additive manufacturing system has finished printing. Unfortunately, it can be difficult to form a perfect seal between the printer and the sealed box, so some powder will always be present outside the print chamber. This can expose operators to inhalation hazards.

[0006] In additive manufacturing systems, significant time may be required to remove the 3D print, clean it, and service the printer before the next 3D print can begin. Even if the 3D print is sealed in a box, it may still be necessary to manually clean the print chamber and manually replace and realign wear parts (such as the spreader blades). Because printing is an inherently dirty process (by dirty, we mean soot, unused powder, weld slag, etc.), everything inside the print chamber, including the spreader blades, gas flow ducts, glass windows, and spreader drive mechanisms, can become covered in dirt. Because it is important to ensure the purity of the printing powder used, it is essential to thoroughly clean the print chamber and gas ducts before switching materials. This may require a thorough cleaning, typically disassembling many components so that the dirt can be removed. This work cannot be performed through glove ports and requires the use of specially trained labor wearing protective equipment such as safety masks.

[0007] Another issue stems from 3D printing, which requires an inert gas environment. When opening the print chamber to the atmosphere, it must be evacuated and purged. This process takes a significant amount of time and results in the loss of expensive inert gas. These operations can take a significant amount of time, and often a new 3D print cannot be started until cleaning and servicing are complete, slowing additive manufacturing throughput.

[0008] In additive manufacturing systems, removing a 3D print from the print chamber may require removing the 3D print from the controlled printing environment. This can have adverse effects on the 3D print, potentially requiring a heat treatment oven for post-processing, such as cool-down and / or subsequent stress relief, annealing, or heat treatment. While additive manufacturing systems can preheat the printing plate within the print chamber and / or maintain the print at a set temperature during printing, they often lack temperature control outside the print chamber. Unfortunately, when a 3D print is removed from the print chamber, it is typically exposed to uncontrolled air, and in many systems, uncontrolled air as well. These factors can affect the material properties of the 3D print. Furthermore, 3D prints are often too hot to be removed immediately from the print chamber, requiring them to remain in the print chamber for hours after finishing a print. This can cause the print chamber to lock up, preventing the system from starting a new print job. Summary of the Invention

[0009] In some embodiments, the print engine of the additive manufacturing system includes a print station configured to hold a removable cartridge. The laser engine including the frame can be arranged to hold at least one removable field-replaceable unit including at least some laser optics or patterning optics. An optical alignment system can be attached to at least one of the print station or the laser engine to align the field-replaceable unit with the removable cartridge.

[0010] In some embodiments, the removable cartridge comprises a sealable chamber having a floor and a laser transparent window.

[0011] In some embodiments, the removable cartridge includes a powder hopper disposed within the sealable chamber and a powder spreader disposed within the sealable chamber for dispensing powder from the powder hopper to the floor.

[0012] In some embodiments, the frame of the laser engine is actively mechanically damped.

[0013] In some embodiments, the laser light passes between multiple field replaceable units.

[0014] In some embodiments, at least one removable field replaceable unit and removable cartridge is used for connection to a facility station that provides gas systems, fluid systems, electrical systems, control systems, and database systems.

[0015] In some embodiments, a print cartridge transporter unit can be used to transport the removable cartridge.

[0016] In some embodiments, a field replaceable unit transporter unit may be provided.

[0017] In some embodiments, the laser engine can direct a two-dimensional patterned laser beam at the removable cartridge.

[0018] In some embodiments, the removable field replaceable units can direct laser beams between each other.

[0019] The additive manufacturing printing method includes placing a removable cartridge in a print station. A laser beam can be directed from a laser engine including a frame holding at least one removable field-replaceable unit including at least some laser optics or patterning optics at the removable cartridge. The field-replaceable unit can be aligned with the removable cartridge using an optical alignment system attached to at least one of the print station or the laser engine.

[0020] In some embodiments, the print engine of the additive manufacturing system includes a print station configured to hold a removable cartridge, and the laser engine includes a frame for holding a plurality of removable field replaceable units, each of which can have at least some laser optics or patterning optics for directing a laser beam to the removable cartridge of the print station.

[0021] In some embodiments, the print engine of the additive manufacturing system includes a print station configured to hold a removable cartridge. The laser engine includes a frame for holding a plurality of removable field replaceable units. Each field replaceable unit can have at least some laser optics or patterning optics to direct a laser beam to the removable cartridge of the print station, the laser beam passing through the plurality of field replaceable units before being directed to the removable cartridge.

[0022] Non-limiting and non-exhaustive embodiments of the present disclosure are described with reference to the following figures, in which like reference numerals refer to like parts throughout the various views unless otherwise specified. [Brief explanation of the drawings]

[0023] [Figure 1A] 1 illustrates a print cartridge for an additive manufacturing system in partial cross section. [Figure 1B] 1 shows a print cartridge transporter. [Figure 1B(i)] 1 shows an automatically driven transporter. [Figure 1C] 1 illustrates installation of a print cartridge into a print module of an additive manufacturing system. [Figure 1D] 1 shows the print cartridge interface. [Figure 1E] 1 shows a print archive module. [Figure 1F]1 illustrates the use of an auxiliary printing module. [Figure 1G] Shown is the factory layout for an eight-system work cell. [Figure 1G(i)] 1 illustrates the use of large format print cartridges and various transporter mechanisms for large format print cartridges. [Figure 1G(ii)] 1 illustrates the use of large format print cartridges and various transporter mechanisms for large format print cartridges. [Figure 1G(iii)] 1 illustrates the use of large format print cartridges and various transporter mechanisms for large format print cartridges. [Figure 1H] 1 illustrates an alternative embodiment of a print cartridge that can interact with an XY gantry that can traverse the entire area of ​​a printing plate within the print cartridge. [Figure 1I] 1 illustrates an alternative embodiment of a print cartridge with a bellows connection. [Figure 1J] 10 illustrates an alternative embodiment of a print cartridge with a bellows connection and a secondary XY gantry. [Figure 1K] 10 illustrates an alternative embodiment of a print cartridge with a bellows connection and a printhead connected to push against a window. [Figure 1L] Illustrates the concept of a wiper blade that keeps the laser input window clear. [Figure 1M] 1 illustrates an alternative embodiment of an additive manufacturing system having a fixed window. [Figure 1N] 1C shows the alternative embodiment of FIG. 1M in an open position. [Figure 1O] 1 illustrates print facility controls for various stations included in a printing system. [Figure 1P] 1 shows a print facility control of possible stations. [Figure 1Q] 1 illustrates the placement of field replaceable units within a printing module, including a laser engine. [Figure 1Q(i)] 1 illustrates an embodiment that includes active and passive vibration damping mechanisms within the frame. [Figure 1R] FIG. 1 is a perspective view of a field replaceable unit (FRU). [Figure 1S] FIG. 1 shows a block diagram of an example additive manufacturing system. [Figure 1T] 1 shows a block diagram of a laser station. [Figure 2] 1 illustrates a method of operation of a cartridge-based additive manufacturing system. [Figure 3] 1 illustrates a cartridge-based additive manufacturing system capable of providing a one-dimensional or two-dimensional light beam to a cartridge. [Figure 4] 1 illustrates a method of operating a cartridge-based additive manufacturing system that can provide a one-dimensional or two-dimensional light beam to a cartridge. DETAILED DESCRIPTION OF THE INVENTION

[0024] In the following description, reference is made to the accompanying drawings which form a part hereof, and which show, by way of illustration, specific exemplary embodiments in which the disclosure may be practiced. These embodiments are described in sufficient detail to enable those skilled in the art to practice the concepts disclosed herein, and it should be understood that modifications can be made to the various disclosed embodiments and other embodiments can be utilized without departing from the scope of the present disclosure. Accordingly, the following detailed description is not to be taken in a limiting sense.

[0025] Figure 1A shows a partial cross-section of a 3D printing cartridge 1A for an additive manufacturing system. The 3D printing cartridge (hereafter "cartridge") is designed to isolate all "dirty" printing functions from the rest of the system and the operator environment, allowing for easy replacement or removal. By "dirty," we mean areas where powder is present, processed for printing, or where soot is generated. Whenever cartridge 1A is connected to a companion device, such as a printer, powder removal, or storage station (described below), the companion device can provide the necessary maintenance to operate the cartridge as needed, depending on which station it is connected to (e.g., a printer station has full control over the cartridge, while a storage station only provides heating, power, and gas reclamation, and can use the camera and lights). Cartridge 1A is designed to be sealed when removed from its companion station.

[0026] Cartridge 1A is built around a floor or base plate 24A. Fresh powder for a new print is stored in powder hopper 2A, which may have the capacity to store all the powder needed for a full-volume print. New powder is metered onto base plate 24A through powder door 23A. Powder is swept onto the plate by powder spreader 4A using a powder spreader blade. Powder spreader drive 5A moves the powder spreader back and forth, sandwiching printing plate 12A.

[0027] Window 3A seals the top of cartridge 1A from powder and gas leaks and allows a laser beam (not shown) to pass through to deposit the powder. Window 3A allows access to the cartridge for loading printing plates, unloading prints, and cleaning and servicing cartridge components (seals, spreader blades, etc.). The interior of cartridge 1A can be illuminated and imaged by camera and light 22A. The camera and light can be positioned inside or outside the sealed chamber, or both, to capture photographs and / or focus on the scene within the cartridge, specifically the printing plate. The camera and light can also be mounted on a motion stage, allowing the user to pan or zoom on items of interest during printing. This camera can be combined with secondary printing diagnostics, such as a pyrometer, motion detector, photodiode, thermal camera, or other sensor, to automatically detect events and pan / zoom the camera to focus on the desired location. In some embodiments, the operator can view the camera image in an electronic or virtual window rather than looking directly through a physical port or window in the cartridge.

