WO2019014257A1 - Systèmes et méthodes de manipulation et de distribution de poudre automatisées - Google Patents

Systèmes et méthodes de manipulation et de distribution de poudre automatisées Download PDF

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Publication number
WO2019014257A1
WO2019014257A1 PCT/US2018/041495 US2018041495W WO2019014257A1 WO 2019014257 A1 WO2019014257 A1 WO 2019014257A1 US 2018041495 W US2018041495 W US 2018041495W WO 2019014257 A1 WO2019014257 A1 WO 2019014257A1
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WO
WIPO (PCT)
Prior art keywords
powder
additive manufacturing
container
source
blend
Prior art date
Application number
PCT/US2018/041495
Other languages
English (en)
Inventor
David W. Heard
William J. STEINER
Original Assignee
Arconic Inc.
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by Arconic Inc. filed Critical Arconic Inc.
Publication of WO2019014257A1 publication Critical patent/WO2019014257A1/fr

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Classifications

    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C64/00—Additive manufacturing, i.e. manufacturing of three-dimensional [3D] objects by additive deposition, additive agglomeration or additive layering, e.g. by 3D printing, stereolithography or selective laser sintering
    • B29C64/20—Apparatus for additive manufacturing; Details thereof or accessories therefor
    • B29C64/255—Enclosures for the building material, e.g. powder containers
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B22—CASTING; POWDER METALLURGY
    • B22F—WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
    • B22F10/00—Additive manufacturing of workpieces or articles from metallic powder
    • B22F10/20—Direct sintering or melting
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B22—CASTING; POWDER METALLURGY
    • B22F—WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
    • B22F10/00—Additive manufacturing of workpieces or articles from metallic powder
    • B22F10/30—Process control
    • B22F10/34—Process control of powder characteristics, e.g. density, oxidation or flowability
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B22—CASTING; POWDER METALLURGY
    • B22F—WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
    • B22F12/00—Apparatus or devices specially adapted for additive manufacturing; Auxiliary means for additive manufacturing; Combinations of additive manufacturing apparatus or devices with other processing apparatus or devices
    • B22F12/50—Means for feeding of material, e.g. heads
    • B22F12/52—Hoppers
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B22—CASTING; POWDER METALLURGY
    • B22F—WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
    • B22F12/00—Apparatus or devices specially adapted for additive manufacturing; Auxiliary means for additive manufacturing; Combinations of additive manufacturing apparatus or devices with other processing apparatus or devices
    • B22F12/50—Means for feeding of material, e.g. heads
    • B22F12/57—Metering means
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B22—CASTING; POWDER METALLURGY
    • B22F—WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
    • B22F12/00—Apparatus or devices specially adapted for additive manufacturing; Auxiliary means for additive manufacturing; Combinations of additive manufacturing apparatus or devices with other processing apparatus or devices
    • B22F12/50—Means for feeding of material, e.g. heads
    • B22F12/58—Means for feeding of material, e.g. heads for changing the material composition, e.g. by mixing
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B22—CASTING; POWDER METALLURGY
    • B22F—WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
    • B22F3/00—Manufacture of workpieces or articles from metallic powder characterised by the manner of compacting or sintering; Apparatus specially adapted therefor ; Presses and furnaces
    • B22F3/004—Filling molds with powder
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C64/00—Additive manufacturing, i.e. manufacturing of three-dimensional [3D] objects by additive deposition, additive agglomeration or additive layering, e.g. by 3D printing, stereolithography or selective laser sintering
    • B29C64/30—Auxiliary operations or equipment
    • B29C64/307—Handling of material to be used in additive manufacturing
