WO2021113300A1

WO2021113300A1 - Powderbed containment for 3d build printing system parts

Info

Publication number: WO2021113300A1
Application number: PCT/US2020/062804
Authority: WO
Inventors: Michael Birk BINNARD; Johnathan Agustin MARQUEZ; Daniel Gene Smith
Original assignee: Nikon Corporation
Priority date: 2019-12-03
Filing date: 2020-12-02
Publication date: 2021-06-10

Abstract

A processing machine used for building a part includes a mechanical assembly comprising a build table configured to support the part being built. The processing machine has no pre-fabricated powder-containment structure configured to surround or to contain the part as the part is being built. The processing machine also includes a powder supply assembly that distributes powder onto the build table to form a powder layer, and an energy system that directs an energy beam at a portion of the powder on the build table to form a portion of the part being built.

Description

PCT PATENT APPLICATION of

DANIEL GENE SMITH, MICHAEL BIRK BINNARD, and JOHNATHAN AGUSTIN MARQUEZ for

POWDERBED CONTAINMENT FOR 3D BUILD PRINTING SYSTEM PARTS

CROSS REFERENCE TO RELATED APPLICATION

[0001] This application claims priority to U.S. Provisional Application No.

62/943,010 filed on December 3, 2019 and entitled “POWDERBED CONTAINMENT FOR 3D BUILD PRINTING SYSTEM PARTS”. As far as permitted, the contents of U.S. Provisional Application No. 62/943,010 are incorporated in their entirety herein by reference.

BACKGROUND

[0002] Current three dimensional (3D) metal print systems have walls or pre fabricated powder-containment structures for containing metal powder used to build a part. These 3D metal print systems have several disadvantages. Typically, the 3D metal print systems operate at high temperatures needed to melt the powder and a seal is required between a table or support structure and the walls of the system housing the powder used to build and contain the part. This seal is not only a source of friction as the table is moved, but is also subject to extreme temperatures, wear, and damage by exposure to abrasive powder used to build the part. BRIEF DESCRIPTION OF THE DRAWINGS

[0003] Various embodiments of the invention are disclosed in the following detailed description and the accompanying drawings.

[0004] FIG. 1 A depicts a cross-sectional side view of an embodiment of a processing machine for part manufacturing according to disclosed techniques.

[0005] FIG. IB depicts a cross-sectional side view of the embodiment of the processing machine of FIG. 1 A after downward movement of the build table during a build process.

[0006] FIG. 1C depicts a top-down view of the embodiment of the processing machine of FIG. 1 A during a build process that shows a part in a powder bed and a containment structure as they are being built.

[0007] FIG. ID depicts a cross-sectional side view of the embodiment of the processing machine of FIG. 1 A illustrating a technique for part manufacturing as disclosed herein.

[0008] FIG. IE depicts a cross-sectional side view of the embodiment of the processing machine of FIG. 1 A illustrating a technique for part manufacturing as disclosed herein.

[0009] FIG. 2A depicts a cross-sectional side view of an embodiment of a processing machine for part manufacturing according to disclosed techniques.

[0010] FIG. 2B depicts a top-down view of the embodiment of the processing machine of FIG. 2 A that shows a part in a powder bed and a containment structure being built along with the part during a build process.

[0011] FIG. 2C depicts a cross-sectional side view of another embodiment of a processing machine for part manufacturing according to disclosed techniques.

[0012] FIG. 2D depicts a cross-sectional side view of still another embodiment of a processing machine for part manufacturing according to disclosed techniques. [0013] FIG. 3 depicts a top-down view of an exemplary build process showing a part in a powder bed and two containment structures being built along with the part according to disclosed techniques.

[0014] FIG. 4 depicts a top-down view of an exemplary build process showing a part in a powder bed and two containment structures having struts for additional support being built along with the part according to disclosed techniques.

[0015] FIG. 5A depicts a side view of a portion of the embodiment of the processing machine of FIG. 1 A configured to build a part within a perforated sacrificial outer containment structure.

[0016] FIG. 5B depicts a side view of a portion of the embodiment of the processing machine of FIG. 2A is configured to build a part within a perforated sacrificial outer containment structure.

[0017] FIG. 6 shows an embodiment of an extractor device in an exemplary processing machine for part manufacturing according to disclosed techniques, the extractor device being configured to extract a part by extracting a perforated outer containment structure from the mechanical assembly.

[0018] FIGS. 7A-7C are flow diagrams of exemplary methods of powder containment in a 3D metal print system.

[0019] FIGS. 8A-8D are flow diagrams of exemplary methods for building a part using a processing machine as disclosed herein.

DETAILED DESCRIPTION

[0020] The invention can be implemented in numerous ways, including as a process; an apparatus; a system; a composition of matter; a computer program product embodied on a computer readable storage medium; and/or a processor, such as a processor configured to execute instructions stored on and/or provided by a memory coupled to the processor. In this specification, these implementations, or any other form that the invention may take, may be referred to as techniques. In general, the order of the steps of disclosed processes may be altered within the scope of the invention. Unless stated otherwise, a component such as a processor or a memory described as being configured to perform a task may be implemented as a general component that is temporarily configured to perform the task at a given time or a specific component that is manufactured to perform the task. As used herein, the term ‘processor’ refers to one or more devices, circuits, and/or processing cores configured to process data, such as computer program instructions.

[0021] A detailed description of one or more embodiments of the invention is provided below along with accompanying figures that illustrate such embodiments. The invention is described in connection with such embodiments, but the invention is not limited to any embodiment. The scope of the invention is limited only by the claims and the invention encompasses numerous alternatives, modifications and equivalents. Numerous specific details are set forth in the following description in order to provide a thorough understanding of the invention. These details are provided for the purpose of example and the invention may be practiced according to the claims without some or all of these specific details. For the purpose of clarity, technical material that is known in the technical fields related to the invention has not been described in detail so that the disclosed technique is not unnecessarily obscured.

[0022] For the reasons discussed above, it would be advantageous to provide a processing machine that has no walls or pre-fabricated powder-containment structure configured to surround or to contain a part being built by the processing machine in order to overcome problems with current 3D print systems. Accordingly, techniques are disclosed herein for a processing machine comprising a mechanical assembly that includes a build table configured to support a part being built and that has no pre-fabricated powder-containment structure configured to surround or to contain the part as the part is being built. The processing machine also includes a powder supply assembly that distributes powder onto the build table to form a powder layer. The processing machine further includes an energy system that directs an energy beam at a portion of the powder on the build table to form a portion of the part being built. In some embodiments, the processing machine includes a mechanism for moving the build table as the part is being built. In further embodiments, the processing machine includes a three-dimensional (3D) metal print system, and the part includes a metal part built by the 3D print system.

[0023] In some embodiments, a processing machine for building a part comprises a build table configured to support a part being built. In some cases, the build table is movable along a first axis in a fixed structure configured to surround the build table in a direction orthogonal to the first axis. The processing machine further comprises a powder supply assembly that distributes powder onto the build table to form a powder layer and an energy system that directs an energy beam at a portion of the powder on the build table to form a portion of the part being built. The build table is movable without contacting the fixed structure and a gap between the build table and the fixed structure varies as the build table moves.

[0024] In some embodiments, the fixed structure includes an upper plate member having a surface that is substantially parallel to a top surface of the build table and a wall that surrounds the powder layer and the build table. An upper surface of the upper plate member can correspond to a top surface of the powder layer. In some cases, the upper plate member has an inclined side wall that surrounds the powder layer and the build table. The upper plate member can also include a conical opening that surrounds the powder layer and the build table. A lower opening of the conical opening can be wider than an upper opening at the surface of the upper plate member. In some cases, the wall that surrounds the powder layer and the build table has a vertical portion that surrounds the powder layer and the build table.

[0025] In some embodiments, the processing machine includes a sweep plane. The sweep plane can comprise a substantially flat surface of a part positioned at the plane defined by a sweeping action of a rake on the powder surface. For example, the sweep plane can comprise a part that has a flat surface coplanar with the top surface of the powder after the powder is swept by the rake. The sweep plane can comprise a conical surface configured to fit around or surround the build table at a start of a process for building the part. The build table is fitted around an underside surface of the sweep plane at a start of the process for building the part. In some embodiments, the underside surface of the sweep plane has a conical surface, and the build table has a flat circular disk-shape, such that the build table fits around the conical surface of the sweep plane.

[0026] In some embodiments, the energy system is configured to direct the energy beam at a portion of the powder on the build table to form a portion of a containment structure around the part being built and the containment structure is built as the part is being built. In some cases, the containment structure comprises a plurality of containment structures. Additionally or in the alternative, the energy system can be configured to direct the energy beam at a portion of the powder on the build table to build struts that provide additional support to the containment structure. In some cases, the containment structure comprises a perforated sacrificial outer containment structure for containing the part being built. In some cases, the containment structure is formed on a variable metal powder deposition area (e.g., a variable metal powder deposition area) on the build table.