[0028] Gas supply duct 6A supplies inert gas to the cartridge, ensuring optimal atmospheric conditions for each print. Gas return duct 7A removes the inert gas. The gas passes through HEPA filter 8A to remove impurities (soot, suspended nanoparticles of powder, etc.). The gas is then sent to a gas recycler (not shown), which is installed in the target equipment. When the cartridge is removed from the target equipment, gas supply port 9A and gas return port 10A are sealed to maintain the atmosphere inside the cartridge. The gas is then purified in other equipment to remove oxygen, moisture, etc.

[0029] The Z-axis lowers the printing plate after printing each layer, allowing a new layer of powder to be spread and subsequently printed. In this design, Z-axis frame 11A holds the Z-axis components. Printing plate (AKA build plate) 12A is where the powder is deposited during printing. Printing plate heater 13A contains the heating mechanism for printing plate 12A (optional) and can also insulate and / or cool seal plate 14A. Seal plate A is fitted with seal 15A, which confines the powder to Z-axis frame 11A. Z-axis bottom plate 16A closes the bottom end of Z-axis frame 11A and contains any powder that may slip through seal 15A. Plunger 17A interfaces with the Z-axis drive system for remote, automatic, and precise interfacing. Plunger seal 18A mates with bottom plate 16A, further sealing cartridge 1A against powder and / or gas leakage.

[0030] Interface plate 19A contains all of the cartridge's inputs and outputs (compressed air, power, input / output signals, gas, cooling water, etc.). It is designed to make all of these connections when the cartridge is connected to the mating device. The interface can also include a mechanism to electronically identify each cartridge when mated with the mating device. Rollers 20A allow cartridge 1A to be rolled onto the mating rails of the mating device. Forklift tube 21A allows the cartridge to be lifted and moved by a forklift or other transport system.

[0031] In another embodiment, the interface plate can be configured to mate with various types or models of printers.

[0032] In one embodiment, drive components (e.g., motors, actuators, etc.) can be located in the mating station and linkages can be employed to transfer power from the external drive components to the drive components within the cartridge. This reduces the cost and complexity of each cartridge. For example, powder distribution drive 5A can be coupled to a linkage structure that automatically connects when the cartridge is connected to the print station / engine via a gear system, belt system (as shown in 5A), magnetic confinement, electric, magnetic, inductive, hydraulic, or other similar types of signal or energy transfer. Similarly, gas and fluid exchange between the cartridge and a compatible mating station can use external powder, fluid, and / or gas pumps that hook up to the cartridge either at interface panel 19A or other convenient location, allowing powder (to hopper 2A), fluid, or gas transfer without the need to overload the cartridge with an internal service transfer motor / pump. The internal impeller (used to transfer powder or fluid) can be powered by an external motor via the aforementioned linkages.

[0033] Power coupling through interface panel 19A can be electrical, inductive, or optical, the latter two allowing for the simultaneous transfer of both power and communications. Additionally, diagnostic information from the various sensors built into the cartridge can be generated via electrical or optical methods.

[0034] In one embodiment, cartridge 1A can include an electronic identification, such as electronically readable memory 25A, or other electronically readable indicia, such as attached text, a QR code, or a barcode. Memory 25A can provide electronic information about the cartridge or cartridge components and can be used to identify its make, model, type, powder type, or other defining details about the unit, its subcomponents, or their intended use. This information can be used to inform the print engine about the material to be printed, the desired atmosphere (pressure and temperature), or other printing-related aspects, allowing the print engine to accommodate the print cartridge or subassembly as needed. Induced changes can include actions such as automatic replacement of the internal lens assembly, adjustment of the lens assembly z-height / final light projection, laser parameter adjustments such as power per unit area, pulse shape, pulse duration, pulse repetition rate, wavelength, spatial pulse shape, tile size, spatial energy distribution within a tile, changes to data diagnostics, data feedback algorithms, print process feedback algorithms, or algorithmic changes to how tiles are positioned during the printing process. Electronic information from the electronic memory 25A associated with the print cartridge can be read at any station to gather data on how much printing has occurred and other key metrics such as the number of spreader cycles, z-axis adjustments, temperature cycles, pressure cycles, or other attributes that the cartridge or sub-cartridge has undergone along the way. This information can also be stored in a central database by any of the stations, one of the subsystems, the factory automation system, the cartridge itself, the cartridge transport system, or other partner / interface equipment.

[0035] FIG. 1B illustrates one embodiment of an additive manufacturing system 1B including an embodiment of a cartridge 2B. As shown, cartridge 2B is transported to a print station 11B on a custom transfer fixture 4B carried by a transporter (here represented by a forklift truck 3B). The transporter can interface with the cartridge so that all or some of its services and functions are active, or the cartridge can be partially or completely disconnected from service and non-functional while being transported by the transporter. As described in more detail below, print engine 11B is a system module that includes a print station and a laser engine station. Once cartridge 2B is prepared (i.e., loaded with new powder, new printing plates installed, all cartridge components inspected, refreshed, and aligned, filled with appropriate gases, printing plates preheated, etc.) in another companion device, such as a preparation service station (not shown), it is ready to print.

[0036] The transporter 3B aligns the transport fixture 4B with the mating rail 5B. Once aligned, the capture mechanism 6B retracts the print cartridge 2B into the print station 11B. The print cartridge 2B is aligned and secured in place within the print station 11B. As the cartridge 2B retracts into place, its interface plate (similar to that described with reference to FIG. 1A) aligns with the print station's interface plate 9B. Once the cartridge 2B is secured in place, the interface plate fully engages, providing services (such as compressed air, electrical power, input / output signals, gas, and cooling water) to the print cartridge 2B. Securing in place can alternatively or additionally be achieved using permanent or electromagnets, pins, clamps, hooks, cables, tilts, air bearings, linear slides, linkages, or robotic end effectors. Additionally, hardware keying can be used as an additional safety measure against improper operation, such as when reactive metals are loaded into the cartridge and assurance is needed that the atmosphere within the print station is suitable to prevent explosions. Additional or alternative keying, such as electronic, optical, and software, can be used as an overlay security measure to prevent unauthorized use of FRUs independent of their authorized stations.

[0037] Once mated, the Z-axis piston 7B rises in unison with the Z-axis plunger (similar to that described with respect to FIG. 1A). Upon contact, an automatic clamp 8B connects the two. The cartridge's Z-axis is now fully controlled by print station 11B. The built-in optical diagnostics (camera / sensor) and lighting within the cartridge are now powered by print station 11B, and diagnostic images / data can be displayed in virtual window 10B and / or directed by the print station to transmit images / data elsewhere.

[0038] Once printing is complete, transporter 3B aligns transport fixture 4B with print cartridge 2B. Capture mechanism 6B pushes print cartridge 2B so that it deploys into transport fixture 4B. Print cartridge 2B engages and locks into transport fixture 4B. Transporter 3B is now ready to deliver cartridge 2B to another station or destination device. Print station 11B is now ready for use, so another print cartridge can be loaded into place and the next print can begin with minimal downtime between prints. Note that this second print cartridge may contain an entirely different printable material.

[0039] In this example, the transporter (3B) is a human-driven cartridge transporter, but in other embodiments, the transporter can be partially or fully automated. In other examples, a partially or fully automated transporter can be guided by a telepresence camera (teleoperator), guided by embedded transponders with simple or complex algorithms such as artificial intelligence, neural networks, deep learning networks, neuromorphic processing, or other automated decision methods, and assisted by any number of optical or non-optical sensors.

[0040] In other embodiments, the module interface (6B) to the cartridge is the same height and the transporter 3B is made to interface and secure with the cartridge 2B without height adjustment, eliminating the need for "forklift-like" movement of the transporter 3B.

[0041] FIG. 1B(i) shows a self-propelled transporter carrying print cartridge 1B(i). The print cartridge (3B(i)) is loaded onto self-propelled transporter 5B(i). The transporter can be controlled by its own software / instructions / programming to deliver cartridge 3B(i) to a destination as directed by instructions placed on cartridge 3B(i), and can be controlled by a manufacturing system control program, instructions loaded therein, telepresence control, or one of the communication connection methods described below. The transporter 5B(i) also includes power / communications to activate the cartridge and allow the control system to monitor diagnostics within the cartridge via a communication system onboard the transporter.

[0042] Figure 1C shows one embodiment of an additive manufacturing system 1C with a front view of a print station 11C holding a print cartridge 2C during printing. The cartridge 2C is aligned and supported by a mating rail 3C. A Z-axis piston 4C rises and connects to the cartridge plunger (similar to that described with reference to Figure 1A). A laser beam 5C exits the print station 11C, passes through a window 6C on the top of the cartridge, and deposits powder onto the printed part within the cartridge 2C. A safety shield 7C prevents laser light from escaping the print station and protects the operator from accidentally contacting the print chamber 2C during printing. The operator can inspect the print by viewing a camera image displayed in a virtual window 8C. Additionally, any diagnostic data, such as images in the visible or invisible wavelength range, optical pyrometrics, or information obtained from a laser ultrasound imaging system (LUIS) or similar high-speed imaging system, can be displayed in the virtual window 8C.

[0043] FIG. 1D shows a 1D example of a front view of a standard cartridge interface. These interface features 6D can be incorporated into all mating devices so that cartridges mate with each in the same way. Cartridge mating rails 6D guide and support the cartridge. A capture mechanism 2D pulls the cartridge into the mating device and pushes it back into a transport fixture (similar to that described with respect to FIG. 1B). The size, material, function, and location of these features can be standardized. A standard interface provides customers with maximum flexibility for handling cartridges. Communication with any one module can be achieved through an interface panel 3D. In some embodiments, communication can be achieved using low- or high-frequency modalities or through a hardware interface; other methods may include RF, Wi-Fi, inductive, Ethernet, USB, or Bluetooth. High-frequency methods may include fiber, Li-Fi, or free-space optical links. Hardware interfaces may include SIM, floppy, DVD, laser DVD, holographic disk, or volumetric optical memory structures. The hardware modality may have a transfer mechanism that is operator installed or that allows the cartridge to physically transfer one of the instruction storage modalities from itself to a similar receptacle interface on the module.