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B33—ADDITIVE MANUFACTURING TECHNOLOGY
    • B33Y—ADDITIVE MANUFACTURING, i.e. MANUFACTURING OF THREE-DIMENSIONAL [3-D] OBJECTS BY ADDITIVE DEPOSITION, ADDITIVE AGGLOMERATION OR ADDITIVE LAYERING, e.g. BY 3-D PRINTING, STEREOLITHOGRAPHY OR SELECTIVE LASER SINTERING
    • B33Y30/00—Apparatus for additive manufacturing; Details thereof or accessories therefor
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B33—ADDITIVE MANUFACTURING TECHNOLOGY
    • B33Y—ADDITIVE MANUFACTURING, i.e. MANUFACTURING OF THREE-DIMENSIONAL [3-D] OBJECTS BY ADDITIVE DEPOSITION, ADDITIVE AGGLOMERATION OR ADDITIVE LAYERING, e.g. BY 3-D PRINTING, STEREOLITHOGRAPHY OR SELECTIVE LASER SINTERING
    • B33Y40/00—Auxiliary operations or equipment, e.g. for material handling
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B33—ADDITIVE MANUFACTURING TECHNOLOGY
    • B33Y—ADDITIVE MANUFACTURING, i.e. MANUFACTURING OF THREE-DIMENSIONAL [3-D] OBJECTS BY ADDITIVE DEPOSITION, ADDITIVE AGGLOMERATION OR ADDITIVE LAYERING, e.g. BY 3-D PRINTING, STEREOLITHOGRAPHY OR SELECTIVE LASER SINTERING
    • B33Y40/00—Auxiliary operations or equipment, e.g. for material handling
    • B33Y40/10—Pre-treatment
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B22—CASTING; POWDER METALLURGY
    • B22F—WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
    • B22F2998/00—Supplementary information concerning processes or compositions relating to powder metallurgy
    • B22F2998/10—Processes characterised by the sequence of their steps
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C64/00—Additive manufacturing, i.e. manufacturing of three-dimensional [3D] objects by additive deposition, additive agglomeration or additive layering, e.g. by 3D printing, stereolithography or selective laser sintering
    • B29C64/10—Processes of additive manufacturing
    • B29C64/141—Processes of additive manufacturing using only solid materials
    • B29C64/153—Processes of additive manufacturing using only solid materials using layers of powder being selectively joined, e.g. by selective laser sintering or melting
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C64/00—Additive manufacturing, i.e. manufacturing of three-dimensional [3D] objects by additive deposition, additive agglomeration or additive layering, e.g. by 3D printing, stereolithography or selective laser sintering
    • B29C64/10—Processes of additive manufacturing
    • B29C64/165—Processes of additive manufacturing using a combination of solid and fluid materials, e.g. a powder selectively bound by a liquid binder, catalyst, inhibitor or energy absorber
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B33—ADDITIVE MANUFACTURING TECHNOLOGY
    • B33Y—ADDITIVE MANUFACTURING, i.e. MANUFACTURING OF THREE-DIMENSIONAL [3-D] OBJECTS BY ADDITIVE DEPOSITION, ADDITIVE AGGLOMERATION OR ADDITIVE LAYERING, e.g. BY 3-D PRINTING, STEREOLITHOGRAPHY OR SELECTIVE LASER SINTERING
    • B33Y10/00—Processes of additive manufacturing
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
    • Y02P—CLIMATE CHANGE MITIGATION TECHNOLOGIES IN THE PRODUCTION OR PROCESSING OF GOODS
    • Y02P10/00—Technologies related to metal processing
    • Y02P10/25—Process efficiency

Definitions

  • the present disclosure is directed towards various embodiments of an automated powder handling and management system and methods of use thereof. More specifically the present disclosure is directed toward an automated system for handling and dispensing additive manufacturing powders that can be used in a three-dimensional (3D) printing process.
  • Powder handling and storage for example, for additive manufacturing powders that can be used in a three-dimensional (3D) printing process can present challenges.
  • the high surface area of powders may result in absorption of water molecules to the surface of the powder when exposed to humidity, which can then have a negative effect on powder properties such as flow and tap density.
  • accurate mixing, dispensing and inventory management of powders can help eliminate waste and improved safety.
  • systems and methods for powder mixing, handling, and dispensing are provided.
  • the systems and/or methods are specifically designed to enable tailored powder mixing at a point of sale, to supply a purchaser with a powdered metal alloy feedstock for additive manufacturing (e.g. 3D printing).