[0027] In some embodiments, the processing machine further comprises an extractor device configured to obtain the part by extracting the containment structure from the build table. In some cases, the extractor device is configured to pierce the perforated sacrificial outer containment structure along perforations in the perforated sacrificial outer containment structure and to peel back or pull aside portions of the perforated sacrificial outer containment structure to expose the part.

[0028] In a processing machine that creates a 3D part using powder deposited in a powder bed, the powder bed temperature may become very high. In such cases, it is desirable to allow the powder bed to cool slowly so that the part is properly annealed. The annealing time may take place in a chamber that contains the powder bed. However, this technique reduces processing throughput, because the processing machine cannot make another part while the chamber is occupied. Also, the unused powder has to be removed with the part, which tends to disperse the powder, making recycling of unused powder difficult or impossible.

[0029] Some embodiments disclosed herein address the problem of powder dispersal by creating a containment structure that contains the part. In these embodiments, the energy system in the processing machine is configured to direct the energy beam at a portion of the powder on the build table to form a portion of a containment structure that contains the part being built. In some embodiments, the containment structure is built as the part is being built. The containment structure reduces the loss of unused powder by containing at least a portion of the unused powder in the powder bed, so that the contained unused powder does not become lost or dispersed. In some embodiments, the processing machine creates one or a plurality of containment structures that contain the part.

[0030] Devices disclosed herein also include a three-dimensional (3D) metal print system for building a metal part comprising: a mechanical assembly that includes a build table configured to support a metal part being built; a powder supply assembly that distributes powder onto the build table to form a powder layer; an energy system that directs an energy beam at a portion of the powder on the build table to form a portion of the metal part being built; and a mechanism for moving the build table as the metal part is being built. The energy system is configured to direct the energy beam at a portion of the powder on the build table to form a portion of a containment structure atop the build table and around the metal part being built. In some embodiments, the containment structure is configured to partially or completely enclose the powder used to build the metal part. In some embodiments, the containment structure is configured to be removed and/or recycled.

[0031] In some embodiments, a method of powder containment in a 3D metal print system comprises building a containment structure configured to contain a metal part being built by the 3D print system while the metal part is being built, wherein walls of the containment structure are built by the 3D print system atop a build table during part fabrication. The containment structure may be built, for example, by depositing layers of powder to form the metal part and the containment structure, such that each of the layers of powder is deposited to form a layer of the metal part and a layer of the containment structure. In some embodiments, the build table is moved vertically after each of the layers of the powder is deposited and irradiated to form layers of the metal part and the containment structure.

[0032] In some embodiments, the containment structure comprises a plurality of containment structures configured to enclose powder being used to build the metal part within the containment structures. The containment structures and the powder therein may be configured to be removed and recycled. In some cases, a thickness of walls of the containment structure is minimized so as to use less of at least one of energy, time, and powder. In some examples, the method further comprises building struts while the metal part is being built, the struts being configured to provide additional support to the walls of the containment structure. In other examples, the containment structure is configured to include a perforated sacrificial outer containment structure for containing the metal part being built.

In some cases, the containment structure is formed on a variable metal powder deposition area (e.g., a variable metal powder deposition area) on the build table.

[0033] In some embodiments, building the containment structure includes defining and generating a variable metal powder deposition area by constructing a perforated sacrificial containment structure around the metal part being built. The perforated sacrificial containment structure is built simultaneously along with the metal part and additional powder for the build process is deposited largely within the perforated sacrificial containment structure.

[0034] In some embodiments, the method further comprises extracting the metal part by extracting the containment structure. As an example, the containment structure can be configured to include a perforated sacrificial outer containment structure for containing the metal part being built and the method can further comprise: extracting the metal part by extracting the perforated sacrificial outer containment structure; piercing the perforated sacrificial outer containment structure along the perforations; and peeling back or pulling aside portions of the perforated sacrificial outer containment structure to reveal the metal part. In some cases, the containment structure is formed on a variable metal powder deposition area (e.g., a variable metal powder deposition area) on the build table. In some cases, building the containment structure further comprises depositing layers of powder to form the metal part and the containment structure, wherein each of the layers of powder is deposited to form a layer of the metal part and a layer of the containment structure. Additionally, building the containment structure can further comprise moving the build table vertically after each of the layers of the powder is deposited to form the metal part and the containment structure.

[0035] In further embodiments, a method for building a part using a processing machine includes distributing powder onto a build table using a powder supply assembly to form a powder layer and directing an energy beam at a portion of the powder on the build table using an energy system to form a portion of the part and to form a portion of a containment structure to contain the part while the part is being built by the processing machine. The portion of the powder may be irradiated by the energy beam to form a layer of the part and a layer of the containment structure. As a specific example, the energy beam may be directed to fuse a portion of the powder to form walls of the containment structure by sintering. In some embodiments, the build table is moved after the powder layer is deposited and irradiated to accommodate deposition of an additional powder layer on the powder layer that was previously deposited and irradiated.

[0036] FIGS. 1A-1E disclose exemplary embodiments that address at least some of the problems and issues associated with three dimensional (3D) print systems having walls or some pre-fabricated powder-containment structure for containing powder that is used to build a part. In the embodiments of FIGS. 1 A-1E, a processing machine is shown having no walls or pre-fabricated powder-containment structure configured to surround or to contain a part being built by the processing machine. An advantage of a processing machine that has no walls or pre-fabricated powder-containment structure configured to surround or to contain a part being built, as disclosed, for example, with respect to FIGS. 1 A-1E, is the elimination of a high temperature seal between the build table and walls of the processing machine. As discussed above, the seal between the build table and the walls of the conventional processing machine creates friction as the build table is moved, is subject to extreme temperatures, wear and damage by exposure to abrasive powder used to build the part.

[0037] Additional problems with a typical conventional build table include thermal expansion of the build table and excessive heat conduction from the walls to the sweep plane and other parts of the processing system. Accordingly, another advantage of the processing machine disclosed, for example, with respect to FIGS. 1 A-1E, is the elimination of paths for thermal conduction from the heated build table, the part, and the powder to the rest of the processing machine. A conduction path through an actuator coupled to the build table can be appropriately cooled. The build table can be removed from the processing machine with the part and the powder atop the build table after fabrication of the part, so that the build table can be moved to a separate chamber for cooling. This feature can greatly increase throughput and the ease of automation. [0038] In some embodiments, the processing machine depicted in FIGS. 1A-1E includes an energy system that is configured to direct an energy beam at a portion of the powder on the build table to form a containment structure atop the build table and around the part being built. The energy system forms a portion of the part and forms a portion of the containment structure to contain the part while the part is being built by the processing machine. In some embodiments, the containment structure is configured to partially or completely enclose the powder used to build the part. Thus, in some embodiments, at least a portion of the powder is contained on the build table within the containment structure as the part is being built. Advantages of this technique include reducing waste of the powder used to build the part, facilitating clean up and recycling of the powder, improving the productivity of part fabrication, and improving usability through automatic generation and editing of the geometry of the containment structure.

[0039] FIG. 1 A depicts a cross-sectional side view of an embodiment of a processing machine 10 for part manufacturing according to disclosed techniques. As provided herein, the processing machine 10 can be an additive manufacturing system, e.g. a three-dimensional (3D) print system, in which a portion of powder 14 (illustrated as small dots) is joined, melted, solidified, and/or fused together in a series of powder layers to manufacture one or more part(s) 11.

[0040] The type of part(s) 11 manufactured with the processing machine 10 or the other processing machines disclosed herein may be, for example, one or more three- dimensional (3D) part(s) having almost any shape or geometry. As a non-exclusive example, part 11 may be a metal part, or another type of part, for example, a resin (plastic) part or a ceramic part, etc. The part 11 may also be referred to as a built part.

[0041] The type of powder 14 joined and/or fused together may be varied to suit the desired properties of the part(s) 11. As a non-exclusive example, the powder 14 may include metal powder grains (e.g., including one or more of titanium, aluminum, vanadium, chromium, copper, stainless steel, or other suitable metals) or alloys for metal three- dimensional printing. Alternatively, the powder 14 may be non-metal powder, a plastic, polymer, glass, ceramic powder, organic powder, an inorganic powder, or any other material known to persons skilled in the art. [0042] Various designs of a processing machine for building a part are provided herein. In the exemplary implementation of FIG. 1 A, processing machine 10 includes a build table 32 configured to support a part 11 being built, the build table 32 being movable along a first axis in a fixed structure configured to surround thereof in a direction orthogonal to the first axis. As an example, FIG. IB depicts a cross-sectional side view of the embodiment of the processing machine of FIG. 1 A after downward movement of the build table along the first axis during a build process.