[0044] In other embodiments, where the cartridge is large (cargo container size), it becomes very heavy. In these embodiments, the cartridge is stationary and the station is carried on the cartridge where the same interface of FIG. 1D allows the station to mate with the stationary cartridge.

[0045] FIG. 1E shows an example of an additive manufacturing system 1E including a storage station or rack 11E, showing three cartridges 2E already installed. A transporter 4E is shown transporting and storing a fourth cartridge 3E in rack 11E. Rack 11E contains four instances of a standard print cartridge interface, consisting of supports, mating rails 5E, an interface plate 6E, and a capture mechanism 7E. Rack 11E also contains a facility station 8E, which houses the means to provide services (compressed air, power, input / output signals, gas, cooling water, etc.) to each cartridge as needed. Facility station 8E can be configured to allow customers flexible use of the rack. The status of each cartridge 2E is available on one or more monitors, which also function as virtual windows 9E, allowing operators to see inside each cartridge.

[0046] Rack 11E provides a storage location for cartridges. Unused or new cartridges may be stored here, full of new powder and new printing plates, ready to be installed in the print engine to start a new print. Rack 11E can preheat printing plates and keep cartridges full of gas as needed for the print job assigned to the cartridge. Cartridges containing newly completed prints can also be stored in rack 11E while awaiting post-processing. Prints can be kept at any temperature, or their temperature can be increased or decreased according to a temperature profile. This allows the print to be annealed or heat-treated to relieve stress or achieve desired mechanical properties. This simply allows time for the print to cool sufficiently so that the powder can be removed. The gas atmosphere can also be changed, for example, by introducing a new gas or gas mixture, to achieve the desired mechanical properties. In other system embodiments, empty cartridges can be stored in storage rack 11E simply to keep them out of the way. Cartridges can be stored in rack 11E whether they are new and filled with powder, fully used with powder, or partially used.

[0047] Diagnostics built into the cartridges can continuously monitor the status of the print. These built-in diagnostics can include part, powder, and environmental temperatures, imaging at multiple wavelengths, vibration and ultrasound imaging, and other modalities such as LUIS volumetric mapping of the printed part. Diagnostic information (images or data) can be shown in the virtual window 9E of any cartridge contained in the rack. Additionally, current and past cartridge information can be transmitted by the control system to other virtual windows or any user interface.

[0048] FIG. 1F shows an example of a print engine 11F with an auxiliary print station 2F attached. The print engine 11F can accommodate print cartridge 3F. The auxiliary print station 2F can accommodate print cartridge 4F. The auxiliary print station 2F prints parts using laser energy generated by the print engine 11F. The print engine can direct laser energy to either cartridge 3F or 4F when installed in the respective print modules 11F and 2F. Processing priority can be set to prioritize cartridge 3F so that most laser shots are directed to cartridge 3F. During times when laser energy cannot be sent to cartridge 3F (e.g., during powder spraying or print cartridge unloading), energy can be directed to cartridge 4F, ensuring maximum laser usage of the print engine 11F.

[0049] FIG. 1G illustrates an alternative embodiment of an additive manufacturing system 1G. Multiple print engines 11G are located in close proximity to the manufacturing floor. A service aisle 2G allows a transporter 3G to transport print cartridges 4G between the print engines and powder stations 5G, racks 6G, and any other associated equipment. A facility station 7G may be located on a mezzanine level 8G to conserve floor space. This printer is particularly suited to this type of multi-unit factory layout due to its short cycle time and fast print speed. This layout allows for the sharing of associated equipment among multiple print stations / engines, improving cost efficiency. In some embodiments, various types of communication between cartridges, print engines, powder stations, and racks are possible. In other embodiments, cartridge identification information can be used to direct automatic, semi-automatic, or manual positioning of the cartridge with the appropriate print engine, powder, or storage module. Communication types that can be used include low-frequency and high-frequency methods such as RF, Wi-Fi, Inductive, Ethernet, USB, Bluetooth (low-frequency type), Fiber, LiFi, and FSO (high-frequency type). Additionally, this information can be transported from the cartridge to the destination station using physical media hardware such as a SIM, floppy, DVD, laser DVD, holographic disk, or volumetric optical media.

[0050] FIG. 1G(i) shows a cartridge embodiment in which the cartridge is large as a cargo container 1G(i). The cartridge contains all of the functional components listed in FIG. 1A, but inside a much larger structure, 2G(i). In this embodiment, the print engine interfaces to the laser system via a movable window present on the top surface of 2G(i), shown as 3G(i) (top surface) and 5G(i) (optical interface). This laser window interface is constructed using one of the cartridge interface embodiments described in FIGS. 1I, 1J, 1K, 1M, or 1N, some of which use embodiment 1L, to assist in cleaning the interface laser window. The movement of the window, 7G(i), across the top surface 3G(i) is shown in direction 9G(i).

[0051] The cartridge movement, as illustrated with respect to FIG. 1G(i), can be by a specialized crane 11G(ii), as illustrated with respect to FIG. 1G(ii), an overhead crane (commonly found at shipping ports), or a rail system 13G(iii) in FIG. 1G(iii). In that case, the printing system may include or be located at a dedicated process station (17G(iii), 19G(iii), or 21G(iii)) where the cartridge (15G(ii)) moves on rails 14G(iii) and stops under the dedicated process station (17G(iii), 19G(iii), or 21G(iii)), where a process is performed on all or a portion of the powder contents of the cartridge. Other processes (23G(iii)) may precede or follow the process shown. The processes can be performed sequentially, in parallel, or in any order, depending on the time and order of the processes.

[0052] FIG. 1H shows an alternative embodiment of an additive manufacturing system 1H. The print chamber inside the print module (aka chamber) 11H has a fixed window 6H at the top of the chamber. The print head 5H can be mounted on an XY gantry so that it can traverse the entire area of ​​the printing plate 2H. This movement is represented by arrow 8H. A laser beam 7H is projected from the print head and passes through the window 6H to deposit powder onto the metal parts on the printing plate 2H. The window must be large enough (approximately the same size as the printing plate) so that the laser can be aimed at the entire area of ​​the printing plate. The powder hopper 4H and Z-axis wall 3H are shown for reference.

[0053] FIG. 1I illustrates an alternative embodiment of an additive manufacturing system 1I. In this embodiment, a chamber 11I includes a window 6I, which is attached to a bellows 7I for free movement in the XY plane (indicated by 10I). After the cartridge is installed at the printing station, the window 6I is secured to the print head 5I at position 9I using a clamp, magnet, kinematic mount, or other suitable mounting mechanism (this can be done manually or automatically). The print head 5I is mounted to an XY gantry so that it can traverse the entire area of ​​the printing plate 2I. This movement is represented by arrow 10I. Due to their mounting, the window 6I moves with the print head 5I. A laser beam 8I is projected from the print head and passes through the window 6I to deposit powder onto the metal components on the printing plate 2I. In this embodiment, the window 6I can be significantly smaller than the printing plate 2I because it is transported across the entire area of ​​the printing plate. A powder hopper 4I and Z-axis wall 3I are shown for reference.

[0054] FIG. 1J shows an alternative embodiment of an additive manufacturing system 1J. The print chamber 11J has a window 6J attached to a bellows 7J for free movement in the XY plane. After the cartridge is installed in the print station, the window 6J is secured at position 9J to a secondary XY gantry 10J attached to the print station using a clamp, magnet, kinematic mount, or other suitable mounting mechanism (alternatively, the secondary XY gantry can be part of the print cartridge). The secondary XY gantry can be much less expensive and lighter than the print head XY gantry because it supports much less weight and does not need to move as quickly or precisely as the print head XY gantry. The print head 5J is attached to the XY gantry so that it can traverse the entire area of ​​the printing plate 2J. This movement is represented by arrow 13J. The print station's system controller can direct the secondary gantry 10J to move simultaneously with the print head 5J. A laser beam 8J is projected from the print head and passes through window 6J to deposit powder onto the metal parts on the printing plate 2J. In this embodiment, window 6J can be significantly smaller than the printing plate, as it follows the print head's movement across the entire area of ​​the printing plate. The powder hopper 4J and Z-axis wall 3J are shown for reference.

[0055] Figure 1K shows an alternative embodiment of an additive manufacturing system 1K. This embodiment is similar to the embodiment shown with respect to Figure 1I, but the attachment 9K is more flexible, allowing the print head to push and move the window 6K. In this embodiment, a mechanism supports the window 6K against gravity to prevent the window from sagging.

[0056] FIG. 1L illustrates an alternative embodiment of an additive manufacturing system 1L. This embodiment is similar to the embodiment illustrated with respect to FIG. 1H, except that the window 6L is periodically cleaned by a wiper 10L mounted on a carriage 9L. The carriage rides on rails 8L and is driven past the window 6L. Each pass of the wiper cleans the window surface of accumulated dirt, allowing the laser energy 7L to pass unimpeded through the window. In some embodiments, the wiper can be a cloth-like material that is dried or soaked in a solvent and then quickly wiped against the interior window of the cartridge. In other embodiments, the wiper can be made from a bristle brush configuration with soft bristles that are stiff enough to not scratch or mar the window but can wipe away any powder. In some embodiments, the wiper can be a gas jet (e.g., an air knife) for non-contact cleaning. In some embodiments, the wiper can be a gas or liquid sprayer, or a combination of such a sprayer and a physical wiper. After cleaning the window, the wiper can be cleaned with a gas jet, wiped over special or textured surfaces to remove powder, or cleaned with a solvent or bath at a separate cleaning location. In some embodiments, the wiper can be replaced when soiled. In some embodiments, a soiled part of the wiper can be moved to expose a new part of the wiper. In some embodiments, the wiper is made from cotton, polyester, wool, carbon fiber strands, Kevlar, fiberglass, aluminized cloth, ceramic cloth, silica cloth, or other suitable material.