  • an apparatus for dispensing a powder mixture comprising: a plurality of input containers configured to retain a source powder; a mixing container configured to mix the source powder received from the plurality of input containers into a powder blend; a feed system fluidly coupling the plurality of input containers to the mixing container, wherein the feed system is configured to feed source powder from the plurality of input containers to the mixing container; an output container fluidly coupled to the mixing container, wherein the output container is configured to receive the powder blend from the mixing container, and wherein the output container is configured to detachable from the apparatus; a control system configured to control powder blend characteristics.
  • the source powder is a metal, a polymer, a thermoplastic, or a color pigments.
  • each of the plurality of input containers comprises a body having a hollow volume to retain the source powder.
  • each of the plurality of input containers retains an inert gas.
  • each of the plurality of input containers further comprises an outlet.
  • the body and the outlet are integrally formed.
  • the body is coupled to the outlet via mechanical fasteners.
  • the coupled body and outlet further comprise seals at coupling points to prevent exposure to the atmosphere.
  • the outlet comprises a sidewall having a slope configured to gravity feed source powder into the feed system.
  • each of the input containers is sealed to prevent access to the powder inside except via connection to the feed system.
  • each of the input containers comprises a metering valve to control the flow of powder from each input container.
  • the apparatus further comprises a metering area configured to control the flow of powder from each input container to the feed system.
  • the mixing container is fluidly coupled to the plurality of input containers.
  • the mixing container is configured to homogenize one or more source powders into a powder blend.
  • the mixing container comprises a body, an inlet in the body configured to receive source powder from the plurality of input containers, and an outlet in the body to discharge the powder blend.
  • the body of the mixing container comprises a hollow volume to retain the powder blend.
  • the body of the mixing container retains an inert gas.
  • the feed system comprises a first end coupled to the input container.
  • the first end of the feed system is coupled to an opening of the outlet.
  • the feed system comprises a second end.
  • the second end of the feed system is coupled to the inlet of the mixing container.
  • the second end of the feed system is coupled to an intermediate powder holder configured to receive source powder from the plurality of input containers via the feed system and transfer the source powder to the mixing container.
  • the intermediate powder holder is configured to weigh source powder from the plurality of input containers.
  • the apparatus further comprises a rotating carousel configured to retain the plurality of input containers.
  • the rotating carousel is configured to position a selected input container to couple to the feed system.
  • the output container comprises a body having a hollow volume to retain the powder blend, an inlet to receive the powder blend from the plurality of input containers, and an outlet to discharge the powder blend.
  • the hollow volume of the mixing container retains an inert gas.
  • control system is configured to allow a user to select the powder blend composition and the amount (e.g. mass, volume) of powder blend to dispense to the output container.
  • control system is configured to maintain an inventory of the source powder levels.
  • control system is configured to alert a user to order more source powder based on powder usage rate.
  • control system is configured to allow the user to save one or more specific predetermined powder blends within the control system.
  • control system is configured to provide a user with one or more pre-set powder blends.
  • control system is configured to recommend an amount of powder blend to be dispensed based on the additive manufacturing process used and the object to be additively manufactured.
  • control system is configured to print labels having barcodes that allow for powder lot tracking and inventory control.
  • control system is configured to prevent users from mixing potentially dangerous (e.g. explosive) powder combinations.
  • potentially dangerous e.g. explosive
  • control system is configured to comply with U.S. Department of Homeland Security chemical facility anti -terrorism act requirements on metal powder storage.
  • the apparatus further comprises one or more sampling points configured to dispense a representative sample of the powder blend.
  • the apparatus further comprises a sample dispensing point to dispense a representative sample of the mixed powder.
  • the apparatus further comprises further comprises an in-situ sampler to analyze a representative sample of the mixed powder.
  • the output container is configured to interface with an apparatus suitable for performing an additive manufacturing process, a hot isostatic pressing process, a metal injection molding process, or powder conform process.
  • a method for dispensing a powder mixture comprising: dispensing a predetermined amount of a plurality of additive manufacturing source powders from a plurality of input containers, wherein the predetermined amount of the additive manufacturing source powders is dispensed into a mixing container; mixing the predetermined amount of the additive manufacturing source powder to form a powder blend; collecting a sample of the powder blend; analyzing the sample to determine powder characteristics; comparing the powder characteristics of the powder blend to the target additive manufacturing powder blend; and dispensing the powder blend to an output container if the powder characteristics of the powder blend match the target additive manufacturing powder blend.