[0043] As shown in FIG. 1 A, processing machine 10 further includes a powder supply assembly 18 that distributes powder 14 onto the build table 32 to form a powder layer. In the example shown, an energy system 22 directs an energy beam 22A at a portion of the powder 14 on the build table 32 to form a portion of the part 11 being built. Processing machine 10 in this example also includes a measurement device 20. The design of each of these components may be varied pursuant to the teachings provided herein. Further, the positions of the components of the processing machine 10 may be different than that illustrated in FIG. 1A. Moreover, the processing machine 10 can include more components or fewer components than illustrated in FIG. 1 A. For example, the processing machine 10 can include a heating device (not shown) that heats the powder layer (e.g., for pre-sintering before formation of the part 11 by energy beam 22A). Further for example, the processing machine 10 can include a cooling device (not shown) that uses radiation, conduction, and/or convection to cool the powder 14 after formation of the part 11. Additionally, in this particular embodiment, the build table 32 is movable without contacting the fixed structure, and a gap between the build table and the fixed structure varies as the build table moves.

[0044] A material bed assembly supports the powder 14 and the part 11 while the part

11 is being built by the processing machine 10. In the implementation illustrated in FIG. 1 A, the material bed assembly includes (i) a mechanical assembly comprising a build table 32 that supports the powder 14 in the powder bed and the part 11; and (ii) a mechanism for moving the build table 32 as the part 11 is being built, the mechanism including an actuator 36. The actuator 36 selectively moves the build table 32 downward after each subsequent layer of powder 14 is added atop the build table 32 in the powder bed and then irradiated to form a layer of the part 11. As an example, FIG. IB shows a cross-sectional side view of the embodiment of the processing machine 10 depicted in FIG. 1 A after the build table 32 has been moved downward by actuator 36, the build table 32 having been moved downward as a result of the build process for building the part.

[0045] Processing machine 10 additionally includes (i) an upper frame assembly 38 that includes the powder supply assembly 18, the measurement device 20, and the energy system 22; and (ii) a lower frame assembly 40 configured to support the actuator 36 and the build table 32. The actuator 36 is configured to selectively move the build table 32 downward relative to the lower frame assembly 40 and relative to the upper frame assembly 38 after each subsequent layer of powder 14 is added atop the build table 32 in the powder bed and then irradiated to form a layer of part 11. According to various embodiments, the build table 32 may take the form of various shapes or configurations. For example, the build table 32 may be flat and rectangular-shaped, flat and circular disk-shaped, or polygonal shaped.

[0046] The powder supply assembly 18 is configured to deposit the powder 14 onto the build table 32 to sequentially form layers of the powder 14 in the powder bed. In the embodiments of FIGS. 1A-1B, the powder supply assembly 18 sequentially forms individual layers of the powder 14 on top of the build table 32. Each layer of the powder 14 is irradiated to build a corresponding layer of part 11, as described below.

[0047] In some embodiments, measurement device 20 is configured to inspect layers of powder 14 or the built part 11 optically, electrically, or physically. As non-exclusive examples, the measurement device 20 may include one or more optical elements such as a uniform illumination device, fringe illumination device (structured illumination device), cameras that function at one or more wavelengths, lens, interferometer, or photodetector, or a non-optical measurement device such as an ultrasonic, eddy current, or capacitive sensor.

[0048] Energy system 22 is controlled to irradiate the powder 14 to form each powder layer of the part 11. In some embodiments, energy system 22 is also configured to direct the energy beam 22A at a portion of the powder 14 on the build table 32 to form a containment structure 28 atop the build table 32 and around the part 11 being built. In some embodiments, as described in more detail with respect to FIGS. 1C-1E below, the containment structure 28 is built to enclose or surround at least a portion of the powder 14 that is used to build part 11. As non-limiting examples, the containment structure 28 may be built to have a cylindrical shape, a rectangular box shape with an open top, or another polygon shape.

[0049] The processing machine 10 is configured to build containment structure 28 as the part 11 is being built. The energy system 22 may, for example, irradiate a portion of each layer of the powder 14 deposited by the powder supply assembly 18 atop the build table 32 to form each layer of the containment structure 28 and to form each layer of the part 11. The build table 32 is moved vertically by the actuator 36 to accommodate an additional layer of powder 14 after each layer of powder 14 is deposited and irradiated to form layers of the part 11 and the containment structure 28. After the build table 32 is moved vertically, the additional layer of powder 14 is deposited on build table 32 and then irradiated to form additional layers of the part 11 and the containment structure 28. FIG. IB depicts a cross- sectional side view of the processing machine 10 after the build table 32 has been moved vertically downward as compared to its initial position shown in FIG. 1 A.

[0050] In some embodiments, the energy system 22 is an electron beam generator and the energy beam 22A is a charged particle electron beam. In this design, for each layer of powder 14 that is deposited atop build table 32, the electron beam generator 22 is controlled (based on a data regarding the part 11 being built and the containment structure 28) to steer the electron beam 22 A to fuse a portion of the powder 14 to form at least a portion of the part 11 and at least a portion of the containment structure 28. As an example, the data can comprise model data generated by a computer-aided design (CAD) tool.

[0051] FIGS. 1A-1B also depict a sweep plane 26, comprising a substantially flat surface of a part positioned at the plane defined by the sweeping action of a rake on the powder surface. In the example shown, sweep plane 26 is a part that has a flat surface coplanar with the top surface of the powder after the powder is swept by the rake and a build table 32 is configured to be fitted to an underside surface 26A of the sweep plane 26 at a start of the process for building the part 11. In some embodiments, the underside surface 26A is configured to be fitted around or to surround the build table 32 at the beginning of the process for building the part 11, as shown, for example, in FIG. 1 A. As a non-exclusive example, the underside surface 26A of the sweep plane 26 may have a conical surface, and the build table 32 may have a flat circular disk-shape, such that build table 32 is fitted to the conical surface 26A of sweep plane 26 without significant gaps. [0052] FIG. 1C depicts a top-down view of the embodiment of the processing machine 10 of FIG. 1 A during a build process. FIG. 1C shows a part 11 in a powder bed comprising powder 14 and a containment structure 28, which is being built along with the part 11. Sweep plane 26 is also shown in FIG. 1C comprising a substantially flat surface of a part (e.g., in this case, sweep plane 26 is positioned to surround containment structure 28) and having a flat surface that is coplanar with the top surface of powder 14.

[0053] Returning to FIG. 1 A, for deposition of the first layer of powder 14, the build table 32 is pushed upwards until the build table 32 comes up to just below the underside surface 26A of the sweep plane 26. In this case, a top surface of the build table 32 may be slightly below a top surface of the sweep plane 26. The height difference between the top surface of the build table 32 and the upper surface of the sweep plane 26 sets or determines the thickness of the first layer of the powder 14 irradiated by system 22 to form a powder layer of part 11 and a powder layer of containment structure 28. In this manner, the part 11 and the containment structure 28 are built simultaneously by irradiating the powder 14.

[0054] In some embodiments, a side surface of the sweep plane 26 is a vertical plane and is parallel to the side surface of the build table 32. In this case, the build table 32 does not contact the side surface of the sweep plane 26. For the deposition of the first layer of powder 14, the build table 32 is controlled by the actuator 36 to set a position lower than the top surface of the sweep plane 26, and the height difference is determined based on the desired thickness of the first layer of the powder 14. In other embodiments, the sweep plane 26 can be eliminated. In such cases, the height of the build table 32 is controlled by the actuator 36 based on a focal plane of the energy system 22.

[0055] As depicted in FIG. IB, after a first layer of powder 14 is added on a top surface of the build table 32 and the first layer of powder irradiated, the actuator 36 moves the build table 32 downward toward lower frame assembly 40, such that the build table 32 is no longer in contact with or fitted against the underside surface 26A of sweep plane 26. In the example shown, the actuator 36 moves the build table 32 downward to accommodate each additional layer of powder 14 that the powder supply assembly 18 deposits atop the layers of powder 14 previously deposited on the build table 32.

[0056] As the build table 32 is moved downward to accommodate each subsequent additional powder layer deposited on the build table, the gap between the underside surface 26A and the top surface of the build table 32 increases. As a result of the increasing gap between the underside surface 26A and the top surface of the build table 32, portions of the powder 29 deposited by the powder supply assembly 18 may fall or pass through the gap outside the walls of the containment structure 28, as shown in FIG. IB. However, much of the powder 14 deposited by the powder supply assembly 18 will fall and be retained inside the walls of the containment structure 28. The containment structure 28 confines the powder 14 within an enclosed area, reducing the amount of powder 29 that falls outside structure 28 and making the powder 14 easier to recycle. The containment structure 28 eliminates the need for the processing machine 10 to have walls or a pre-fabricated powder-containment structure that surrounds or contains build table 32.