[0057] Figure 1M shows an alternative embodiment of an additive manufacturing system 1M. The print head 5M can be mounted on an XY gantry so that it can traverse the entire area of ​​the printing plate 2M. This movement is represented by arrow 8M. The print chamber 11M has an opening 16M located at the top of the chamber. A sliding door 12M can close the opening and a seal 13M can seal it from the ambient environment. The door can be opened and closed by an actuator 14M. The print station 15M has a fixed window 6M that seals the print station from the ambient environment.

[0058] Figure 1N shows the "open" position of an alternative embodiment of an additive manufacturing system 1M. The print station 15N extends the seal 17N toward the top of the print chamber, sealing it from the ambient environment. The door 12N can then be opened by the actuator 14N, leaving the opening 16N open. A laser beam 7N is projected from the print head, passes through the window 6N, and deposits powder onto the metal parts on the printing plate 2N. The window must be large enough (approximately the same size as the printing plate) to allow the laser to target the entire area of ​​the printing plate. In this embodiment, the print chamber 11N is inexpensive because the window 6N is fixed to the print station 15N. The powder hopper 4N and Z-axis wall 3N are shown for reference.

[0059] Figure 1O shows an additive manufacturing system 1O that includes a print facility control system and database connectivity 2O that connects to various stations in the print facility. The control system and database 2O communicate with cartridges 3O, print stations 4O, racks 5O, powder removal stations 6O, transporters (cartridge movement systems) 7O, and facility stations 8O. Each component updates its status and can be reconfigured in real time to optimize facility operation.

[0060] FIG. 1P illustrates an additive manufacturing system 1P that includes various other potential stations that could be part of the system. In some embodiments, cartridges are loaded into the stations. An example of a station is a print station with cartridges, which receives energy (laser or electron beam) from a laser engine (station) to print a part. Typically, a laser engine is only used in conjunction with a print station to form the combination into a print engine. Stations can be arranged and interconnected to form a manufacturing system. A manufacturing system may include stations with many cartridges and support stations captured in a frame arrangement that are coordinated by a control system and receive printing instructions from users to fulfill print orders / jobs. These other functional stations can include dirty processes to reduce human exposure when creating 3D parts. As previously mentioned, 3D printing is messy in itself, and equally messy are cartridge pre- and post-processing, powder post-processing, and printed part post-processing. Additionally, the cartridge system interfaces with various diagnostic systems. The control system and database 2P communicates with the cartridges individually, when connected to one of the listed stations 40P, or when operated by the transporter 5P. The listed stations are not an all-inclusive list, but include the print engine 41P (comprised of the print station 42P and laser engine 43P), the storage (rack) station 44P, the facility station 56P, and the powder preparation / powder removal station 45P. The powder preparation station can be a single station for preparing cartridges, which includes removing powder from cartridges that have already been printed. These two functions (cartridge preparation and powder removal) can be performed in a single station or two separate stations, in which case the preparation station can be called "prep" and the other "powder removal."Other stations can include a surface coating station 46P, a heat treatment station 47P, a CNC / machining station 48P, a surface finishing station 49P, a preparation service station, a deburring station, a powder re-sieving station 52P, a powder surface treatment / coating station 53P, a LUIS diagnostic station 54P, other volume and surface diagnostic stations 55P, and other processing stations 56P. The laser engine 43P can mate and interact with the printing station 42P (forming the printing engine 41P), the surface coating station 46P, the LUIS diagnostic station 54P, and can interact with the heat treatment station 47P and the surface finishing station 49P.

[0061] The printing station 42P, surface coating station 46P, heat treatment station 47P, CNC / machining station 48P, surface finishing station 49P, and deburring station 51P perform post-processing on the printed part. The surface coating station 46P, in conjunction with the laser engine 43P, operates on the printed part to add functional layers to selected surfaces, as in the case of drill bits, airfoil surfaces, turbine blades, or medical implants. The heat treatment station 47P can work in conjunction with the laser engine 43P to anneal and harden the surface, or other traditional methods such as standard heat sources or non-laser sources of directed energy can be used to perform this form of post-processing. The CNC / machining station 48P performs standard subtractive manufacturing on the printed part for the final shape and geometry. The surface finishing station 49P can interact with the laser engine 43P to perform surface smoothing via material transport / surface tension or laser peening / hardening. The surface finishing station 49P can also perform more traditional subtractive methods (which do not require coupling 49P to 43P). The deburring station 51P uses traditional removal machining methods to enhance the surface finish of printed parts. The LUIS diagnostic station 54P couples with the laser engine 43P (consisting of LUIS-specific FRUs) to volumetrically scan printed parts to verify print accuracy, density, and defect statistics. Additionally, LUIS and other volumetric diagnostics (54P and 55P, respectively) can be used in conjunction with the storage station and laser engine to determine the functionality of printed parts under conditioned environments, such as high or low temperatures, high pressure or partial vacuum, or other extreme environments or operations, ensuring printed parts can withstand static operational performance requirements.

[0062] The preparation service station 50P is used to service cartridges and can be used in conjunction with the powder station 45P and facility station 56P. At the preparation station, consumables (such as the blade 4A, build plate 12A, and HEP A filter 8A in Figure 1A) are replaced to minimize human interaction with the dirty environment. Gases and fluids are removed for post-processing via the facility station 56P. Used powder is removed and transferred to the powder re-sieving station 52P for powder recovery.

[0063] The powder processing / coating station processes the powder for chemical or emissivity enhancement. This depends on which powder / metal is being used, but can include chemical or oxide treatments to enhance emissivity (such as increasing absorption on copper or steel by surface treating the powder) or by adding chemical dopants to the powder for special printing parameters.

[0064] Other volumetric diagnostic stations 55P include X-ray tomography, surface scan imaging, high resolution surface, and thermographic imaging, to name a few, where printed parts are manipulated with minimal damaging treatments and no human body is exposed to hazardous measurement methods (as is the case with X-ray tomography).

[0065] Other processing stations can meet customer needs using potentially hazardous processes, testing or diagnostic processes, isolated from workers and / or printed parts.

[0066] Advantageously, the described additive manufacturing system describes a cartridge that includes the entire print chamber and all of its components. The cartridge can be transported between mating machines. The use of a camera and virtual window eliminates the need for a physical window. In one embodiment, a display screen may allow for remote inspection of the cartridge. A laser beam passes through the top window to perform powder deposition, preheating, heat treatment, or other thermal operations. By directing the laser beam to an auxiliary printing station, wasted laser shots can be utilized, increasing manufacturing throughput.

[0067] Other advantages of the described additive manufacturing system are based on the use of electronically readable memory for the cartridges, allowing data to be stored and associated with their intended use. The cartridge design allows for matching the cartridge to a mating device using a standard interface. The cartridge's electronically readable memory can signal actions to be performed on the print engine before, during, or after the printing process. The mating device can read and write information to the electronically readable memory. An operator can access the electronically readable memory using a handheld unit. A storage rack can provide servicing for the cartridges, assign information to the electronically readable memory, or be used to thermally process the print before it is removed from the printing plate.

[0068] The described additive manufacturing system protects workers by isolating them from harmful printer by-products (such as metal powder, soot, weld slag, and inert gases), which are contained within the print cartridge. All mechanical components exposed to printer by-products are removed with the cartridge, which can be opened in a dedicated powder handling station. This arrangement limits the opportunity for printer by-products to escape into the factory environment. Once the cartridge is installed in the powder or prep station, workers can service all cartridge components through glove ports, eliminating the need for workers to wear special protective equipment to service the cartridge. Alternatively, the powder or prep station can be installed in a clean room, and workers wear protective masks and clothing to service the cartridge. This scheme isolates all contamination in the clean room, eliminating exposure to the rest of the factory.

[0069] Another benefit of the additive manufacturing system described above is increased printer uptime by reducing idle time between prints. Once a print is complete, the operator can remove the print cartridge, immediately install a new one, and start a new print. This reduces idle time between prints from hours to minutes. Print cartridges can be cleaned, serviced, and loaded with new powder and a new printing plate offline at a preparation station. This operation is performed in a sealed environment, so the print chamber and powder are not exposed to air, high humidity, or factory contaminants. New cartridges can be prepared in advance to suit the customer's production schedule. New cartridges are placed in a storage rack and can be preheated, cooled, pressurized, or depressurized with the required gas atmosphere. When the printer is available, the new cartridge can be inserted and printing begins immediately. This is because there is no time to wait for the cartridge to preheat or vent atmospheric gases.

[0070] Another advantage of the described additive manufacturing system is that the printer can produce a print in any material (metals such as steel, aluminum, Inconel, titanium, wood, glass, or ceramic) and, as soon as that print is complete, print other materials with little to no downtime for servicing between prints. Because the printer has no residual powder, it does not need to be cleaned before a cartridge with a different material can be printed. This not only saves time, but also offers maximum flexibility to customers, as the printer does not have to be dedicated to handling only one material.

[0071] Another advantage of the described additive manufacturing system is that the cartridges and / or stations can be slightly or highly modified to suit customer requirements. For example, a cartridge can be designed with printing plates of a much smaller surface area or a different shape (i.e., round instead of square). This could, for example, allow a customer to print very expensive materials (e.g., gold) in small volumes. This small volume cartridge can be designed to interface with a variety of printing stations, maximizing the customer's flexibility in what they print.

[0072] Another advantage of the described additive manufacturing system is that it allows for thermal processing of prints (e.g., heat treatment, annealing, controlled cool-down) without removing the print from the controlled environment in which it was printed (i.e., the print cartridge heats and cools, and the atmosphere is controlled). The cartridges are delivered to a storage rack and can be kept at any temperature in any gaseous environment per the customer's instructions. Because the print is not exposed to the atmosphere or cooled, the customer has greater control over influencing material properties. This also reduces the problem of printing plate warping due to thermal stress.

[0073] Another benefit of the described additive manufacturing system is that it can produce prints on any of several print cartridges that can be simultaneously installed in one or more auxiliary print stations, utilizing otherwise wasted laser energy to further reduce overall print time, while also providing customers with flexibility in their print schedules and improving machine utilization.