  • the method comprises selecting the powder blend composition and the amount (e.g. mass, volume) of powder blend to dispense to the output container.
  • the method comprises maintaining an inventory of the source powder levels.
  • the method comprises triggering an alert to order more source powder based on powder usage rate.
  • the method comprises selecting one or more pre-set powder blends.
  • the method comprises selecting a recommended amount of powder blend to be dispensed based on the additive manufacturing process used and the object to be additively manufactured.
  • an apparatus comprises: a plurality of input containers, each input container configured to retain a different source powder, wherein the source powder is an additive manufacturing feedstock component or an additive manufacturing feedstock powder (e.g. as used herein different source powder means: different characteristics of the same powder composition, or different powder compositions, or a combination thereof); a feed system fluidly coupling the plurality of input containers and configured to receive the source powder, the source powder having at least one powder from an input container (e.g.
  • the feed system directs the source powder into a mixing container; wherein the mixing container is configured to receive the source powder from the feed system and mix the source powder into a powder blend; an output container fluidly coupled to the mixing container, wherein the output container is configured to receive the powder blend from the mixing container, and wherein the output container is configured to detach from the apparatus; and a control system configured to tailor powder composition and powder blend to produce a target additive manufacturing feedstock, wherein the plurality of input containers, the feed system, the mixing container, and the output container are configured to retain one of an inert atmosphere or a vacuum.
  • a method comprises: selecting a target additive manufacturing powder feedstock composition (e.g. on a control system); comparing the target additive manufacturing powder feedstock composition to an inventory list, the inventory list including: a plurality of pre blended additive manufacturing powder feedstock compositions and a plurality of component additive manufacturing powder feedstocks; one of: dispensing the pre-blended additive manufacturing powder feedstock to an output container if the target corresponds to a pre-blended additive manufacturing powder feedstock, or if the target does not correspond to a pre-blended AM powder feedstock, then dispensing a predetermined amount of component additive manufacturing powder feedstocks from a plurality of input containers, wherein the predetermined amount of the component additive manufacturing powder feedstocks is dispensed into a mixing container; mixing the predetermined amount of the component additive manufacturing powder feedstocks to form a product additive manufacturing powder feedstock composition; and dispensing the product additive manufacturing powder feedstock composition to an output container.
  • a sample of the product additive manufacturing powder feedstock composition is collected; the sample is analyzing to determine if the product powder characteristics corresponds to the target powder characteristics; and the product powder is dispensed to the output container, provided the product powder characteristics correspond to the target.
  • Figure 1 is a schematic view of an automated powder handling and management system in accordance with some embodiments of the present disclosure.
  • Figure 2 is a schematic view of an automated powder handling and management system in accordance with some embodiments of the present disclosure.
  • Figure 3A-3D is a schematic cross-sectional view of a powder container used with an additive manufacturing machine in accordance with some embodiments of the present disclosure.
  • Figure 4 is a flow diagram of a method for powder mixing, handling, and dispensing in accordance with some embodiments of the present invention.
  • Figure 1 and Figure 2 depict exemplary embodiments of an apparatus 100 for dispensing a powder mixture in accordance with some embodiments of the present disclosure.
  • processes for which the apparatus 100 can be adapted to dispense powder blends include: additive manufacturing, hot isostatic pressing, metal injection molding, and powder conform.
  • the apparatus 100 comprises a plurality of input containers 102.
  • the input containers 102 are replaceable cartridges that can be coupled and decoupled from the apparatus 100.
  • each input container 102 has a hollow volume to retain a different source powder.
  • the source powder is an additive manufacturing feedstock component.
  • different source powder means different characteristics of the same powder composition, or different powder compositions, or a combination thereof.
  • the source powder can include but is not limited to: metals, polymers, thermoplastics, and color pigments.
  • suitable thermoplastics can include but are not limited to polylactic acrylic, acrylonitrile butadiene styrene (ABS), poly ether ether ketone (PEEK), polyetherketoneketone (PEKK), or a combination thereof.
  • the source powder is suitable for use in an additive manufacturing process (i.e. a process of joining materials to make objects from 3D model data, usually layer upon layer, as opposed to subtractive manufacturing methodologies).