[0057] As shown in FIG. IB, as the build table 32 is lowered downward to accommodate each successive layer of deposited powder used for building the part 11, an amount of loose powder 29 may fall off an outer perimeter of the build table 32. Additional components of the processing machine 10 are configured to direct this excess powder to a collection bin or hopper where excess powder can be reclaimed or disposed of in a convenient manner.

[0058] In some processing machines that build 3D parts using powder, some of the powder that is not used to build a part is dispersed or lost when the part is removed from the processing machine. Embodiments as disclosed herein solve this problem by creating one or more containment structures configured to contain the part being built to reduce the dispersal or loss of unused powder. In these embodiments, the processing machine is configured to build one or more containment structures that contain the part while the part is being built. The walls of the containment structure are built atop a build table during fabrication of the part. In some embodiments, computer software automatically generates the containment structure(s) to be built by the processing machine. In some cases, the computer software displays the containment structure for human review and modification.

[0059] FIG. ID depicts a cross-sectional side view of the embodiment of the processing machine 10 of FIG. 1 A illustrating a technique for part manufacturing as disclosed herein. As in the case of the examples described with respect to FIGS. 1 A-1C, processing machine 10 is configured to build a containment structure 28 as a part 11 is being built. However, as shown in FIG. ID, in this case the containment structure 28 comprises an open-box shaped container having sidewalls (e.g., shown on one side as sidewall 17) and a bottom structure 15.

[0060] FIG. IE depicts a cross-sectional side view of the embodiment of the processing machine 10 of FIG. 1 A illustrating another technique for part manufacturing as disclosed herein. As in the case of the examples described with respect to FIGS. 1 A-1D, processing machine 10 is configured to build a containment structure as a part is being built. However, as shown in FIG. IE, in this case the containment structure 16 is formed from sintered powder as opposed to powder that is fully fused or solidified by melting.

[0061] In some cases, a powder layer can be pre-sintered and then an energy beam

22A irradiated at a predetermined area of the pre-sintered powder (e.g., one layer of the part 11) for building a portion of the part 11. Pre-sintering can include preliminary or rough sintering performed to avoid smoking of the powder 14 when the energy beam 22A is irradiated. The pre-sintered powder can be used to form a containment structure 16. In some embodiments, varying degrees of sintering can be used to form the containment structure 16, for example from roughly sintered powder to form a structure having a more porous density to more finely sintered powder to form a more densely packed structure. The containment structure 16 formed from sintered or pre-sintered powder can be brought out from the build table 32 and recycled or reused as powder more easily. Energy system 22 can be used for sintering the powder layer 14 by irradiating the energy beam 22A with lower energy than it is used for fusing (melting) the powder. In some embodiments, a heating device (not shown) can be used for pre-sintering instead of the energy system 22. The heating device may include an IR heater, conduction heater, or some other proper heating device.

[0062] According to some embodiments, a processing machine for building a part comprises a mechanical assembly having a build table configured to support the part being built, a powder supply assembly that distributes powder onto the build table to form a powder layer, an energy system that directs an energy beam at a portion of the powder on the build table to form a portion of the part being built and to form a portion of a containment structure that contains the part, and a mechanism for moving the build table as the part is being built.

In some embodiments, and as described below with respect to FIGS. 2A-2D, the processing machine also includes walls that surround or contain the build table and the part. The walls of the processing machine also reduce the dispersal or loss of unused powder. The processing machine may be, for example, a 3D metal print system.

[0063] FIGS. 2A-2D depict embodiments of a processing machine used to manufacture one or more parts. FIGS. 2A, 2C and 2D depict a cross-sectional side views of various embodiments of a processing machine 200 for part manufacturing according to disclosed techniques. FIG. 2B depicts a top-down view of the embodiment of the processing machine 200 of FIG. 2 A that shows a part 211 in a powder bed 214, and a containment structure 228 being built along with the part 211 during a build process.

[0064] As provided herein, the processing machine 200 depicted in FIGS. 2A-2D can be an additive manufacturing system, e.g. a three-dimensional (3D) print system, in which a portion of powder 214 is joined, melted, solidified, and/or fused together in a series of powder layers to manufacture one or more part(s) 211. The type of powder 214 joined and/or fused together may be varied to suit the desired properties of the part 211.

[0065] As shown in FIGS. 2 A, 2C and 2D, a processing machine 200 includes a mechanical assembly having a build table 232 configured to support the part 211 being built, a powder supply assembly 218 that distributes powder onto the build table to form a powder layer, an energy system 222 that directs an energy beam 222 A at a portion of the powder 214 on the build table 232 to form a portion of the part 211 being built and to form a portion of a containment structure 228 that contains the part 211, and a mechanism for moving the build table as the part is being built. The processing machine also includes walls 224 (shown in various embodiments and configurations with respect to each of FIGS. 2A, 2C, and 2D) that surround or contain the build table and the part. The walls 224 of the processing machine also reduce the dispersal or loss of unused powder. The processing machine may be, for example, a 3D metal print system.

[0066] As shown in FIGS. 2 A, 2C and 2D, the processing machine 200 includes a powder supply assembly 218, a measurement device 220, and an energy system 222, which function as described above with respect to powder supply assembly 18, measurement device 20, and energy system 22, respectively, of FIGS. 1 A-1B, and FIGS. 1D-1E. In the examples of FIGS. 2 A, 2C and 2D, processing machine 200 additionally includes an upper frame assembly 238 on which the powder supply assembly 218, the measurement device 220, and the energy system 222 are disposed. The energy system 222 is configured to irradiate a portion of each layer of the powder 214 deposited by the powder supply assembly 218 to form each layer of the containment structure 228 and to form each layer of the part 211.

[0067] The processing machine 200 also comprises a mechanism for moving the build table 232, which in this case, includes an actuator 236 configured to move the build table 232 vertically downward as the part 211 is being built. After the build table 232 is moved vertically downward, an additional layer of powder 214 is deposited atop the build table 232 and then irradiated by energy system 222 to form additional layers of the part 211 and the containment structure 228.

[0068] In some embodiments, the energy system 222 is controlled to direct an energy beam 222 A at a portion of the powder 214 to form the part 211 and to form a containment structure 228 atop the build table 232. Containment structure 228 has walls that may be built to contain, enclose, and/or surround the powder 214 and the part 211, as shown in FIGS. 2A- 2D. Containment structure 228 may be any desired shape, e.g., circular, rectangular, polygonal, etc. Processing machine 200 is configured to build the containment structure 228 and the part 211 by irradiating portions of the powder 214. The containment structure 228 facilitates moving (e.g., robotically) the part 211 to an annealing area after fabrication, thereby freeing processing machine 200 for the next build, without breaking a vacuum environment around the part. The containment structure 228 also reduces clean up by reducing dispersal of unused powder.

[0069] As shown in FIGS. 2 A, 2C and 2D, the processing machine 200 comprises a fixed structure that includes an upper plate member 224 having a surface that is substantially parallel to a top surface of the build table 232 and a wall that surrounds the powder layer 214 and the build table 232. An upper surface of the upper plate member 224 can correspond to a top surface of the powder layer 214. As shown the various embodiments of FIGS. 2A, 2C, and 2D, a side wall of upper plate member 224 extends downward from the edge of the upper plate member and surrounds or contains the build table 232.

[0070] In the embodiment of FIG. 2A, the processing machine 200 includes walls 224 that surround or contain the build table 232, the powder bed 214, and the part 211. As the build table 232 moves vertically downward during the build process of building the part 211, the walls 224 of the processing machine 200 remain close to, but not contact with the outer edge of the build table 232. This configuration helps to prevent friction between the build table 232 and the walls 224 even under extreme temperature and to prevent excess powder 214 from falling off the build table 232.

[0071] The processing machine 200 shown in FIG. 2 A is configured to build the walls of the containment structure 228 to be adjacent to or close to the walls 224 of the processing machine 200. In other embodiments of this invention, and as described more fully with respect to FIGS. 2C-2D below, the walls of containment structure 228 may be spaced apart from the walls 224 of the processing machine 200.

[0072] In the embodiment of FIG. 2C, the processing machine 200 includes a gap between the walls of upper plate member 224 and the build table 232 so that the build table 232 can move vertically without interference even under extremely high temperatures. In this particular case, the side wall of the upper plate member 224 includes an inclined portion and a vertical portion. As a result of this configuration, the gap is changing (increasing or widening) as the build table moves vertically downward during the build process. Stated in another fashion, the wall of upper plate member 224 does not contact build table 223 within a moving stroke (e.g., a step or vertical downward motion) of the build table 232 during building process of the part 211.

