A method of manufacturing an article

Abstract

A method of manufacturing an article, the method including the steps of: locating a substrate on a build surface; layering an additive manufactured geometry on the substrate using an additive manufacturing technique to produce an article; and removing the article from the build surface.

Description

TITLEA METHOD OF MANUFACTURING AN ARTICLEFIELD OF THE INVENTION

[0001] This invention relates to a method of manufacturing an article. In particular, the invention relates to a method of manufacturing an article utilising additive manufacturing.

[0002] BACKGROUND OF THE INVENTION

[0003] Additive manufacturing has revolutionized the production of complex components by enabling the creation of intricate geometries and customized designs with unparalleled precision. Unlike traditional manufacturing methods, Additive manufacturing processes such as 3D printing offer significant advantages in terms of design flexibility, rapid prototyping, and reduced material waste. By depositing material layer by layer, additive manufacturing allows for the creation of complex structures and internal features that are challenging or impossible to achieve using subtractive manufacturing techniques.

[0004] One of the key benefits of additive manufacturing is its ability to produce complex components with minimal material wastage. Traditional manufacturing methods often result in significant material wastage due to the need for subtractive processes such as cutting, milling, and drilling. In contrast, additive manufacturing processes typically use only the material necessary to build the final product, minimizing waste and reducing environmental impact. This reduction in material wastage not only contributes to cost savings but also aligns with sustainability initiatives aimed at minimizing resource consumption and waste generation.

[0005] However, in certain additive manufacturing processes, particularly those involving metal materials, components must be produced on a build plate. Once the additive manufacturing process is complete, the component must be cut from the build plate, often resulting in additional post-processing steps. For example, the build plateoften needs to be faced before it can be reused for subsequent additive manufacturing processes, adding to the time and effort required for each production cycle. Moreover, the finished component may require additional facing or machining to achieve the desired surface finish and dimensional accuracy, further extending the production time. These post-processing steps can be time-consuming and labor-intensive, detracting from additive manufacturing processes' overall efficiency and productivity.

[0006] While additive manufacturing offers significant advantages in terms of producing complex components with reduced material wastage, there are certain disadvantages related to post-production issues, size limitations, and cost considerations that need to be addressed to realise the potential of additive manufacturing in various industries fully.OBJECT OF THE INVENTION

[0007] It is an object of the invention to overcome and / or alleviate one or more of the above disadvantages and / or provide the consumer with a useful or commercial choice.SUMMARY OF THE INVENTION

[0008] In one form, although not necessarily the only form, the invention resides in a method of manufacturing an article, the method including the steps of: locating a substrate on a build surface; layering an additive manufactured geometry on the substrate using an additive manufacturing technique to produce an article; and removing the article from the build surface.

[0009] Normally, the article is made of metal.

[0010] Preferably a metal of the substrate can bond directly with a metal additive manufactured geometry. More preferably, a metal of the substrate is comparable with a metal of the additive manufactured geometry.

[0011] Metals that may be utilised include titanium, stainless steel, aluminium, nickel alloys, cobalt chrome alloys, tool steel, copper alloys and precious metals. Other suitable metals may be used.

[0012] The additive manufactured geometry is typically complex in shape compared to the shape of the substrate. The substrate is normally mass-produced. For example, the substrate may be cast, stamped, forged, extruded, rolled or the like techniques. The substrate may utilise a secondary production method such as machine, turning, milling, polishing or the like techniques. The secondary production methods are normally subtractive manufacturing techniques.

[0013] Preferably the substrate is in the form of a metal sheet or plate. The metal sheet or plate may be cut to a desired shape. This can be achieved through any suitable technique such as machining, shearing, laser cutting, plasma cutting, waterjet cutting, punching or the like.

[0014] The additive manufactured geometry can be of any desired shape. Typically, the additive manufactured geometry is of a shape that cannot be produced using traditional techniques without substantial material wastage.