[0074] Another advantage of the described additive manufacturing system is that the cartridge and mating equipment functionality can be implemented as standard or optional features on additive manufacturing systems from other equipment manufacturers. This technology is offered as a subsystem to be integrated into additive manufacturing equipment using laser powder bed fusion or other 3D printing methods. Additive manufacturing systems that utilize the cartridge / station approach benefit from this approach. The cartridges and stations can be modified slightly or significantly to suit the specific needs of the manufacturer or customer.

[0075] Various alternatives or extensions to the various components of the described additive manufacturing system are contemplated, for example:

[0076] The bellows in the embodiment illustrated with respect to Figures 1H, 1I, and 1J can be replaced or supplemented with a series of sliding plates (such as cables) that support the window so that it is free to move in the X and Y axes but does not sag in the Z axis.

[0077] The powder hopper may be partially filled by the user if less powder is needed for a particular print.

[0078] Blade spreaders can be replaced with rollers or electrostatic spreaders.

[0079] The powder spreader drive can be remotely located and driven with an appropriate interface that transfers power to the mechanism (e.g., a flex shaft). The powder spreader can be actuated by many types of actuators, including gear drives. In some embodiments, the powder spreader can be a removable and upgradeable subsystem of the cartridge.

[0080] The HEPA filter can be located in the print cartridge of the printer, or in both locations. The HEPA filter can also have a pre-filter, such as a vortex separator or screen, to handle large amounts of soot.

[0081] Multiple gas supply and return ports can be supported and the gas supply and return ports can be physically located in different locations on the cartridge to prevent mixing of different powder types.

[0082] In some embodiments, the camera can capture video and still images to provide a virtual window. The camera and light can illuminate and capture multiple wavelengths of light (e.g., IR, visible, or UV). The camera can be an array of several cameras, recording still and / or video images from many different angles at one or many wavelengths of light. The light can be an array of one or many lights, illuminating the cartridge from various angles and at various wavelengths. The virtual window can be viewed from anywhere, allowing images to be sent to a remote viewing location. The virtual window monitor can be located on the cartridge itself, in front of the print station, or as a monitor display mounted on an industrial monitor / keyboard arm. In some embodiments, the cartridge can also have a physical window or port that allows direct viewing by eye or an external camera or other sensor.

[0083] Various types of cartridge transport are contemplated. In some embodiments, rollers can be replaced with telescopic tubes, pick-and-place robots, overhead lifts, rails, or conveyors. Forklift tubes can be replaced with automated equipment such as carts, belt conveyors, or robotic equipment such as rails, bottom-lift stackers, robotic tugs, or robotic forklifts. Alternative embodiments include the use of overhead gantry / crane mechanisms; floor-rolling carts or buggies (manual or fully automated); manual or automated rail systems that can be wheeled or wheelless (magnetic levitation, air bearing); robotic manipulators; and conformal body power suits.

[0084] The plunger / z-axis piston can be matched with a zero-point clamp or other kind of automatic clamp.

[0085] The safety shield can be part of the cartridge, attached to the print engine, or a combination of both. Its material makes it opaque to laser light. The exterior surface should be cool to the touch while the system is operating.

[0086] To prevent cross-contamination between powder types, the interface plate can use different configurations or be positioned in different areas (e.g., moving left and right or up and down) depending on the type of gas or powder used in the cartridge. For example, the recycling gas port for a cartridge containing steel powder can be on the left side, while the recycling gas port for a cartridge containing aluminum powder can be on the right side. Because the ports for different materials do not line up, operators cannot accidentally connect the wrong cartridge to the gas recycler. In some embodiments, multiple gas recyclers within each print engine can support the printing of different materials. For example, an external motor can be used to drive gas recycling impellers, switching between two sets of impellers. This allows only one expensive motor to drive two relatively inexpensive impellers in separate gas ducts for different materials. In some embodiments, a gas recycling module (gas cartridge) can be inserted or removed from the print engine depending on the material that needs to be processed. In some embodiments, the gas recycling equipment, including filters, can be installed directly on the print engine. In other embodiments, the filters and "material-dependent" equipment are installed in the cartridge unit itself, completely avoiding cross-contamination when installing different cartridges containing different materials.

[0087] Storage racks can be various sizes to accommodate one or more cartridges. Cartridges can be programmed in the storage rack and automatically set to run jobs based on predetermined job scheduling. Electronic memory held within each cartridge can interface with robotic handling systems, cranes, rails, and conveying equipment, or communicate with transporters and / or their operators or systems to tell them which print station / engine to connect to in a production environment. Cartridges can be battery powered, allowing for sensors and information-providing capabilities when removed.

[0088] A print engine may be fitted with multiple auxiliary print stations (ie, 1-N), where N may be 1, 10, 100, or 1000, or any number in between or greater.

[0089] The print cartridges can be filled with the same or different materials while printing simultaneously or sequentially.

[0090] The laser light can be split between the printing stations before patterning, where each printing station has its own light valve or patterning device. In other embodiments, the laser light can be split between the chambers after patterning, where the first chamber acquires the positive (dominant) image and subsequent chambers acquire the remaining (negative) images.

[0091] The energy fluence directed at each cartridge can be the same or can vary depending on the type of material.

[0092] In one embodiment, print cartridge and / or print engine usage can be prioritized, with each print cartridge or engine being prioritized before or during printing. For example, the priority cartridge can remain static or change based on input (i.e., from the user, such as a change in job priority, or due to print completion, print error, or other external desire). The priority of any cartridge can be promoted or demoted. For example, if there are two cartridges and the highest priority cartridge becomes idle (due to user intervention, subsystem processing such as spraying or image loading, an error, etc.), the priority is changed to the previously lower priority cartridge, thereby maximizing overall print throughput. This variation applies to any number of cartridges greater than one. As another example, a customer could prioritize printing high-temperature prints in the primary print station where the primary cartridge is inserted, and assign a lower priority to room-temperature, light-load prints in the auxiliary print station. The lower-temperature prints can proceed at a much slower pace without sacrificing print quality or keeping the auxiliary chamber unnecessarily hot.

[0093] Each print cartridge in each print station can print the same print file or different print files. Each print can be started and stopped while the print in the auxiliary print cartridge continues to print. A print cartridge can be installed and removed from a print station during a multi-chamber printing operation without interrupting the printing process in the chambers that are not removed.

[0094] Figure 1Q shows the field-replaceable units (FRUs) inside a print engine and its associated facility station 1Q. Cartridge 3Q is shown loaded into a print station (15Q) that attaches a laser engine (13Q) to form the print engine (9Q). Laser light is generated, conditioned, patterned, and analyzed within the FRUs (e.g., 5Q) before passing from the laser engine 13Q to the print station 15Q through galvo optics 4Q. The laser engine consists of an active or passive vibration-damped frame (11Q) that holds multiple FRUs (5Q). The facility station (7Q) provides gas, electrical, communications (to the control system and database), and fluid systems to the print engine (9Q). The FRUs (5Q) are subsystems of the laser engine that incorporate the laser optics, patterning optics, various adaptive optics, and various diagnostic subsystems and their associated optics.

[0095] The Galvo Optics 4Q includes an optical alignment system to assist with alignment (detailed in the FRU Periscope section below), high-speed galvos for dynamic tile printing sequencing, optics for delivering patterned light to the floor, and systems for floor diagnostics, cooling, control, and communications.

[0096] The FRUs are individually packaged and aligned before being packaged in their own inert, purified atmosphere. They are loaded into the laser engine station on alignment rails and, once loaded, automatically connect to the frame system 11Q, which features a connection panel similar to that shown on the cartridge. The frame system (11Q) is a structured housing, which can be 3D printed or machined, that forms the mechanical, electrical, fluid, gas, control, and communications infrastructure specifically for the FRUs, as well as the print station and cartridge. Each FRU includes active and / or passive vibration isolation within the housing, while the frame includes active and / or passive vibration control (6Q) to isolate the FRUs from internal vibrations coming from the environment in which the print engine resides and from noise and vibration induced by the fluid and gas flow pumps, cooling fans, and print cartridges. For example, the rails and / or frame on each FRU may include pneumatic, piezoelectric, voice coil, or similar mechanical, or electromechanical actuators to counteract vibrations sensed by accelerometers within each FRU, adjusting the FRU's coordinate system relative to the frame or other FRUs and adjusting and compensating via system control logic. The FRU interface within the frame provides kinematic alignment, allowing the FRU to easily slide in and connect to the facility services provided by the frame, and an optical path that allows the FRU to pass the high-fluence laser generated from the FRU through the patterning FRU, compensation FRU, and diagnostic FRU to the print station and cartridge. While cartridges may contain diagnostics, specialized diagnostics reside on the FRU, and floor information illuminated by lasers or other collinear light sources travels from the cartridge to these diagnostics, providing real-time, high-speed, and specialized imaging diagnostics such as LUIS. The FRU system allows for complete versatility in mixing and matching sources, optics, and diagnostics to optimize the printing system.

[0097] The way the FRUs are aligned and matched to the frame system allows for easy assembly and high-speed rotation of the laser engine without the need for highly trained personnel to oversee the alignment of complex laser systems. The kinematic characteristics of the FRU frame allow the relative position of the optical FRUs to be maintained at the level required for optically aligned subsystems. Furthermore, because each laser, optics, and diagnostic subsystem is incorporated into one or more individual FRUs, replacing these subsystems becomes routine, easing ownership, upgrades, and consumables without the need for highly trained personnel. Furthermore, because each FRU is assembled as a single unit and can be considered a "plug-and-play" component, if anything within an FRU needs to be replaced, the entire FRU can be replaced and returned for repair / maintenance, minimizing downtime to the print engine and print jobs.