[0073] FIG. 2D depicts a cross-sectional side view of another embodiment of processing machine 200 described with respect to FIGS. 2A-2C. In this particular embodiment, upper plate member 224 includes a vertical side wall that is set back from a top edge of upper plate member 224 and extends vertically downwards. As shown in FIG. 2D, a cross section of the upper plate member 244 having vertical side walls as described herein resembles a T-shape. In particular, the processing machine 200 is configured to have a gap between the build table 232 and the upper plate member 224 when the build table 232 is at the position where a top surface of the build table 232 and a top surface of the upper plate member 224 are coplanar. This gap increases or widens when the build table is moved vertically downward as the part 211 is being built during the build process.

[0074] According to some embodiments, the containment structure built by the processing machine as disclosed herein includes a plurality of containment structures configured to contain or enclose powder being used to build the part within the containment structures. The containment structures may be configured to be removed and/or recycled. Various embodiments of processing machines as described herein (e.g., processing machine 10 of FIGS. 1A-1E and processing machine 200 of FIGS. 2A-2D) can be used to build each of the plurality of containment structures along with the part during a build process. In some cases, the use of one or more containment structures facilitates ease of removal and/or recycling after a part has been built. As an example, after a part is built, containment structures may be opened and removed, unused powder may be reprocessed for later use, and walls of containment structures may be recycled to produce more powder for later use. Examples of embodiments that use two containment structures configured to contain or enclose powder being used to build a part are described below with respect to FIG. 3 and FIG. 4.

[0075] FIG. 3 depicts a top-down view of an exemplary build process showing a part in a powder bed and two containment structures being built along with the part according to disclosed techniques. In particular, FIG. 3 depicts a top-down view 300 of a part 311 being built in a powder bed 314 and two containment structures 328A and 328B being built along with the part 311. As shown in FIG. 3, two containment structures 328A and 328B are built as a part 311 is built, the containment structures 328A and 328B together being configured to surround the part 311 as it is being built. Walls of a processing machine, shown here at 324 (e.g., walls of upper plate member 224 of processing machine 200 as described with respect to FIGS. 2A, 2C, and 2D), surround the two containment structures 328A and 328B. Alternatively, in embodiments that employ a processing machine such as processing machine 10 of FIGS. 1A-1E, 324 can also represent a sweep plane (e.g., such as sweep plane 26) positioned to surround the two containment structures 328A and 328B and having a flat surface that is coplanar with the top surface of powder 314 at the start of the build process.

[0076] An energy system (e.g., energy system 22 in processing machine 10 of FIGS.

1A-1B, 1D-1E, or energy system 222 in processing machine 200 of FIGS. 2A, 2C, and 2D) is controlled to direct an energy beam (e.g., energy beam 22A of FIGS. 1 A-1B, 1D-1E, or energy beam 222A of FIGS. 2A, 2C, and 2D) at a portion of powder 314 deposited atop a build table (e.g., build table 32 of FIGS. 1 A-1B, 1D-1E, or build table 232 of FIGS. 2A, 2C, and 2D) to form the part 311 and the two containment structures 328A and 328B. [0077] In this case, the containment structures 328 A and 328B are shown adjacent to each other and adjacent to different sides of the part 311. In particular, the containment structures 328A and 328B are built to surround the part 311 on two sides. In this particular example, each of the containment structures surrounds about half of the part 311.

[0078] Referring to FIG. 3, containment structure 328A is built on one side (in this case, the left side) of the build table surrounding the part 311 on one side (in this case, its left side). In this example, the walls of containment structure 328A are built to enclose powder 314 deposited on the left side of the build table as shown in FIG. 3. Similarly, containment structure 328B is built on the other side (in this case, the right side) of the build table surrounding the part 311 on its other side (in this case, its right side). In this example, the walls of containment structure 328B are built to enclose powder 314 deposited on the right side of the build table as shown in FIG. 3. Additionally, the walls of the containment structure 328A are built around the left side of the part 311 with a small gap therebetween, and the walls of the containment structure 328B are built around the right side of the part 311 with a small gap therebetween, as shown in FIG. 3. The containment structures 328 A and 328B together nearly enclose, but do not entirely surround part 311, because narrow gaps of unfused powder remain between the walls of containment structure 328A and containment structure 328B on either side of part 311. The containment structures 328 may be any desired shape, e.g., circular, rectangular, etc.

[0079] In the embodiment of FIG. 3, a processing machine as disclosed herein (e.g., processing machine 10 of FIGS. 1A-1E, or processing machine 200 of FIGS. 2A-2D) can be used to build the walls of containment structures 328A and 328B to be adjacent to or close to the walls of the processing machine. The processing machine is configured to build the containment structures 328A and 328B from portions of the powder 314 as the part 311 is being built. A powder supply assembly (e.g., powder supply assembly 18 of FIGS. 1A-1B, ID- IE, or powder supply assembly 218 of FIGS. 2A, 2C, and 2D) deposits layers of powder 314 atop the build table (e.g., build table 32 of FIGS. 1 A-1B, 1D-1E, or build table 232 of FIGS. 2A, 2C, and 2D). An energy system (e.g., energy system 22 of FIGS. 1A-1B, 1D-1E, or energy system 222 of FIGS. 2 A, 2C, and 2D) can irradiate a portion of each layer of the powder deposited by the powder supply assembly to form a layer of each of the containment structures 328A and 328B and to form a layer of the part 311. The build table is moved vertically downward to accommodate an additional layer of powder after each of the layers of powder is irradiated by the energy system. After the build table is moved vertically downward, the powder supply assembly deposits a subsequent layer of powder atop the build table.

[0080] The containment structures 328A and 328B facilitate moving (e.g., robotically) the part 311 to an annealing area after fabrication, thereby freeing the processing machine (e.g., processing machine 10 of FIGS. 1 A-1E, or processing machine 200 of FIGS. 2A-2D) for the next build without breaking a vacuum around the part. The containment structures 328A and 328B also reduce clean up by reducing dispersal of unused powder. In contrast to embodiments of the containment structure 28 of FIGS. 1 A-1E, and containment structure 228 of FIGS. 2A-2D, the embodiment comprising a plurality of containment structures described with respect to FIG. 3 facilitates more easily separating the part 311 from the containment structures 328 A and 328B.

[0081] In some embodiments, the energy system in the processing machine is configured to direct the energy beam at a portion of the powder atop the build table to build struts configured to provide additional support to the containment structure while the part is being built. In such cases where struts are used for additional support to the containment structure, the walls of the containment structure can be built to be less thick or to consume less material so as to use less of at least one of energy, time, and powder. In some embodiments, the processing machine includes walls that surround the containment structure and the build table. The use of struts configured to provide additional support to the containment structure while the part is being built is described in more detail below with respect to FIG. 4.

[0082] FIG. 4 depicts a top-down view of an exemplary build process showing a part in a powder bed and two containment structures having struts for additional support being built along with the part according to disclosed techniques. In particular, FIG. 4 illustrates a top-down view 400 of a part 411 being built in a powder bed 414 along with two containment structures 428A and 428B having struts (e.g., shown at 450A and 450B respectively) for additional structural support. As in the case of FIG. 3, in this case, walls of a processing machine, shown here at 424 (e.g., walls of upper plate member 224 of processing machine 200 as described with respect to FIGS. 2 A, 2C, and 2D), surround the containment structures 428 A and 428B. Alternatively, in embodiments that employ a processing machine such as processing machine 10 of FIGS. 1A-1E, 424 can also represent a sweep plane (e.g., such as sweep plane 26) positioned to surround the two containment structures 428A and 428B and having a flat surface that is coplanar with the top surface of powder 414 at the start of the build process.

[0083] In the embodiment of FIG. 4, the energy system (e.g., energy system 22 of

FIGS. 1 A-1B, 1D-1E, or energy system 222 of FIGS. 2A, 2C, and 2D) is controlled to direct an energy beam (e.g., energy beam 22A of FIGS. 1A-1B, 1D-1E, or energy beam 222A of FIGS. 2A, 2C, and 2D) at a portion of powder 414 deposited atop a build table (e.g., build table 32 of FIGS. 1 A-1B, 1D-1E, or build table 232 of FIGS. 2A, 2C, and 2D) to form the part 411 and the two containment structures 428 A and 428B. The containment structure 428A has walls that enclose the powder 414 deposited atop the left side of the build table in FIG. 4. The containment structure 428B has walls that enclose the powder 414 deposited atop the right side of the build table in FIG. 4. Walls of the containment structure 428A are built around the left side of the part 411, and walls of the containment structure 428B are built around the right side of the part 411, as shown in FIG. 4. As with the embodiment of FIG. 3, the containment structures 428 A and 428B together do not entirely surround part 411, because narrow gaps of unfused powder remain between walls of containment structure 428A and walls of containment structure 428B on either side of part 411. The containment structures 428A and 428B may be any desired shape, e.g., circular, rectangular, etc.