[0015] The additive manufacturing technique used may layer the additive manufactured geometry. The additive manufacturing technique may include, but not limited to Selective Laser Melting, Electron Beam Melting, Direct Metal Laser Sintering or Binder Jetting

[0016] Additive manufacturing, as used herein, refers to any process by which material is built up to form a geometry, whether by layering, volumetric curing, directed deposition, or other methods, and is not limited to traditional layer-by-layer techniques. In embodiments, future additive manufacturing techniques that do not rely on traditional layering may be employed. For example, volumetric additive manufacturing processes, such as computed axial lithography or holographic curing, which form a three-dimensional geometry within a photo-reactive medium without sequential layering, may also be used to form the additive manufactured geometry. The invention is not limited to any particular additive manufacturing process, provided that it enables the geometry to be formed on the substrate as described.

[0017] The build surface may form part of a build body. The build body is typically in the form of a build plate. The build surface is typically planar.

[0018] The build body may include fastening points to fasten the substrate to the build plate. The build surface may have fastening points to fasten the substrate to the build plate. The fastening points may be apertures. The apertures may be threaded. Bolts may be used to fasten the surface to the build plate. Fastening the substrate to the build plate may not damage the build plate. Any fastening points are within the spirit and scope of the invention.

[0019] The substrate may have more than one layer. Normally the substrate has a first layer that is a metal layer. When the substrate has a second layer, the second layer may be metal or non-metal. The second layer may be a cladding layer, a flux layer, an adhesive layer or the like layer. Where the second layer is used as a cladding layer, the cladding layer is typically made of a compatible alloy. The compatible alloy is normally of a lower melting point.

[0020] In another form, the invention resides in an article produced using a method of manufacturing, the method including the steps of: locating a substrate on a build surface; layering an additive manufactured geometry on the substrate using an additive manufacturing technique to produce an article; and removing the article from the build surface.

[0021] The article may be produced such that it is supported by the build surface, and depending on the intended application, may either be subsequently removed from the build surface or retained thereon for in situ use. For example, in some embodiments, the substrate or build surface may form part of the final product or serve as a mounting platform for further assembly or operation.BRIEF DESCRIPTION OF THE DRAWINGS

[0022] An embodiment of the invention will now be described with reference to the accompanying drawings in which:

[0023] Figure 1 is a schematic perspective view of a manufactured article according to a first embodiment of the invention;

[0024] Figure 2 is a schematic sectional view of a manufactured article, as shown in Figure 1 .

[0025] Figure 3 is a schematic perspective view of a heat exchanger that utilises a manufactured article produced using the method described in relation to Figure 1 and Figure 2; and

[0026] Figure 4 is a schematic sectional view of the heat exchanger, as shown in Figure 4.DETAILED DESCRIPTION OF A PREFERRED EMBODIMENT

[0027] Figure 1 and 2 shows a schematic representation of an article 10 mounted to a build plate 5. The article 10 is made from metal such as aluminium or titanium. The build plate 5 is made from any suitable material, such as tool steel, aluminium or titanium.

[0028] The article 10 includes substrate 11 and an additive manufactured geometry 12. The substrate 11 and the additive manufactured geometry 12 are made from the same metal. For example, both the substrate 11 and the additive manufactured geometry 12 are both made from aluminium. It would be appreciated by a person skilled in the art that different grades of the same material may also be used for the substrate 11 and the additive manufactured geometry 12.

[0029] In this embodiment, the substrate 11 includes a first metal layer 13 and a second alloy layer 14. The first metal layer 13 is in the form of an aluminium sheet. The second alloy layer 14 is in the form of a cladding layer. The cladding layer is made from aluminium alloy with lower melting point than the first metal layer 13.

[0030] The additive manufactured geometry 12 is shown in the schematic representations as rectangular prism. However, it would be appreciated by a personskilled in the art that this rectangular prism represents any complex shape that is advantageously produced using additive manufacturing. For example, the additive manufacture geometry may be a series of closely stacked cooling pins used for heat exchange purposes that would be virtually impossible to produce without using an additive manufacturing method such as Electron Beam Melting.