  • non-limiting examples of source powder suitable for an additive manufacturing process includes aluminum, silicon, magnesium, or a combination thereof.
  • the hollow volume of the input container 102 retains the source powder and an inert gas.
  • the inert gas is chosen based on the source powder in the input container.
  • the inert gas is a gas that does not chemically react with the source powder.
  • the inert gas is a noble gas such as argon, xenon, krypton, or the like.
  • the inert gas is nitrogen (N 2 ).
  • the input container 102 has a body 112 having a hollow volume to retain the source powder.
  • the input container 102 is any suitable shape to hold the source powder, such as cylindrical, circular, or square.
  • the input container has an outlet 114.
  • the walls of the outlet 114 may be at a suitable angle to provide a suitable amount of powder flow from the input containers 102.
  • the walls of outlet 114 may have a curvature and slope to gravity feed powder into the feed system described below.
  • the walls of the outlet 114 are vertical.
  • the walls of the outlet 114 form a funnel shape.
  • the curvature and slope of the walls of the outlet can be varied based on the flow properties of the powder.
  • flow properties include but are not limited to: shear properties of the powder, wall friction properties (e.g. a measurement of the sliding resistance between the powder and the surface of the process equipment), powder density, powder compressibility, and powder permeability (e.g. a measure of the powder's resistance to air flow).
  • the curvature and slope of the walls of the outlet is determined using a powder rheometer, for example a FT4 Powder Rheometer® from Freeman Technology, a part of Micromeritic Instrument Corporation.
  • the body 112 is integrally formed with the outlet 114 (e.g.
  • the body and the outlet are formed from a single piece of material).
  • the body 112 is coupled to the outlet 114 with mechanical fasteners, such as bolts, screws or other appropriate mechanical fastening devices.
  • the coupled components 112, 114 may have appropriate seals at the coupling points to prevent exposure to the atmosphere.
  • the input container 102 is sealed to prevent access to the powder inside except via connection to the feed system 106 described below.
  • the input containers 102 are disposed within a hollow volume of a body of the apparatus 100. In some embodiments, the input containers 102 are disposed outside the body of the apparatus 100 or are disposed partially within the body of the apparatus 100. In some embodiments, the body of the apparatus 100 is a suitable storage container to comply with any applicable flammable metal powder regulations.
  • each input container 102 has a metering valve to control the flow of powder from each input container 102. Providing a metering valve at each input container reduces or prevents undesired powder cross-contamination. In some embodiments, the metering valve can be a rotary metering valve.
  • the apparatus 100 further comprises a feed system 106 fluidly coupling the plurality of input containers 102.
  • the feed system 106 is configured to receive source powder from the plurality of input containers 102 and direct the source powder to the mixing container 104.
  • the source powder has at least one powder from an input container (e.g. a plurality of powders from at least two input containers).
  • the feed system 106 comprises a first end coupled to the input container 102.
  • the first end of the feed system 106 is coupled to an opening of the outlet 1 14.
  • the feed system 106 comprises a second end.
  • the second end of the feed system 106 is coupled to the inlet of the mixing container 104.
  • the feed system comprises a metering valve, for example a rotary metering valve, configured to deliver a predetermined amount of powder from the input container 102 to the mixing container.
  • the feed system 106 is a flexible pipe. In some embodiments, the feed system 106 is a rigid pipe. In some embodiments, the feed system 106 is detachable from the input container 102. In some embodiments, the feed system 106 is detachable from the mixing container 104. In some embodiments, the feed system is mechanically coupled to the input container 102 and the mixing container 106 via suitable fasteners (e.g. screws, nuts and bolts) or mating threaded portions.
  • suitable fasteners e.g. screws, nuts and bolts
  • the apparatus 100 comprises a rotating carousel configured to accept the input containers 102.
  • the rotating carousel positions a selected input container 102 to couple to the feed system 106.
  • the input containers 102 are detachable from the rotating carousel.
  • the apparatus 100 comprises an intermediate powder holder 116 configured to receive source powder from the plurality of input containers 102 via the feed system 106 and transfer the source powder to the mixing container 104.