[0084] In the embodiment of FIG. 4, the containment structure 428 A includes struts

450A, and the containment structure 428B includes struts 450B. Struts 450A provide additional support to the containment structure 428A that allows the thickness of the walls of the containment structure 428A to be reduced. Struts 450B provide additional support to the containment structure 428B that allows the thickness of the walls of the containment structure 428B to be reduced.

[0085] In some cases, the processing machine (e.g., processing machine 10 of FIGS.

1 A-1E, or processing machine 200 of FIGS. 2A-2D) is configured to build the walls of containment structures 428 A and 428B to be adjacent to or close to the walls of the processing machine. The processing machine builds the containment structures 428A-428B, including struts 450A-450B, from portions of the powder 414 as the part 411 is being built. [0086] A powder supply assembly (e.g., powder supply assembly 18 of FIGS. 1A-1B,

1D-1E, or powder supply assembly 218 of FIGS. 2A, 2C, and 2D) deposits layers of powder 414 atop the build table (e.g., build table 32 of FIGS. 1 A-1B, 1D-1E, or build table 232 of FIGS. 2A, 2C, and 2D). An energy system (e.g., energy system 22 of FIGS. 1A-1B, 1D-1E, or energy system 222 of FIGS. 2 A, 2C, and 2D) can irradiate a portion of each layer of the powder 414 deposited by the powder supply assembly to form a layer of each of the containment structures 428A and 428B, including struts 450A-450B, and to form a layer of the part 411. The build table is configured to move vertically downward to accommodate an additional layer of powder 414 after each of the layers of powder 414 is irradiated by the energy system. After the build table is moved vertically downward, the powder supply assembly deposits an additional layer of powder 414 atop the build table.

[0087] In further embodiments, the containment structure built by the processing machine comprises a perforated sacrificial outer containment structure for containing the part being built. In these embodiments, the perforated sacrificial outer containment structure is constructed around the part being built, such that the perforated sacrificial containment structure is built simultaneously along with the part. The energy beam generated by the energy system is directed at a portion of the powder atop the build table to form the perforated sacrificial outer containment structure for containing the part being built. The additional powder for the build process is deposited largely within the containment structure. The problem of extracting the part in a simple, efficient, and cost-effective manner is solved by providing a technique for generating a perforated sacrificial outer containment structure for containing the part being built and by providing an extraction tool to obtain the part after the build. The containment structure may, for example, be formed of sintered powder.

[0088] FIG. 5 A depicts a side view of a portion of the embodiment of the processing machine of FIG. 1 A configured to build a part within a perforated sacrificial outer containment structure. In this embodiment, a perforated sacrificial outer containment structure is built for a variable powder deposition area containing a part being built. This construct is particularly useful where powder deposition can be controlled or varied to focus deposition in a selected area (the variable powder deposition area) so as to concentrate the powder deposition within the selected area containing the part being built. In these embodiments, stated in another fashion, the variable powder deposition area is defined and generated by constructing the containment structure around the part being built, such that the containment structure is built simultaneously along with the part.

[0089] As shown in FIG. 5 A, a part 511 can be built within and along with a perforated sacrificial outer containment structure 528 by a processing machine as disclosed herein (e.g., processing machine 10 of FIGS. 1 A-1E, or processing machine 200 of FIGS. 2A-2D), for example, by irradiating layers of powder 514 deposited by a powder supply assembly (e.g., powder supply assembly 18 of FIGS. 1A-1B, 1D-1E, or powder supply assembly 218 of FIGS. 2 A, 2C, and 2D) in a variable powder deposition area.

[0090] An energy system (e.g., energy system 22 of FIGS. 1A-1B, 1D-1E, or energy system 222 of FIGS. 2A, 2C, and 2D) is controlled to direct an energy beam (e.g., energy beam 22A of FIGS. 1A-1B, 1D-1E, or energy beam 222A of FIGS. 2A, 2C, and 2D) at a portion of powder 514 to form the part 511 and the perforated sacrificial outer containment structure 528 atop the build table (e.g., build table 32 of FIGS. 1 A-1B, 1D-1E, or build table 232 of FIGS. 2A, 2C, and 2D). In the example shown, the perforated sacrificial outer containment structure 528 is built simultaneously along with the part 511. The containment structure 528 contains the part 511 and the powder 514 deposited atop the build table. The additional powder 514 for the build process is deposited largely within the containment structure 528.

[0091] In the embodiments of FIGS. 5A-5B, the containment structure 528 is cylindrical. Also, the containment structure 528 includes perforations 560 that run from a top point of the containment structure 528 to a bottom point of containment structure 528, as well as around the lower edge of containment structure 528, as shown by dotted lines in the lower part of FIG. 5 A. The perforations 560 allow the containment structure 528 to be extracted more easily as disclosed herein, for example, with respect to FIG. 6. Other embodiments of perforated outer containment structures in other shapes (e.g., polygons or irregular shapes) can be used to define and generate a variable powder deposition area containing the part being built.

[0092] In other embodiments, a perforated sacrificial outer containment structure may be formed by a processing machine as described herein (e.g., processing machine 10 of FIGS. 1 A-1E, or processing machine 200 of FIGS. 2A-2D). As a more specific example, FIG. 5B illustrates a side view of a portion of processing machine 200 including the build table 232, actuator 236, walls 224, and a support platform 240 that supports actuator 236. In the embodiment of FIG. 5B, processing machine 200 is configured to build a part 511 within perforated sacrificial outer containment structure 528 by irradiating layers of powder 514 that are deposited by powder supply assembly 218 in a variable powder deposition area. The energy system 222 in processing machine 200 is controlled to direct an energy beam 222A at a portion of the powder 514 to form the part 511 and the perforated sacrificial outer containment structure 528 atop the build table 232. The perforated sacrificial outer containment structure 528 is built simultaneously along with the part 511. The perforated sacrificial outer containment structure 528 contains the part 511 and the powder 514 deposited atop the build table 232. The additional powder 514 for the build process is deposited largely within the containment structure 528. The walls 224 of the processing machine 200 contain the build table 232 as the actuator 236 lowers the build table 232 during the build process, as described above with respect to FIGS. 2A-2B.

[0093] In some embodiments, the processing machine includes an extractor device configured to obtain or extract the part by extracting the containment structure from the mechanical assembly. The extractor device may be configured to pierce the perforated sacrificial outer containment structure along perforations in the perforated sacrificial outer containment structure and to peel back or pull aside portions of the perforated sacrificial outer containment structure to reveal the part.

[0094] FIG. 6 illustrates an example of an extractor device 601 in a processing machine (e.g., processing machine 10 or processing machine 200) configured to extract the part 511 by extracting the perforated sacrificial outer containment structure 528 from the mechanical assembly. Extractor device 601 is configured to pierce the perforated sacrificial outer containment structure 528 using teeth 602 along the perforations 560. The sharp tips of teeth 602 can easily penetrate the un-melted powder between part 511 and the containment structure 528. As the extractor device is lowered further, the outward-slanting surfaces of teeth 602 push outward on containment structure 528, fracturing the perforations 560. Extractor device 601 is thereby able to peel back or pull aside portions of the perforated sacrificial outer containment structure 528 to reveal the part 511. The extractor device 601 provides a simple, efficient, and cost-effective technique for extracting and relocating a part from a variable powder deposition area in the processing machine. As described herein, the extractor device 601 and the perforated sacrificial outer containment structure 528 can be used to reduce the cost, mass, and difficulty of distributing and recycling large volumes of powder in a powder bed by tailoring the build area to the part size.

[0095] In some embodiments, methods are disclosed for building a part using a processing machine as disclosed herein and as described with respect to FIGS. 1 A-1E and FIGS. 2A-2D. Some exemplary methods are described with respect to the following figures.

[0096] FIGS. 7A-7C are flow diagrams of exemplary methods of powder containment in a 3D metal print system.

[0097] As shown in FIG. 7A, a method 700 of powder containment in a 3D metal print system includes building a containment structure configured to contain a powder and a metal part being built from the powder by the 3D print system while the metal part is being built at 710. In the exemplary method shown, the walls of the containment structure are built from the powder by the 3D print system atop a build table during part fabrication. As an example, a processing machine (e.g., processing machine 10 of FIGS. 1 A-1E, or processing machine 200 of FIGS. 2A-2D) can be used to build a containment structure configured to contain a powder and a metal part being built by the processing machine while the metal part is being built.

[0098] In some embodiments, the containment structure comprises a plurality of containment structures configured to enclose powder being used to build the metal part within the containment structures and the containment structures and the powder therein are configured to be removed and recycled. FIGS. 3 and 4 describe embodiments having a plurality of containment structures configured to enclose powder being used to build the part. In some cases, a thickness of walls of the containment structure is minimized so as to use less of at least one of energy, time, and powder. As an example and as described with respect to FIG. 4 herein, the method can further comprise building struts while the metal part is being built. The struts are configured to provide additional support to the walls of the containment structure.