[0098] Figure 1Q-I illustrates passive and active vibration damping structures within frame 1Q(i). The print engine in Figure 1Q is shown in detail in 2Q(i) with a segment of frame 3Q(i) cut away. The structured frame, which can be 3D printed or mechanically assembled, can consist of structured material 5Q(i) with pathways for various services provided by the facility station, such as electrical / communications, power, and control, conveyed by appropriate conduits 7Q(i), as well as pathways for fluid-filled gas and / or cooling fluid conduits (9Q(i)) and active and passive damping conduits (11Q(i)). In the case of fluid-transport systems such as pumps and impellers, the passive vibration damping feature in this exemplary system could be a mechanical bladder region where the fluid conduits expand to obstruct the passage of vibrations traveling along the fluid line. In active damping, sensors (15Q(i) and 19Q(i)) placed in line before the activation structure sense unwanted vibrations in the damping conduits 11Q(i), and a control system directs actuators 17Q(i) to modify the bladder regions to eliminate or attenuate these vibrations by changing the impedance load seen by the fluid in 11Q(i) as it passes through one of these bladder regions. Subsequent sensors 19Q(i) can be placed to ensure compliance and additional adjustments to 17Q(i), or other such adjustments upstream and downstream from the adjustment bladders shown in the figure. While the depiction of the linear layout of the conduits is shown with respect to passive / active damping conduits, this arrangement can be modified so that the damping conduits 11Q(i) are more distributed throughout the frame. In some embodiments, the internal structure of the frame can be foam filled with control fluid to provide distributed passive damping, while a series of distributed sensors 15Q(i) can be distributed along the frame to provide control adjustments to the distributed array of bladders for overall control of vibration throughout the frame structure.

[0099] Figure 1R shows various features of FRU1R. The FRU is an optical subsystem in a box. The FRU's external structure allows it to easily slide into the laser engine frame system on rails (5R). The rails guide the FRU to an interface panel within the frame, and the connections (2R) secure it to the frame services, supplying the FRU with the gases, fluids, electricity, and communications required for the facility station and control system. The 3R and 7R features on the FRU's external structure kinematically position and secure the FRU in place relative to the frame system—and thus, relative to the other FRUs in that system. This method ensures optical alignment between FRUs, minimizes alignment requirements, and allows highly trained laser technicians to operate the laser system without assembly alignment. Inside the FRU, alignment datums (example, 13R) are built into the optical platform, facilitating the construction of the optical subsystem. Optical alignment of the FRU is performed relative to the same system coordinate system used by the frame system during FRU assembly. Upon insertion and connection into the frame system, final optical alignment is performed using a mechanized periscope 15R to ensure the exit parameters of any one FRU match those required by the next FRU. This same method is used between the last FRU on the laser engine and the receiving optics of the print station, ensuring continuous alignment throughout the entire print engine. Additionally, the diagnostic FRU includes the same mechanized optical output periscope, ensuring that the image on the floor is faithfully captured by the imaging sensor within the diagnostic FRU.

[0100] The mechanized periscopes on all FRUs are controlled by the control system in conjunction with the diagnostics on the printing station and other diagnostic FRUs. The mechanized periscopes can include real-time compensation (such as piezoelectric, voice coil, pneumatic or similar actuators) to mitigate some vibration adjustments, especially when they are in frequency bands that cannot be compensated for by the frame system, such as in the case of high speed drilling and other percussive movements found in some factory settings.

[0101] In some FRUs, additional enhancements include telescopes that allow for focal plane changes to be adjusted as a function of tile print order, tile rotation to ensure edges and seams are aligned independent of tile print order, and laser trackers calibrated to floor locations to ensure tile print locations are designed as some examples that can be implemented to print FRU to FRU or FRU to FRU configurations on the floor or end-use location.

[0102] A diagnostic subsystem is included with each FRU and may also be packaged in a standalone housing. The diagnostic subsystem includes sensors and metrology to monitor bed and powder condition, component and subsystem safety, laser damage threshold, and component laser damage evolution, ensuring optimal alignment for optimal laser throughput to the bed. Diagnostics can include imaging the print at a variety of different wavelengths (generated by the laser FRU), under a variety of different frame rates, and, in the case of the LUIS, varying phase and polarization parameters to examine print quality during and after the printing process. Measurement modalities include, but are not limited to, bed, powder, and print temperature; high- and low-speed imaging; grain growth; grain strain magnitude and orientation; voids, contamination, and nucleation sites; backscattering to monitor damage threshold and evolution; and phase information to adaptively correct optical aberrations and improve print quality.

[0103] FIG. 1S shows a block diagram of an additive manufacturing system 1S including an additive manufacturing printing system (2S) formed at least in part from one or more stations (e.g., as listed in box 40P in FIG. 1P) interconnected via a control system / database (e.g., box 2P in FIG. 1P). The additive manufacturing system 1S can include, for example, a print engine (4S) with a print station (6S) connected to a laser engine (10S), and various other modules, such as a facility station (12S) and a transporter unit (16S) for transporting components or materials. In some embodiments, the laser engine 12S can further include one or more field-replaceable units 14S, which can include a laser, a laser amplifier, or at least some laser optics and patterning optics. In some embodiments, the field-replaceable units 14S are moved into position by the transporter unit 16S and are positioned to distribute the laser beam between each other, enabling the utilization of specialized field-replaceable units that primarily provide one or more of laser generation, amplification, patterning, redirection, or alignment, for example, as well as beam quality testing. In some embodiments, the laser engine 12S can provide a two-dimensional patterned laser beam. The print station 6S can be loaded with a removable print cartridge 8S by a transporter unit 16S. The laser engine 10S delivers a patterned high-fluence energy beam 15S to the print station 6S, which can spatially manipulate the layered powder area in the print cartridge (8S) to print one layer of the object, one tile at a time. A desired object can be printed into the print cartridge 8S over a series of layers.

[0104] Figure 1T shows a block diagram of one embodiment of a laser engine (4T) used in an additive manufacturing system (2T). The laser engine 4T is a station that is part of the additive manufacturing printing system (2T). The laser engine can include an arrangement of various substations that can be used to print objects within the additive manufacturing system 2T. When used to print objects within the additive manufacturing system 2T, the laser engine 4T can include subsystems arranged in a manner that enables the generation and adjustment of one or more wavelengths of laser light, with each wavelength being composed of low, medium, or high fluence, which are fed into the print chamber via an optical subsystem, a patterning subsystem, a diagnostic subsystem, and a control subsystem for fabrication, inspection, measurement, or post-processing of 3D printed parts. The subsystems can be hard-mounted or arranged in field-replaceable units (FRUs). The FRU system can include multiple laser subsystems 6T used to fabricate and print as part of a diagnostic system (illumination and reference), or for post-processing of previously printed parts. The optical subsystem or FRU8T can transmit, adjust, pattern, or change the position, scale, and intensity of light generated within the laser FRU / subsystem from its origin to and from the print. The diagnostic subsystem or FRU10T can consist of any number of metrology or diagnostic subsystems for measuring the quality of light sent to the floor by either the laser FRU6T or optical FRU8T structures or emitted by the printed part, and monitor the health and potential failures of these subsystems, as well as the health and potential failures of the printed part and the supporting environment and printing conditions. The control subsystem or FRU12T can be a circuit, mechanism, fixture, or component that governs, communicates, or applies corrective action to other subsystems within the additive manufacturing system 2T. The various subsystems can be packaged into individual FRUs, or FRUs of any functionality can be conveniently combined into any FRU.For example, in some embodiments, a laser FRU may include some or all of the various optical, diagnostic, and control subsystems.

[0105] FIG. 2 shows a process flow 200 for the operation of a cartridge-based additive manufacturing system. In step 202, a new or reused cartridge is placed into the print engine. In step 204, laser energy is directed into the cartridge to build a 3D part. In step 204, laser energy is directed into the cartridge to fuse, sinter, melt, or otherwise modify the powder layers. In step 206, additional powder is deposited and subjected to laser energy, and the process is repeated incrementally to build each layer and produce the 3D printed structure. In step 208, the cartridge can be removed and serviced at another powder processing station. The serviced or new cartridge can be placed into the print engine to manufacture additional or new 3D prints.

[0106] In another embodiment shown with respect to FIG. 3, an additive manufacturing system such as that shown with respect to FIGS. 1A-H and the process flow of FIG. 2 can be represented by various modules forming an additive manufacturing method and system 300. As seen in FIG. 3, the laser source and amplifier 312 can be configured as a continuous or pulsed laser. In other embodiments, the laser source includes a pulsed electrical signal source, such as an arbitrary waveform generator or equivalent, acting on a continuous laser source, such as a laser diode. In some embodiments, this can also be achieved via a fiber laser or fiber-launched laser source that is then modulated by an acousto-optic or electro-optic modulator. In some embodiments, a high-repetition-rate pulse source using a Pockels cell can be used to generate pulse trains of arbitrary length.

[0107] Types of lasers that can be used include, but are not limited to, gas lasers, chemical lasers, dye lasers, metal vapor lasers, solid state lasers (e.g., fiber), semiconductor (e.g., diode) lasers, free electron lasers, gas dynamic lasers, "nickel-like" samarium lasers, Raman lasers, or nuclear pumped lasers.

[0108] Gas lasers can include lasers such as helium-neon lasers, argon lasers, krypton lasers, xenon ion lasers, nitrogen lasers, carbon dioxide lasers, carbon monoxide lasers, or excimer lasers.

[0109] Chemical lasers can include lasers such as hydrogen fluoride lasers, deuterium fluoride lasers, COIL (chemical oxygen-iodine lasers), or Agil (all vapor phase iodine lasers).

