ADDITIVE LAYER MANUFACTURING

• US 20140015172A1
• Filed: 03/20/2012
• Published: 01/16/2014
• Est. Priority Date: 03/25/2011
• Status: Abandoned Application

• Current Assignee: BAE Systems Plc
• Original Assignee: BAE Systems Plc
• Inventors: Sidhu, Jagjit, Wescott, Andrew David
• Application Number:
  US14/007,256
• Publication Number:
  US 20140015172A1
• Time in Patent Office: Days
• US Class Current: 264/497
• CPC Class Codes: B22F 10/25 Direct deposition of metal particles, e.g. direct metal deposition [DMD] or laser engineered net shaping [LENS]
• CPC Class Codes: B22F 10/73 of powder
• CPC Class Codes: B22F 12/53 Nozzles
• CPC Class Codes: B22F 12/57 Metering means
• CPC Class Codes: B28B 1/001 Rapid manufacturing of 3D objects by additive depositing, agglomerating or laminating of material selective deposition modelling of metallic powder B22F10/00; rapid manufacturing of 3D objects in general and in particular of plastics B29C64/00
• CPC Class Codes: B29C 64/141 using only solid materials
• CPC Class Codes: B29C 64/153 using layers of powder being selectively joined, e.g. by selective laser sintering or melting
• CPC Class Codes: B33Y 30/00 Apparatus for additive manufacturing; Details thereof or accessories therefor
• CPC Class Codes: B33Y 40/00 Auxiliary operations or equipment, e.g. for material handling
• CPC Class Codes: C22C 49/14 characterised by the fibres or filaments
• CPC Class Codes: Y02P 10/25 Process efficiency

Abstract

An additive layer manufacturing system and method are provided. The system includes a powder delivery system providing at least one powder feed from a powder stock to a powder exit adjacent a deposition point. The powder delivery system further comprises at least one valve system proximal to the powder exit for controlling the flow of the at least one powder feed at the deposition point.

Claims

1-15. -15. (canceled)

16. An additive layer manufacturing system comprising:

a powder delivery system including at least one powder feed from a powder stock to a powder exit adjacent a deposition point, the powder delivery system further comprising at least one valve system proximal to the powder exit for controlling flow of the at least one powder feed at the deposition point.

17. A system according to claim 16, further comprising a laser source directed at the deposition point.

18. A system according to claim 16, wherein the powder delivery system further comprises a nozzle, and the nozzle comprises the at least one valve system.

19. A system according to claim 18, further comprising a laser source directed at the deposition point and wherein the laser source and the nozzle are provided on an integrated deposition head.

20. A system according to claim 16, wherein the at least one valve system is configured to selectively divert its said powder feed away from the deposition point.

21. A system according to claim 20, wherein the valve system returns powder from the selectively diverted powder feed to the powder stock.

22. A system according to claim 20, wherein the valve system includes an inlet line, an outlet line and a bypass line, and is arranged to selectively connect the inlet line to either the outlet line or the bypass line.

23. A system according to claim 16, wherein the at least one powder feed comprises at least one material selected from metals, ceramics, powders and fibres or a mixture thereof.

24. A system according to claim 16, comprising a plurality of powder delivery systems, each said powder delivery system including a valve system proximal to the powder exit for controlling the flow of powder feed at the deposition point and a powder feed, wherein each said powder feed feeds a different powder material.

25. A method of preparing a layered structure, the method including:

using a powder delivery system to feed powder from at least one powder feed from a powder stock to a powder exit adjacent a deposition point, and

using at least one valve system proximal to the powder exit for controlling flow of the at least one powder feed at the deposition point.

26. A method according to claim 25, further including:

directing a laser beam at the deposition point;

depositing a said powder from the powder exit onto the deposition point such that the powder is heated by the laser beam, and

selectively activating the at least one valve system so as to divert the flow of powder away from the powder exit.

27. A method according to claim 25, wherein the powder delivery system comprises a plurality of said valve systems, and in which the method further includes selectively activating the valve systems to alternate or mix different materials.

28. A method according to claim 26, further including selectively activating a said valve system such that no powder exits at the deposition point while activating the laser beam to apply a heat treatment or laser process to material at the deposition point.

29. A method according to claim 26, further comprising providing a fluid delivery system, and further comprising selectively activating the at least one said valve system such that no powder exits at the deposition point, while deactivating the laser beam, and activating the fluid delivery system to provide thermal management (including forced cooling) of material at the deposition point.

30. An Additive Layer Manufacturing deposition head including an arrangement for receiving at least one powder feed from a powder stock and at least one valve system arranged, in use, proximal to a powder exit adjacent a deposition point for controlling flow of the at least one powder feed at the deposition point.