[0099] In some embodiments, the containment structure is configured to include a perforated sacrificial outer containment structure for containing the metal part being built. In some cases, building the containment structure includes defining and generating a variable powder deposition area by constructing a perforated sacrificial containment structure around the metal part being built. As an example, described herein with respect to FIGS. 5A-5B, the perforated sacrificial containment structure is built simultaneously along with the metal part and additional powder for the build process is deposited largely within the perforated sacrificial containment structure.

[00100] FIG. 7B is a flow diagram of an exemplary method 701 of powder containment in a 3D metal print system. As in the method 700 of FIG. 7A, the method 701 of FIG. 7B includes building a containment structure configured to contain a powder and a metal part being built from the powder by the 3D print system while the metal part is being built at 711. Here, the walls of the containment structure are built from the powder by the 3D print system atop a build table during part fabrication. As shown in FIG. 7B, method 701 further comprises extracting the metal part by extracting the containment structure at 721.

[00101] FIG. 7C is a flow diagram of an exemplary method 702 of powder containment in a 3D metal print system. The method 702 of FIG. 7C includes building a containment structure configured to contain a powder and a metal part being built from the powder by the 3D print system while the metal part is being built at 712. The walls of the containment structure are built from the powder by the 3D print system atop a build table during part fabrication and, in the example shown, the containment structure is configured to include a perforated sacrificial outer containment structure for containing the metal part being built. An example of a perforated sacrificial outer containment structure is described herein with respect to FIGS. 5A-5B.

[00102] As shown in FIG. 7C, method 702 further comprises extracting the metal part by extracting the perforated sacrificial outer containment structure at 722; piercing the perforated sacrificial outer containment structure along the perforations at 732, and peeling back or pulling aside portions of the perforated sacrificial outer containment structure to reveal the metal part at 742. An example of extracting the metal part by extracting the perforated sacrificial outer containment structure is described with respect to FIG. 6. In particular, an extractor device 601 (as described with respect to FIG. 6) can be used to pierce the perforated sacrificial outer containment structure along the perforations (e.g., shown at 732) and to peel back or pull aside portions of the perforated sacrificial outer containment structure to reveal the metal part (e.g., shown at 742). [00103] Building the containment structure further comprises depositing layers of powder to form the metal part and the containment structure. Each of the layers of powder is deposited to form a layer of the metal part and a layer of the containment structure.

[00104] In some embodiments and as described more fully with respect to FIGS. 1 A- 1E and FIGS. 2A-2D, building the containment structure further comprises moving the build table vertically after each of the layers of the powder is deposited to form the metal part and the containment structure.

[00105] Exemplary methods for building a part using a processing machine as disclosed herein are described below with respect to FIGS. 8A-8D.

[00106] FIG. 8A depicts a flow diagram of a method 800 for building a part using a processing machine. At 810, the method 800 includes distributing powder onto a build table using a powder supply assembly to form a powder layer. At 820, the method 800 includes directing an energy beam at a portion of the powder on the build table using an energy system to form a portion of the part and to form a portion of a containment structure to contain the part while the part is being built by the processing machine. Directing the energy beam at a portion of the powder can include directing the energy beam to fuse a subset of the portion of the powder to form walls of the containment structure. Additionally or in the alternative, directing the energy beam at the portion of the powder can include irradiating the portion of the powder to form a layer of the part and a layer of the containment structure.

[00107] In some embodiments, as described with respect to FIGS. 1 A-1E and FIGS. 2A-2D herein, the method includes moving the build table after the powder layer is deposited to accommodate deposition of an additional powder layer on the powder layer. In some cases, the containment structure comprises a plurality of containment structures that enclose powder being used to build the part. As an example, a plurality of containment structures that enclose powder being used to build the part is described with respect to FIGS. 3 and 4.

[00108] FIG. 8B depicts a flow diagram of a method 801 for building a part using a processing machine. At 811, the method 801 includes distributing powder onto a build table using a powder supply assembly to form a powder layer. At 821, the method 801 includes directing an energy beam at a portion of the powder on the build table using an energy system to form a portion of the part and to form a portion of a containment structure to contain the part while the part is being built by the processing machine, including by directing the energy beam at a subset of the portion of the powder on the build table to build portions of struts that provide additional support to the walls of the containment structure. An exemplary build process showing a part in a powder bed and two containment structures having struts for additional support being built along with the part according to disclosed techniques is described with respect to FIG. 4.

[00109] FIG. 8C depicts a flow diagram of a method 802 for building a part using a processing machine. At 812, the method 802 includes distributing powder onto a build table using a powder supply assembly to form a powder layer. At 822, the method 802 includes directing an energy beam at a portion of the powder on the build table using an energy system to form a portion of the part and to form a portion of a containment structure to contain the part while the part is being built by the processing machine, including by directing the energy beam at a subset of the portion of the powder on the build table to form a portion of a perforated sacrificial containment structure for containing the part being built. An example of building a perforated sacrificial outer containment structure is described herein with respect to FIGS. 5A-5B.

[00110] In some embodiments, the method includes fitting the build table around an underside of a sweep plane having a conical surface at a start of a process of building the part. As an example, FIG. 1 A depicts an exemplary configuration that includes fitting a build table around an underside of a sweep plane having a conical surface at the start of a process of building the part.

[00111] FIG. 8D depicts a flow diagram of a method 803 for building a part using a processing machine. At 813, the method 803 includes distributing powder onto a build table using a powder supply assembly to form a powder layer. At 823, the method 800 includes directing an energy beam at a portion of the powder on the build table using an energy system to form a portion of the part and to form a portion of a containment structure to contain the part while the part is being built by the processing machine. Directing the energy beam at a portion of the powder can include directing the energy beam to fuse a subset of the portion of the powder to form walls of the containment structure. Additionally or in the alternative, directing the energy beam at the portion of the powder can include irradiating the portion of the powder to form a layer of the part and a layer of the containment structure. [00112] In some embodiments, the containment structure comprises a plurality of containment structures configured to enclose powder being used to build the metal part within the containment structures and the containment structures and the powder therein are configured to be removed and recycled. A plurality of containment structures that enclose powder being used to build the part is described with respect to FIGS. 3 and 4. In some cases, a thickness of walls of the containment structure is minimized so as to use less of at least one of energy, time, and powder. As an example, the method can further comprise building struts while the metal part is being built. The struts are configured to provide additional support to the walls of the containment structure. An example of building struts for additional support to the containment structure is provided herein with respect to FIG. 4.

[00113] In some embodiments, the containment structure is configured to include a perforated sacrificial outer containment structure for containing the metal part being built. In some cases, forming a portion of a containment structure includes defining and generating a variable powder deposition area by constructing a perforated sacrificial containment structure around the metal part being built (as described for example with respect to FIGS. 5 A and 5B). The perforated sacrificial containment structure can be formed simultaneously along with the metal part. Additional powder for the build process is deposited largely within the perforated sacrificial containment structure.

[00114] At 833, the method 803 includes extracting the part from the containment structure using an extractor device. In some cases, the part is extracted by forming a perforated sacrificial outer containment structure for containing the part and extracting the perforated sacrificial outer containment structure containing the part. An example of extracting the metal part by extracting the perforated sacrificial outer containment structure is described with respect to FIG. 6. In particular, an extractor device 601 (as described with respect to FIG. 6) can be used to pierce the perforated sacrificial outer containment structure along the perforations (e.g., shown at 732) and to peel back or pull aside portions of the perforated sacrificial outer containment structure to reveal the metal part (e.g., shown at 742).

[00115] The foregoing description of the exemplary embodiments of the present invention has been presented for the purpose of illustration. The foregoing description is not intended to be exhaustive or to limit the present invention to the examples disclosed herein.

In some instances, features of the present invention can be employed without a corresponding use of other features as set forth. Many modifications, substitutions, and variations are possible in light of the above teachings, without departing from the scope of the present invention.

Claims

What is claimed is:

1. A processing machine for building a part, the processing machine comprising: a build table configured to support a part being built, the build table being movable along a first axis in a fixed structure configured to surround thereof in a direction orthogonal to the first axis; a powder supply assembly that distributes powder onto the build table to form a powder layer; and an energy system that directs an energy beam at a portion of the powder on the build table to form a portion of the part being built, wherein the build table is movable without contacting the fixed structure, and wherein a gap between the build table and the fixed structure varies as the build table moves along the first axis.

2. The processing machine of claim 1, wherein the fixed structure includes an upper plate member having a surface that is substantially parallel to a top surface of the build table and a wall that surrounds the powder layer and the build table.

3. The processing machine of claim 2, wherein the surface that is substantially parallel to a top surface of the build table includes a sweep plane comprising a conical surface configured to fit around or surround the build table at a start of a process for building the part.