[0110] The metal vapor laser may include lasers such as a helium-cadmium (HeCd) metal vapor laser, a helium-mercury (HeHg) metal vapor laser, a helium-selenium (HeSe) metal-vapor laser, a helium-silver (HeAg) metal-vapor laser, a strontium vapor laser, a neon-copper (NeCu) metal-vapor laser, a copper vapor laser, a gold vapor laser, or a manganese (Mn / MnCl) vapor laser. Alkali metal vapor lasers such as rubidium may also be used. Solid-state lasers include ruby ​​lasers, Nd:YAG lasers, NdCrYAG lasers, Er:YAG lasers, neodymium YLF (Nd:YLF) solid-state lasers, neodymium-doped yttrium orthovanadate (Nd:YVO4) lasers, neodymium-doped yttrium calcium oxoborate Nd:YCa4O(BO3)3 or simply Nd:YCOB, neodymium-glass (Nd:glass) lasers, titanium sapphire (Ti:sapphire) lasers, thulium YAG (Tm:YAG) lasers, ytterbium YAG (Yb:YAG) lasers, ytterbium:2O3 (glass or ceramic) lasers, ytterbium-doped glass lasers (rod, plate / chip, and fiber), holmium YAG ( Ho:YAG laser, chromium ZnSe (Cr:ZnSe) laser, cerium-doped lithium strontium (or calcium) aluminum fluoride (Ce:LiSAF, Ce:LiCAF), promethium-147-doped phosphate glass (147Pm +3 These lasers may include lasers such as trivalent uranium-doped calcium fluoride (U:CaF) solid-state lasers, divalent samarium-doped calcium fluoride (Sm:CaF) lasers, or F-center lasers.

[0111] Semiconductor lasers can include laser medium types such as GaN, InGaN, AlGaInP, AlGaAs, InGaAsP, GaInP, InGaAs, InGaAsO, GaInAsSb, lead salt, vertical cavity surface emitting laser (VCSEL), quantum cascade laser, hybrid silicon laser, or combinations thereof.

[0112] As shown in FIG. 3, additive manufacturing system 300 uses a laser capable of providing one- or two-dimensional directed energy as part of energy patterning system 310. In some embodiments, one-dimensional patterning can be in the form of linear or curved strips, raster lines, spiral lines, or any other suitable format. Two-dimensional patterning can include separated or overlapping tiles or images with varying laser intensity. Two-dimensional image patterns with non-square boundaries can be used, overlapping or interpenetrating images can be used, and images can be provided by more than one energy patterning system. Energy patterning system 310 uses a laser source and amplifier 312 to direct one or more continuous or intermittent energy beams to beam shaping optics 314. After shaping, the beam is patterned, if necessary, by energy patterning unit 316, with a portion of the energy typically directed to rejected energy processing unit 318. The patterned energy is relayed by image relay 320 to article processing unit 340 in one embodiment as a two-dimensional image 322 focused near floor 346. The article processing unit 340 can include a cartridge, as described above. The article processing unit 340 has a plate or floor 346 (with walls 348) that together form a sealed cartridge chamber containing material 344 (e.g., metal powder) dispensed by a powder hopper or other material dispenser 342. Patterned energy directed by the image relay 320 can melt, fuse, sinter, bond, change crystal structure, affect stress patterns, or otherwise chemically or physically modify the dispensed and dispersed material 344 to form a structure with desired properties. A control processor 350 can connect to various sensors, actuators, heating or cooling systems, monitors, and controllers to coordinate the operation of the laser source and amplifier 312, beam shaping optics 314, laser patterning unit 316, and image relay 320, as well as other components of the system 300.As will be appreciated, the connection can be wired or wireless, continuous or intermittent, and provide for feedback (e.g., thermal heating can be adjusted in response to sensed temperature).

[0113] In some embodiments, the beam shaping optics 314 can include a wide variety of imaging optics to combine, focus, diverge, reflect, refract, homogenize, intensity adjust, frequency adjust, or otherwise shape and direct one or more laser beams received from the laser source and amplifier 312 toward the laser patterning unit 316. In one embodiment, multiple light beams, each having a different wavelength of light, can be combined using wavelength-selective mirrors (e.g., dichroic) or diffractive elements. In other embodiments, multiple beams can be homogenized or combined using polygonal mirrors, microlenses, and refractive or diffractive optical elements.

[0114] The laser patterning unit 316 can include static or dynamic energy patterning elements. For example, the laser beam can be blocked by a mask with fixed or movable elements. Pixel-addressable masking, image generation, or transmission can be used to increase the flexibility and ease of image patterning. In some embodiments, the laser patterning unit includes addressable light valves that provide patterning, alone or in combination with other patterning mechanisms. Light valves can be transmissive, reflective, or use a combination of transmissive and reflective elements. Patterns can be dynamically changed using electrical or optical addressing. In one embodiment, a transmissive optically addressed light valve acts to rotate the polarization of light passing through the valve, and optically addressed pixels form patterns defined by an optical projection source. In another embodiment, a reflective optically addressed light valve includes a write beam to change the polarization of a read beam. In certain embodiments, light valves that are not optically addressed can be used. These may include, but are not limited to, electrically addressable pixel elements, movable mirror or micromirror systems, piezo or micro-actuated optics, fixed or movable masks or shields, or other conventional systems capable of providing high intensity light patterning.

[0115] The rejected energy processing unit 318 is used to disperse, redirect, or utilize energy that is not patterned and does not pass through the image relay 320. In one embodiment, the rejected energy processing unit 318 can include passive or active cooling elements to remove heat from both the laser source and amplifier 312 and the laser patterning unit 316. In other embodiments, the rejected energy processing unit can include a "beam dump" to absorb and convert to heat beam energy not used to define the laser pattern. In yet other embodiments, the beam shaping optics 314 can be used to recycle the rejected laser beam energy. Alternatively, or in addition, the rejected beam energy can be directed to the article processing unit 340 for heating or further patterning. In certain embodiments, the rejected beam energy can be directed to an additional energy patterning system or article processing unit.

[0116] In one embodiment, a "switchyard" style optical system can be used. Switchyard systems are suitable for reducing wasted light in additive manufacturing systems caused by the rejection of unwanted light by the pattern being printed. Switchyards involve redirecting complex patterns from generation (in this case, a plane where a structured or unstructured beam is imparted with a spatial pattern) to distribution through a series of switch points. Each switch point can change the spatial profile of the incident beam as needed. Switchyard optical systems can be utilized, for example, but not limited to, in laser-based additive manufacturing techniques that apply a mask to light. Advantageously, in various embodiments according to the present disclosure, wasted energy can be reused in a homogenized form or as patterned light used to maintain high power efficiency or high throughput rates. Furthermore, wasted energy can be recycled and reused to increase intensity and print more difficult materials.

[0117] The image relay 320 can receive the patterned image (one-dimensional or two-dimensional) from the laser patterning unit 316 directly or through a switchyard and guide it to the article processing unit 340. In a manner similar to the beam-shaping optics 314, the image relay 320 can include optics for combining, focusing, diverging, reflecting, refracting, adjusting the intensity, adjusting the frequency, or otherwise shaping and directing the patterned light. The patterned light can be directed using movable mirrors, prisms, diffractive optical elements, or solid optics that do not require substantial physical movement. One of multiple lens assemblies can be configured to provide incident light with a magnification ratio, where the lens assembly includes both a first set of optical lenses and a second set of optical lenses, and the second set of optical lenses is interchangeable with the lens assembly. Rotation of one or more mirror sets mounted on the compensation gantry and a final mirror mounted on the build platform gantry can be used to direct the incident light from the leading mirror to a desired location. The translational motion of the compensation gantry and the build platform gantry can also ensure that the distance of the incident light from the leading mirror of the article processing unit 340 is substantially equal to the image distance. In effect, this allows for rapid variation of the light beam delivery size and intensity across different material build area locations while ensuring high system availability.

[0118] The material dispenser 342 (e.g., powder hopper) within the article processing unit 340 (e.g., cartridge) can disperse, remove, mix, provide gradations or variations in material type or particle size, or adjust material layer thickness. The materials can include metals, ceramics, glasses, polymer powders, other fusible materials capable of thermally induced phase changes from solid to liquid and back again, or combinations thereof. The materials can also include composites of fusible and infusible materials, where either or both components can be selectively targeted by an imaging relay system to melt the fusible component while leaving the infusible material behind or subject it to vaporization, destruction, combustion, or other destruction processes. In certain embodiments, slurries, sprays, coatings, wires, strips, or sheets of material can be used. Unwanted material can be removed for disposal or reuse using blowers, vacuum systems, sweeping, vibration, shaking, tilting, or inversion of the bed 346.

[0119] In addition to material handling components, the article processing unit 340 can include components for holding and supporting 3D structures, mechanisms for heating or cooling the chamber, auxiliary or support optics, and sensors and controls for monitoring or adjusting material or environmental conditions. The article processing unit can support, in whole or in part, a vacuum or inert gas atmosphere to reduce unwanted chemical interactions and mitigate the risk of fire or explosion (especially reactive metals). In some embodiments, various pure or other mixtures of atmospheres can be used, including Ar, He, Ne, Kr, Xe, CO, N, O, SF, CH, CO, N, O, C, H, C, H, C, H, C, H, C, H, C, H, C, H, i-C, H, 10 , C4H 10 , 1-C4H8, cic-2, C4H7, 1, 3-C4H6, 1, 2-C4H6, C5H 12 , n-CH 12 , i-C5H 12 , n-CH 14 , C2H3Cl, C7H 16 , C8H 18 , C 10 H22 , C 11 H 24 , C 12 H 26 , C 13 H 28 , C 14 H 30 , C 15 H 32 , C 16 H 34 , O6H6, C6H5-CH3, C8H 10 , CHOH, CHOH, iCH. In some embodiments, refrigerants or large inert molecules (including but not limited to sulfur hexafluoride) can be used. An enclosure atmosphere composition having at least about 1% He by volume (or number density) can be used, along with a selected percentage of inert / non-reactive gases.

[0120] In certain embodiments, multiple article handling units, cartridges, or build chambers, each having a build platform for holding a powder bed, can be used in combination with multiple optomechanical assemblies arranged to receive and direct one or more incident energy beams to the cartridges. Using multiple cartridges, one or more print jobs can be printed simultaneously.