  • the intermediate powder holder 116 weights the source powder from the plurality of input containers 102 to determine that a correct amount of source powder is fed to the mixing container 104.
  • the intermediate powder holder 116 rests on a scale to weight the source powder.
  • the intermediate powder holder 116 has a hollow volume to hold source powder.
  • individual amounts of source powder can be transferred to the intermediate powder holder 116, weighed and transferred to the mixing container 104.
  • all the source powder to be mixed in the mixing container 104 can be transferred to the mixing container 104, weighed, and then transferred to the mixing container 104.
  • the apparatus 100 further comprises a mixing container 104.
  • the mixing container 104 is configured to receive source powder from the feed system 106.
  • the mixing container 104 is configured to mix the source powder into a powder blend.
  • the mixing container 104 is fluidly coupled to the plurality of input containers 102 such that the source powder flows from the plurality of input containers 102 to the mixing container 104.
  • the mixing container 104 is any suitable container that can homogenize one or more source powders (i.e. a powder blend).
  • the powder blend can be a mixture of different powders or can be a mixture of the same powder from different sources.
  • the mixing container 104 comprises a body.
  • the body of the mixing container 104 comprises a hollow volume to retain the powder blend, an inlet to receive source powder from the plurality of input containers 102 and an outlet to discharge the powder blend.
  • the hollow volume of the mixing container 104 retains the powder blend and an inert gas, as described above with respect to the input container.
  • the apparatus 100 further comprises an output container 108.
  • the output container 108 is configured to receive the powder blend from the mixing container 104.
  • the output container 108 is fluidly coupled to the mixing container 104 such that the powder blend flows from the mixing container 104 to the output container 108.
  • the output container 108 receives the powder blend from the mixing container 104 via a flexible pipe.
  • the output container 108 receives the powder blend from the mixing container 104 via a rigid pipe.
  • the output container 108 is any suitable shape to hold the powder blend, such as cylindrical, circular, or square.
  • the output container 108 comprises a body.
  • the body of the output container 108 comprises a hollow volume to retain the powder blend, an inlet to receive the powder blend from the plurality of input containers 102 and an outlet to discharge the powder blend.
  • the hollow volume of the mixing container 104 retains the powder blend and an inert gas, as described above with respect to the input container.
  • the output container 108 is detachable from the apparatus 100.
  • the apparatus 100 further comprises a gas transport system.
  • the gas transport system is configured to provide an inert gas to the one or more of the components of the systems described above, such as the mixing container 104 and the output container 108.
  • the gas transport system is configured to remove atmosphere the one or more of components of the systems described above to maintain a vacuum within the one or more of components of the systems.
  • the gas transport system comprises an inert gas source, an inert gas flow path, such as tubes or pipes, to transfer inert gas to one or more components of the apparatus 100, one or more valves to control the flow of inert gas, a vent flow path, such as tubes or pipes, to remove any atmosphere within the one or more components that is replaced by the inert gas.
  • the apparatus 100 further comprises a control system 110.
  • the control system 110 is a computer/control system (processor and/or memory), which includes any such computing device capable of sending and receiving information/messages (e.g. over a network, to and from other computing devices (e.g. servers, etc.).
  • computing devices include laptops, personal computers, multiprocessor systems, microprocessor-based systems; network PCs, and/or programmable consumer electronics (e.g. cameras).
  • the computer/control system can be configured wirelessly or with wires to enable communication between components and/or other computing devices.
  • the control system 110 is configured to tailor the powder composition and powder blend to produce a target additive manufacturing feedstock.
  • the target additive manufacturing feedstock is user selected via the control system 110.
  • the control system 110 is configured to maintain an inventory of the source powder levels.
  • the control system 110 is configured to alert a user of the apparatus to order more source powder based on powder usage rate.
  • the control system 110 is configured to allow the user to select a desired powder blend.
  • the control system 110 is configured to allow a user to save one or more specific desired powder blends within the control system.
  • the control system 110 is configured to provide a user with one or more pre-set powder blends.
  • control system 110 is configured to recommend an amount of powder blend to be dispensed based on the additive manufacturing process used and the object to be additively manufactured.
  • control system 110 is configured to print labels having barcodes that allow for powder lot tracking and inventory control.