[0031] To produce the article 10, the substrate 11 is produced in volume using traditional manufacturing techniques. In this embodiment, a large aluminium sheet is produced. A cladding layer is then applied to one side of the aluminium sheet again using known manufacturing techniques. Typically roll bonding is used to bond the cladding to the aluminium sheet. The aluminium sheet with cladding layer is then cut to a desired size to produce the substrate 11 . Many substrates 11 can be cut from the single large aluminium sheet with a cladding layer.

[0032] The substrate 11 is then precisely positioned on the build plate using traditional methods such as fasteners (not shown) and thread holes in the build plate (not shown). The precise positioning of the substrate 11 on the build plate can be essential as a machine that is used to create the additive manufactured geometry 12 uses the build plate 5 as a reference point. Hence, if the substrate 11 is incorrectly positioned on the build plate 5, then the substrate 11 and the manufactured geometry 12 will be misaligned. It would be appreciated by a person skilled in the art that the substrate 11 can also be held and positioned on the build plate using clamps.

[0033] Accurate alignment between the substrate and the build plate can help to ensure that the additive manufactured geometry is formed in the correct position and orientation relative to the substrate. Alignment may be achieved using mechanical referencing features, machine vision systems, or digital calibration routines that correlate the substrate's geometry with the coordinate system of the additive manufacturing machine.

[0034] Once the substrate 11 is positioned on the build plate 5, the additive manufacturing process is commenced, and layer by layer, the additive manufactured geometry 12 is built up until it is completed. As the substrate 11 and the additive manufactured geometry 12 are made from the same material, the additivemanufacturing process bonds (eg. using Electron Beam Melting) the top of the substrate 11 and bottom of the additive manufactured geometry 12 together.

[0035] When the additive manufactured geometry 12 is completed, the substrate 11 is unfastened from the build plate 5. Generally, article 10 is then ready for use with no or limited post-finishing processes being required. The build plate 5 is ready to be utilised for the next article 10.

[0036] The above method provides several advantages, including reducing the required post-processing procedures such as removing support structures and machining operations that are used to finish the article 10. This method also has the advantage of removing the need to resurface the build plate after an article is removed, reducing production time and cost. These advantages improve the efficiency and productivity of the additive manufacturing process by reducing the number of processes required after additive manufacture has been completed. Furthermore, the use of a cladding layer means the substrate acts as a brazing interface between the additive manufactured geometry and other components allowing it to be joined with brazing, enabling the manufacture of components that combine the advantages of additive and traditionally manufactured geometries.

[0037] Further, the substrate 11 can be manufactured more quickly and cheaply than being produced solely through the additive manufacturing process. This, in turn, enables the article 10, which includes an additive-manufactured geometry 12, to also be produced more quickly and cheaply.

[0038] The substrate 11 may be of any suitable geometry, including flat, curved, irregular, or contoured surfaces, depending on the requirements of the article to be formed. This allows the additive manufacturing process to be applied to a wide range of base components or pre-existing parts, including those with complex shapes or non- planar surfaces. In embodiments this helps to eliminate the need for post-build joining steps and may expand the range of compatible applications and part integrations.

[0039] Figures 3 and 4 show a heat exchange 20 that utilises an article 10 that is manufactured using the method described in Figures 1 and 2. Like reference numerals have been used to describe like components.

[0040] The heat exchanger 20 utilises an article 10 and a series of tubes 21. The article 10 includes a substrate 11 that has a first metal layer 13 and second alloy layer 14. The first metal layer 13 is in the form of an aluminium sheet. The second alloy layer 14 is in the form of a cladding layer. The cladding layer is made from aluminium alloy with a lower melting point than the first metal layer 13.

[0041] The additive manufactured geometry 12 is shown in the schematic representations as a rectangular hollow tank. It would be appreciated by a person skilled in the art that both the external and internal geometry of the tank can be various complex shapes depending on the desired outcomes of the heat exchanger 20.

[0042] The additive manufactured geometry 12 is made from a different aluminium alloy as the substrate 11 but that are compatible from a bonding perspective.. The additive manufactured geometry 12 is layered onto the substrate 11 . The second alloy layer 14 (or cladding layer) faces outwardly. The additive manufactured geometry 12 is bonded to the first metal layer 13.