4. The processing machine of claims 2 or 3, wherein the upper plate member has an inclined side wall that surrounds the powder layer and the build table.

5. The processing machine of any one of claims 2 to 4, wherein the upper plate member has a conical opening that surrounds the powder layer and the build table.

6. The processing machine of claim 5, wherein a lower opening of the conical opening is wider than an upper opening at the surface of the upper plate member.

7. The processing machine of any one of claims 2 to 6 wherein an upper surface of the upper plate member corresponds to a top surface of the powder layer.

8. The processing machine of any one of claims 2 to 7, wherein the wall has a vertical portion that surrounds the powder layer and the build table.

9. The processing machine of any one of claims 1 to 8 further comprising a mechanism for moving the build table as the part is being built.

10. The processing machine of claim 9, wherein the mechanism for moving the build table moves the build table along at least the first axis.

11. The processing machine of claim 10, wherein the first axis is parallel to a vertical direction.

12. The processing machine of any one of claims 1 to 11, wherein the energy system is configured to direct the energy beam at a portion of the powder on the build table to form a portion of a containment structure around the part being built, and wherein the containment structure is built as the part is being built.

13. The processing machine of claim 12, wherein the containment structure comprises a plurality of containment structures.

14. The processing machine of claims 12 or 13, wherein the energy system is configured to direct the energy beam at a portion of the powder on the build table to build struts that provide additional support to the containment structure.

15. The processing machine of any one of claims 12 to 14, wherein the containment structure comprises a perforated sacrificial outer containment structure for containing the part being built.

16. The processing machine of any one of claims 12 to 15, wherein the containment structure is formed on a variable metal powder deposition area on the build table.

17. The processing machine of any one of claims 12 to 16 further comprising an extractor device configured to obtain the part by extracting the containment structure from the build table.

18. The processing machine of claim 17, wherein the containment structure comprises a perforated sacrificial outer containment structure for a powder deposition area containing the part being built, and wherein the extractor device is further configured to pierce the perforated sacrificial outer containment structure along perforations in the perforated sacrificial outer containment structure and to peel back or pull aside portions of the perforated sacrificial outer containment structure to expose the part.

19. The processing machine of any one of claims 12 to 18, wherein: the processing machine comprises a 3D metal print system; the part being built comprises a metal part being built by the 3D print system; and the containment structure is built by the 3D print system atop the build table.

20. The processing machine of claim 19, wherein the containment structure is configured to enclose metal powder used to build the metal part, and wherein the containment structure is configured to be removed and recycled.

21. A method of powder containment in a 3D metal print system comprising: building a containment structure configured to contain a powder and a metal part being built from the powder by the 3D print system while the metal part is being built, wherein walls of the containment structure are built from the powder by the 3D print system atop a build table during part fabrication.

22. The method of claim 21, wherein the containment structure comprises a plurality of containment structures configured to enclose powder being used to build the metal part within the containment structures, and wherein the containment structures and the powder therein are configured to be removed and recycled.

23. The method of claim 21, wherein a thickness of walls of the containment structure is minimized so as to use less of at least one of energy, time, and powder, and further comprising building struts while the metal part is being built, wherein the struts are configured to provide additional support to the walls of the containment structure.

24. The method of claim 21, wherein the containment structure is configured to include a perforated sacrificial outer containment structure for containing the metal part being built.

25. The method of claim 21, wherein building the containment structure includes constructing a perforated sacrificial containment structure around the metal part being built, wherein the perforated sacrificial containment structure is built simultaneously along with the metal part, and wherein additional powder for the build process is deposited largely within the perforated sacrificial containment structure.

26. The method of claim 21 further comprising extracting the metal part by extracting the containment structure.

27. The method of claim 21, wherein the containment structure is configured to include a perforated sacrificial outer containment structure for containing the metal part being built, and wherein the method further comprises: extracting the metal part by extracting the perforated sacrificial outer containment structure; piercing the perforated sacrificial outer containment structure along the perforations; and peeling back or pulling aside portions of the perforated sacrificial outer containment structure to reveal the metal part.

28. The method of any one of claims 21 to 27, wherein building the containment structure further comprises depositing layers of powder to form the metal part and the containment structure, wherein each of the layers of powder is deposited to form a layer of the metal part and a layer of the containment structure.

29. The method of claim 28, wherein the layers of powder are deposited on a variable metal powder deposition area on the build table, and wherein the variable powder deposition area is defined and generated by building the containment structure.

30. The method of claims 28 or 29, wherein building the containment structure further comprises moving the build table vertically after each of the layers of the powder is deposited to form the metal part and the containment structure.

31. A method for building a part using a processing machine, the method comprising: distributing powder onto a build table using a powder supply assembly to form a powder layer; and directing an energy beam at a portion of the powder on the build table using an energy system to form a portion of the part and to form a portion of a containment structure to contain the part while the part is being built by the processing machine.

32. The method of claim 31, wherein directing the energy beam at the portion of the powder further comprises directing the energy beam to fuse a subset of the portion of the powder to form walls of the containment structure.

33. The method of claims 31 or 32 further comprising moving the build table after the powder layer is deposited to accommodate deposition of an additional powder layer on the powder layer.

34. The method of any one of claims 31 to 33, wherein directing the energy beam at the portion of the powder further comprises irradiating the portion of the powder to form a layer of the part and a layer of the containment structure.

35. The method of any one of claims 31 to 34, wherein the containment structure comprises a plurality of containment structures that enclose powder being used to build the part.

36. The method of any one of claims 31 to 35, wherein directing the energy beam at the portion of the powder further comprises directing the energy beam at a subset of the portion of the powder on the build table to build portions of struts that provide additional support to the walls of the containment structure.

37. The method of any one of claims 31 to 34, wherein directing the energy beam at the portion of the powder further comprises directing the energy beam at a subset of the portion of the powder on the build table to form a portion of a perforated sacrificial containment structure for containing the part being built.

38. The method of any one of claims 31 to 37 further comprising fitting the build table around an underside of a sweep plane having a conical surface at a start of a process of building the part.

39. The method of any one of claims 31 to 38 further comprising extracting the part from the containment structure using an extractor device.

40. A 3D metal print system for building a metal part, the 3D metal print system comprising: a build table configured to support a metal part being built; a powder supply assembly that distributes powder onto the build table to form a powder layer; an energy system that directs an energy beam at a portion of the powder on the build table to form a portion of the metal part being built; and a mechanism for moving the build table as the metal part is being built, wherein the energy system is configured to direct the energy beam at a portion of the powder on the build table to form a portion of a containment structure atop the build table that contains the metal part being built.

41. The 3D metal print system of claim 40, wherein the containment structure is configured to enclose metal powder used to build the metal part.

42. The 3D metal print system of claims 40 or 41, wherein the containment structure is configured to be removed and recycled.

43. The 3D metal print system of any one of claims 40 to 42, wherein the containment structure comprises a plurality of containment structures configured to enclose powder being used to build the metal part within the plurality of containment structures.

44. The 3D metal print system of any one of claims 40 to 43 further comprising building struts while the metal part is being built, wherein the struts are configured to provide additional support to walls of the containment structure.

45. The 3D metal print system of any one of claims 40 to 44, wherein the containment structure is configured to include a perforated sacrificial outer containment structure for containing the metal part being built.

46. The 3D metal print system of claim 45, wherein the perforated sacrificial outer containment structure is formed on a variable metal powder deposition area on the build table.

47. The 3D metal print system of any one of claims 40 to 46, wherein the containment structure is formed of sintered powder.

48. A processing machine for building a part, the processing machine comprising: a mechanical assembly comprising a build table configured to support a part being built by the processing machine; a powder supply assembly that distributes powder onto the build table to form a powder layer; and an energy system that directs an energy beam at a portion of the powder on the build table to form a portion of the part being built, wherein the energy system is configured to direct the energy beam at a portion of the powder on the build table to form a portion of a containment structure around the part being built.

49. The processing machine of claim 48, wherein the containment structure is built as the part is being built.

50. The processing machine of claims 48 or 49, wherein the energy system is configured to direct the energy beam at a portion of the powder on the build table to build walls of the containment structure adjacent to the walls of the mechanical assembly.

51. The processing machine of any one of claims 48 to 50, wherein the containment structure comprises a plurality of containment structures.

52. The processing machine of any one of claims 48 to 51, wherein the energy system is configured to direct the energy beam at a portion of the powder on the build table to build struts that provide additional support to the containment structure.

53. The processing machine of any one of claims 48 to 52, wherein the containment structure comprises a perforated sacrificial outer containment structure for containing the part being built.

54. The processing machine of claim 53, wherein the perforated sacrificial outer containment structure is formed on a variable metal powder deposition area on the build table.