[0121] In another embodiment, one or more article processing units, cartridges, or build chambers can have a cartridge maintained at a fixed height while the optics are vertically movable. The distance between the final optics of the lens assembly and the top surface of the powder bed a can be maintained essentially constant by indexing the final optics upward a distance equivalent to the thickness of the powder layer while keeping the build platform at a fixed height. Advantageously, large, heavy objects can be more easily manufactured compared to vertically moving the build platform because precise micron-scale movements of the constantly changing mass of the build platform are not required. Typically, build chambers intended for metal powder volumes greater than about 0.1-0.2 cubic meters (i.e., greater than 100-200 liters or heavier than 500-1,000 kg) benefit most from maintaining the build platform at a fixed height.

[0122] In one embodiment, a portion of the powder bed layer in the cartridge can be selectively melted or fused to form one or more temporary walls from the fused portion of the powder bed layer to contain another portion of the powder bed layer on the build platform. In selected embodiments, fluid passages can be formed in the one or more first walls to enable improved thermal management.

[0123] In some embodiments, an additive manufacturing system can include an article handling unit or cartridge that supports a powder bed that can be tilted, inverted, and shaken to substantially separate the powder bed from the build platform within a hopper. The powdered material that forms the powder bed can be collected in the hopper for reuse in a subsequent print job. The powder collection process can be automated, and vacuum or gas jet systems can also be used to assist in powder evacuation and removal.

[0124] In some embodiments, an additive manufacturing system can be configured to easily handle parts longer than the available build chamber or cartridge. A continuous (long) part can be advanced longitudinally from a first zone to a second zone. In the first zone, granules of selected granular material can be bonded. In the second zone, unbonded granules of granular material can be removed. A first portion of the continuous part can advance from the second zone to a third zone, while a final portion of the continuous part is formed in the first zone, with the first portion maintained in the same lateral and transverse position that the first portion occupied in the first and second zones. In fact, additive manufacturing and cleanup (e.g., separation and / or reclamation of unused or unbonded granular material) can be performed in parallel (i.e., simultaneously) at different locations or zones on the part conveyor without the need to stop for granular material and / or part removal.

[0125] In another embodiment, additive manufacturing capabilities can be improved by using an enclosure that limits the exchange of gaseous materials between the interior of the enclosure and the exterior of the enclosure. An airlock provides an interface between the interior and exterior and has multiple additive manufacturing chambers within it, including one that supports powered bed fusion. A gas management system maintains gaseous oxygen within the enclosure below a limiting oxygen concentration, allowing for flexibility in the types and processes of powders that can be used with the system.

[0126] In another manufacturing embodiment, the article processing unit, cartridge, or build chamber can be housed within an enclosure, allowing the build chamber to fabricate parts weighing 2,000 kilograms or more, thereby increasing capacity. A gas management system can maintain gaseous oxygen within the enclosure at concentrations below atmospheric levels. In some embodiments, an airlock operates as a buffer between the gaseous environment within the enclosure and the gaseous environment outside the enclosure, and to a location outside both the enclosure and the airlock, allowing wheeled vehicles to transport parts from within the enclosure through the airlock.

[0127] Another manufacturing embodiment involves collecting powder samples from the powder bed in real time. An Ingestar system is used for in-process collection and characterization of powder samples. Collection can be performed periodically, and characterization results in adjustments to the powder bed fusion process. The Ingestar system can be used for one or more of the following actions, such as audits, process adjustments, or changes to printer parameters or verifying proper use of licensed powder materials, as needed.

[0128] Further improvements to the additive manufacturing process are described as possible through the use of manipulator devices such as cranes, lifting gantries, robotic arms, or similar devices that allow for the manipulation of parts that are difficult or impossible for humans to move. The manipulator devices can grasp various manipulation points that are permanently or temporarily additively manufactured on the part, allowing for the repositioning and manipulation of the part.

[0129] The control processor 350 can be connected to control any component of the additive manufacturing system 300 described herein, including the lasers, laser amplifiers, optics, thermal controls, build chambers, and manipulator devices. The control processor 350 can be connected to various sensors, actuators, heating or cooling systems, monitors, and controllers to coordinate their operation. A wide range of sensors, such as imagers, light intensity monitors, thermal sensors, pressure sensors, or gas sensors, can be used to provide information used for control and monitoring. The control processor can be a single central controller or, alternatively, can include one or more independent control systems. The controller processor 350 is provided with an interface that allows for the input of manufacturing instructions. The use of a wide range of sensors enables a variety of feedback control mechanisms that improve quality, manufacturing throughput, and energy efficiency.

[0130] One embodiment of the operation of a manufacturing system suitable for additive or subtractive manufacturing is shown in FIG. 4. In this embodiment, a flowchart 400 illustrates one embodiment of a manufacturing process supported by the described optical and mechanical components. In step 402, material is placed in a cartridge, bed, chamber, or other suitable support. The material may be a metal sheet for laser cutting using subtractive manufacturing techniques, or a powder that can be melted, fused, sintered, induced to change crystal structure, subjected to stress patterns, or otherwise chemically or physically modified by additive manufacturing techniques to form a structure with desired properties.

[0131] In step 404, unpatterned laser energy is emitted by one or more energy emitters, including but not limited to solid-state or semiconductor lasers, and then amplified by one or more laser amplifiers. In step 406, the unpatterned laser energy is shaped and modified (e.g., intensity modulated or focused). In step 408, this unpatterned laser energy is patterned, and energy that does not form part of the pattern is processed in step 410 (this may include converting it to waste heat, reusing it as patterned or unpatterned energy, or waste heat generated by cooling the laser amplifier in step 404). In step 412, the patterned energy, forming a one- or two-dimensional image, is relayed toward the material. In step 414, the image is applied to the material, and portions of a 3D structure are either ablated or additively built. In additive manufacturing, these steps can be repeated (loop 418) until an image (or a different image and subsequent images) has been applied to all desired areas of the top layer of material. Once the application of energy to the top layer of material has finished, a new layer can be applied (loop 416) to continue building the 3D structure. These process loops continue until the 3D structure is complete, provided that any remaining excess material can be removed or reused.

[0132] Many modifications and other embodiments of the invention will come to mind to one skilled in the art having the benefit of the teachings presented in the foregoing descriptions and the associated drawings. It is understood, therefore, that the invention is not limited to the particular embodiments disclosed, and modifications and embodiments are intended to be included within the scope of the appended claims. It is also understood that other embodiments of the invention can be practiced in the absence of elements / steps not specifically disclosed herein.

Claims

1. 1. A print engine for an additive manufacturing system, comprising: a printing station configured to hold a removable cartridge containing a powder bed; a laser engine including a frame holding at least one removable field replaceable unit including at least some laser optics or patterning optics; a laser beam is directed from the field replaceable unit to the removable cartridge; an optical alignment system mounted to at least one of the print station or the laser engine for optically aligning the field replaceable unit with respect to the removable cartridge.

2. The print engine of claim 1 , wherein the removable cartridge includes a sealable chamber having the powder bed and a laser transmissive window.

3. 3. The print engine of claim 2, wherein the removable cartridge comprises a powder spreader disposed within the sealable chamber for dispensing powder from a powder hopper onto the powder bed.

4. The print engine of claim 1 , wherein the frame of the laser engine is actively mechanically damped.

5. The print engine of claim 1 , wherein the laser light passes between a plurality of field replaceable units.

6. 10. The print engine of claim 1, further comprising a connection to a facility station that provides one or more of a gas system, a fluid system, an electrical system, a control system, and a database system to the at least one removable field replaceable unit and the removable cartridge.

7. The print engine of claim 1 further comprising a print cartridge transporter unit.

8. The print engine of claim 1 further comprising a field replaceable unit transporter unit.

9. The print engine of claim 1 , wherein the laser engine is capable of directing a two-dimensional patterned laser beam at the removable cartridge.

10. The print engine of claim 1 , wherein the removable field replaceable units are capable of directing laser beams between each other.

11. 1. An additive manufacturing printing method, comprising: disposing a removable cartridge at a printing station, the removable cartridge including a powder bed; directing a laser beam from a laser engine including a frame holding at least one removable field replaceable unit including at least some laser optics or patterning optics at said removable cartridge; and optically aligning the field replaceable unit with respect to the removable cartridge using an optical alignment system attached to at least one of the print station or the laser engine.

12. 12. The additive manufacturing printing method of claim 11, wherein the removable cartridge includes a sealable chamber having the powder bed and a laser transmissive window.

13. 13. The additive manufacturing printing method of claim 12, wherein the removable cartridge includes a powder spreader disposed within the sealable chamber for dispensing powder from a powder hopper onto the powder bed.

14. The additive manufacturing printing method of claim 11 , wherein the frame of the laser engine is actively mechanically damped.

15. The additive manufacturing printing method of claim 11 , wherein the laser light passes between a plurality of field replaceable units.

16. 12. The additive manufacturing printing method of claim 11, further comprising connecting said at least one removable field replaceable unit and said removable cartridge to a facility station that provides gas systems, fluid systems, electrical systems, control systems, and database systems.

17. The additive manufacturing printing method of claim 11 further comprising a print cartridge transporter unit.

18. The additive manufacturing printing method of claim 11 , further comprising a field replaceable unit transporter unit.

19. 12. The additive manufacturing printing method of claim 11, wherein the laser engine is capable of directing a two-dimensional patterned laser beam at the removable cartridge.

20. The additive manufacturing printing method of claim 11 , wherein the removable field replaceable units are capable of directing laser beams between each other.

21. 1. A print engine for an additive manufacturing system, comprising: a printing station configured to hold a removable cartridge having a sealable chamber containing a powder bed; a laser engine including a frame for holding a plurality of removable field replaceable units, each field replaceable unit having at least some laser optics or patterning optics for directing a laser beam to the removable cartridge in the printing station;

22. 1. A print engine for an additive manufacturing system, comprising: a printing station configured to hold a removable cartridge having a sealable chamber containing a powder bed; a laser engine including a frame for holding a plurality of removable field replaceable units, each field replaceable unit having at least some laser optics or patterning optics for directing a laser beam at the removable cartridge in the printing station, the laser beam passing through the plurality of field replaceable units before being directed at the removable cartridge;

Images