[0043] A series of holes 15 are located through the substrate 11 . These holes 15 are produced using a secondary subtractive production method such a milling or CNC machining. The holes 15 are normally produced in the substrate 11 prior to the layer of the additive manufactured geometry 12. However, it would be appreciated that the secondary subtractive production method may be undertaken after the layering of the additive manufactured geometry 12 to the substrate 11 . The holes 15 are sized shaped to fit the tubes 21.

[0044] To produce the heat exchanger 20, the tubes 21 are located within the holes 15 in the substrate 11 of the article 10. The tubes 11 and the substrate 11 are heated to achieve the melting point of the second alloy layer 14 (or cladding layer). This second alloy layer melts and flows around and into the holes 15, joining the tubes 21 and substrate 11 together. That is, tubes 21 are brazed to the first alloy layer 13. By attaching the tubes 21 to the article 10, the heat exchanger 20 is produced.

[0045] It should be appreciated that Figure 3 and 4 show only a single example of how the method disclosed in Figures 1 and 2 can be performed. It would be appreciated by a person skilled in the art that the example is not limiting, For example, holes are located in the substrate 11 may not be required and a further part may be brazed directly onto the substrate 11 using the cladding layer. Other machining types may also be used. Further, the internal and external shape of the additive manufactured geometry 12 unlimited.

[0046] In this specification, the terms "comprise", "comprises", "comprising" or similar terms are intended to mean a non-exclusive inclusion, such that a system, method or apparatus that comprises a list of elements does not include those elements solely, but may well include other elements not listed.

[0047] The reference to any prior art in this specification is not, and should not be taken as, an acknowledgement or any form of suggestion that the prior art forms part of the common general knowledge.

[0048] It should be appreciated that various other changes and modifications may be made to the embodiments described without departing from the spirit or scope of the invention.

Claims

CLAIMS:1 . A method of manufacturing an article, the method including the steps of: locating a substrate on a build surface; layering an additive manufactured geometry on the substrate using an additive manufacturing technique to produce an article; and removing the article from the build surface.

2. The method of claim 1 wherein the article is made of metal.

3. The method of claim 1 or claim 2 wherein a metal of the substrate can bond directly with a metal additive manufactured geometry.

4. The method of any one of the preceding claims wherein the metal of the substrate is comparable with the metal of the additive manufactured geometry.

5. The method of any one of the preceding claims wherein additive manufactured geometry is complex in shape compared to the shape of the substrate.

6. The method of any one of the preceding claims wherein the substrate is mass- produced.

7. The method of any one of the preceding claims wherein the substrate may utilise a secondary production method that uses subtractive manufacturing techniques.

8. The method of any one of the preceding claims wherein the substrate is in the form of a metal sheet or plate.

9. The method of claim 9 wherein a metal sheet or plate is cut to a desired shape.

10. The method of any one of the preceding claims wherein the additive manufactured geometry is of a shape that cannot be produced using traditional techniques.

11. The method of any one of the preceding claims wherein the build surface forms part of a build body.

12. The method of claim 11 wherein the build body is in the form of a build plate.

13. The method of claim 11 or claim 12 wherein the build body includes fastening points to fasten the substrate to the build plate.

14. The method of any one of claims 11 to 13 wherein the build surface has fastening points to fasten the substrate to the build plate.

15. The method of any one of the preceding claims wherein the substrate has more than one layer.

16. The method of claim 15 wherein the substrate has a first layer and the first layer is a metal layer.

17. The method of claim 15 or 16 wherein the substrate has a second layer and the second layer is either a metal or non-metal layer.

18. The method of claim 17 wherein the second layer is a cladding layer, a flux layer or an adhesive layer or the like layer.

19. The method of claim 17 or 18 wherein when the second layer is a cladding layer, the cladding layer is made of a compatible alloy.

20. The method of claim 19 wherein the compatible alloy is of a lower melting point.

21. A product produced using the method as claimed any one of Claims 1 to 20.

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