  • control system 110 is configured to prevent users from mixing potentially dangerous powder combinations (e.g. powder combinations that are explosive).
  • the control system 110 is configured to comply with U.S. Department of Homeland Security chemical facility anti -terrorism act requirements on metal powder storage, including but not limited to: a lock and key system, a finger print recognition system, and a security key fob system (e.g. a wireless transmitter and receiver system) which restricts access to the source powder.
  • the control system 110 is configured to control the inert gas feed system.
  • the apparatus 100 further comprises a sampling point 118 configured to dispense a representative sample 120 of the powder blend.
  • the sampling point 118 includes a valve and a nozzle to discharge the representative sample 120.
  • the sampling point is fluidly coupled to the mixing container 104 via a flow path, such as tubes or pipes.
  • the representative sample 120 is dispensed in a detachable container.
  • the control system 110 can print labels for the sample container providing information such as powder blend composition.
  • the apparatus comprises a plurality of sampling points 118.
  • the apparatus 100 further comprises an in-situ sampler 122 to analyze a representative sample 120 of the mixed powder.
  • the in-situ sampler can perform, for example, a moisture analysis, powder particle size distribution analysis, thermogravimetric analysis, and bulk density analysis.
  • the output container 108 is configured to interface with an apparatus suitable for performing processes including but not limited to additive manufacturing process, a hot isostatic pressing process, a metal injection molding process, and powder conform process.
  • the output container 108 is configured to interface with and provide a powder blend to an additive manufacturing apparatus.
  • Figure 3A-3E shows a portion of an exemplary additive manufacturing apparatus 300, wherein the output container 108 is configured to interface with the additive manufacturing apparatus 300.
  • Figure 3A depicts a portion of an exemplary additive manufacturing apparatus 300 comprising a powder dispenser elevator 302, a build platform elevator 304, a collector elevator 305, and a re-coater mechanism 306.
  • the re-coater mechanism 306 is configured to traverse laterally over the powder dispenser elevator 302, build platform elevator 304, and collector elevator 305.
  • the re-coater mechanism 306 is configured to transfer a layer of powder from the powder dispenser elevator 302 to the build platform elevator 304.
  • Figure 3B depicts the output container 108 interfacing with the additive manufacturing apparatus 300.
  • the output container 108 is positioned over and interfaces with the powder dispenser elevator 302.
  • Figure 3C depicts a cross-sectional view of the output container 108 interfacing with the additive manufacturing apparatus 300.
  • a bottom 308 of the output container 108 is a moveable slide gate.
  • the moveable slide gate is detachably coupled to the re-coater mechanism 306 at a first end 310.
  • the re-coater mechanism 306 is positioned proximate the output container 108.
  • an additive manufacturing chamber (not shown) in which the additive manufacturing apparatus 300 is disposed, can be sealed and purged of atmosphere to avoid exposing the powder in the output container 108 to atmosphere, which can negatively impact the quality of the additively manufactured part made from the powder.
  • the re-coater mechanism 306 traverses horizontally in a direction opposite the output container 108.
  • the moveable slide gate detachably coupled to the re-coater mechanism 306 is pulled along with the re-coater mechanism 306 until a second end 312, opposite the first end 310 is removed from the output container 108.
  • the powder dispenser elevator 302 is lowered until all the powder in the output container 108 is transferred to the powder dispenser elevator 302.
  • the re-coater mechanism 306 traverses horizontally in a direction toward the output container 108.
  • the moveable slide gate detachably coupled to the re-coater mechanism 306 is pushed by the re-coater mechanism 306 until the moveable slide gate is returned to its original position shown in Figure 3C.
  • the output container 108 is removed from the additive manufacturing chamber (not shown) and the additive manufacturing process can proceed.
  • FIG. 4 is a flow diagram 400 of a method for dispensing a powder mixture in accordance with some embodiments of the present invention.
  • the method 400 is performed by the apparatus 100 described above.
  • the method 400 begins at 401 by selecting a target additive manufacturing powder feedstock composition (e.g. on a control system 1 10).
  • a predetermined amount of a plurality of additive manufacturing source powders is dispensed from a plurality of input containers, wherein the predetermined amount of the source powders is dispensed into a mixing container.
  • the predetermined amount of the additive manufacturing source powder is mixed to form a predetermined powder blend.
  • a sample of the powder blend is collected.
  • the sample is analyzed to determine powder characteristics.
  • the powder characteristics of the powder blend is compared to the target additive manufacturing powder blend (e.g. by the control system 1 10).
  • the powder blend is dispensed to an output container if the powder characteristics of the powder blend match the target additive manufacturing powder blend.
  • the method 400 further comprises, cleaning the components of the apparatus 100 used to perform the method 400 to prevent contamination of a subsequent powder blend with a prior powder blend.
  • the cleaning comprises a solvent wash for the components of the apparatus 100, wherein a flow of solvent is circulated through any components of the apparatus that come in contact with the powder.
  • the solvent can be an alcohol wash.
  • the cleaning comprises blowing a gas, such as air or an inert gas, through the interior of the components of the apparatus 100 to dislodge and remove powder particles that adhere to the components of the apparatus 100.
  • a cleaning fluid transport system is configured to provide a solvent to the one or more of the components of the systems described above, such as the mixing container 104 and the output container 108.
  • the cleaning fluid transport system comprises a cleaning fluid source, a cleaning fluid flow path, such as tubes or pipes, to transfer cleaning fluid to one or more components of the apparatus 100, one or more valves to control the flow of cleaning fluid, a vent flow path, such as tubes or pipes, to remove any used cleaning fluid within the one or more components.
  • a method comprises: selecting a target additive manufacturing powder feedstock composition (e.g.
  • the target additive manufacturing powder feedstock composition comparing the target additive manufacturing powder feedstock composition to an inventory list, the inventory list including: a plurality of pre blended additive manufacturing powder feedstock compositions and a plurality of component additive manufacturing powder feedstocks; one of: dispensing the pre-blended additive manufacturing powder feedstock to an output container if the target corresponds to a pre-blended additive manufacturing powder feedstock, or if the target does not correspond to a pre-blended AM powder feedstock, then dispensing a predetermined amount of component additive manufacturing powder feedstocks from a plurality of input containers, wherein the predetermined amount of the component additive manufacturing powder feedstocks is dispensed into a mixing container; mixing the predetermined amount of the component additive manufacturing powder feedstocks to form a product additive manufacturing powder feedstock composition; and dispensing the product additive manufacturing powder feedstock composition to an output container.
  • a sample of the product additive manufacturing powder feedstock composition is collected; the sample is analyzing to determine if the product powder characteristics corresponds to the target powder characteristics; and the product powder is dispensed to the output container, provided the product powder characteristics correspond to the target.

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  • Engineering & Computer Science (AREA)
  • Chemical & Material Sciences (AREA)
  • Materials Engineering (AREA)
  • Manufacturing & Machinery (AREA)
  • Mechanical Engineering (AREA)
  • Physics & Mathematics (AREA)
  • Optics & Photonics (AREA)
  • Automation & Control Theory (AREA)

Abstract

Dans certains modes de réalisation, l'invention concerne un appareil pour distribuer un mélange de poudre, comprenant : une pluralité de récipients d'entrée configurés pour retenir une poudre source ; un récipient de mélange conçu pour mélanger la poudre source reçue de la pluralité de récipients d'entrée en une poudre soutirée ; un système d'alimentation couplant de manière fluidique la pluralité de récipients d'entrée au récipient de mélange, le système d'alimentation étant conçu pour acheminer la poudre source de la pluralité de récipients d'entrée vers le récipient de mélange ; et un récipient de sortie couplé de manière fluidique au récipient de mélange, le récipient de sortie étant configuré pour recevoir la poudre soutirée du récipient de mélange, et le récipient de sortie étant configuré pour être détaché de l'appareil ; un système de commande configuré pour contrôler des caractéristiques de mélange de poudre.
PCT/US2018/041495 2017-07-10 2018-07-10 Systèmes et méthodes de manipulation et de distribution de poudre automatisées WO2019014257A1 (fr)

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DE102020208252A1 (de) 2020-07-01 2022-01-05 Eos Gmbh Electro Optical Systems Mischvorrichtung zum Herstellen einer Pulvermischung
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