WO2022197612A1

WO2022197612A1 - Systems and methods of supplying material to additive manufacturing system in vacuum environment

Info

Publication number: WO2022197612A1
Application number: PCT/US2022/020199
Authority: WO
Inventors: Patrick Shih CHANG; Matthew David Rosa
Original assignee: Nikon Corporation
Priority date: 2021-03-17
Filing date: 2022-03-14
Publication date: 2022-09-22

Abstract

Containers for sealing and delivering consumable materials to an additive manufacturing system at an internal pressure below ambient atmospheric pressure, systems and methods for heating and reducing the moisture content of such consumable materials, and systems and methods of providing consumable materials to an additive manufacturing system in a vacuum environment are disclosed herein. An additive manufacturing system can include an environmental chamber configured to maintain a vacuum environment in an interior of the environmental chamber, a powder supply assembly situated in the environmental chamber, and a transfer system coupled to the environmental chamber and configured to receive a container containing a powder material and direct the powder material from the container to the powder supply assembly in the environmental chamber while maintaining the vacuum environment.

Description

SYSTEMS AND METHODS OF SUPPLYING MATERIAL TO ADDITIVE MANUFACTURING SYSTEM IN VACUUM ENVIRONMENT

CROSS REFERENCE TO RELATED APPLICATION

[001] The present application claims the benefit of U.S. Provisional Application No. 63/162,190, filed March 17, 2021. The disclosure of U.S. Provisional Application No. 63/162,190 is incorporated herein by reference in its entirety.

FIELD

[002] The present disclosure pertains to systems and methods of supplying material to additive manufacturing systems in a vacuum environment.

BACKGROUND

[003] Additive manufacturing systems or three-dimensional printing systems are used to print three-dimensional objects. Existing three-dimensional printing systems are relatively slow, have a low throughput, are expensive to operate, and/or generate excessive waste. There is a never-ending search to increase the speed and throughput, and reduce the cost of operation, for three-dimensional printing systems.

[004] In many additive manufacturing systems, material is applied to the object or workpiece in layers, and fused with the object by, for example, application of heat. For example, in electron beam melting or similar systems, an electron beam or other high energy beam is used to melt sequential layers of material, such as metal or polymeric powder, onto the workpiece. Such systems typically operate in a vacuum environment, such as in an environmentally controlled chamber. Thus, replenishing consumable materials such as powder typically requires venting the chamber in order to deliver the supplies to the system. During this procedure, printing typically must be stopped, and cannot resume until the chamber is returned to sufficiently low pressure for the energy beam to be reestablished. This can require considerable time, resulting in lengthy delays when consumable supplies must be replenished. Accordingly, there exists a need for improvements to additive manufacturing systems. SUMMARY

[005] Certain embodiments of the disclosure pertain to containers for sealing and delivering consumable materials to an additive manufacturing system at an internal pressure below ambient atmospheric pressure, systems and methods for heating and reducing the moisture content of such consumable materials, and systems and methods of providing consumable materials to an additive manufacturing system in a vacuum environment. In a representative embodiment, an additive manufacturing system, comprises an environmental chamber configured to maintain a vacuum environment in an interior of the environmental chamber, a powder supply assembly situated in the environmental chamber, and a transfer system coupled to the environmental chamber and configured to receive a container containing a powder material and direct the powder material from the container to the powder supply assembly in the environmental chamber while maintaining the vacuum environment.

[006] In any or all of the disclosed embodiments, the transfer system further comprises an actuator configured to selectively open a container received by the transfer system, or allow the container to open, upon activation of the actuator.

[007] In any or all of the disclosed embodiments, the transfer system comprises a port configured to form a seal with a body of a container when a container is coupled to the port.

[008] In any or all of the disclosed embodiments, the port comprises a gate valve movable between an open position and a closed position, the gate valve being configured to seal the port from the environmental chamber when the gate valve is in the closed position.

[009] In any or all of the disclosed embodiments, the port comprises a tubular body having a first end portion, a second end portion, and a tubular body wall extending between the first end portion and the second end portion, and the gate valve extends across the tubular body in the closed position and seals the first end portion of the tubular body from the second end portion.

[010] In any or all of the disclosed embodiments, the first end portion of the tubular body is configured to receive a container, and when a container is received by the first end portion, the gate valve, the tubular body wall, and the container define a sealed volume within the port.

[011] In any or all of the disclosed embodiments, the additive manufacturing system further comprises a vacuum pump system in fluid communication with the first end portion of the tubular body and configured to reduce a pressure in the sealed volume when a container is received by the first end portion.

[012] In any or all of the disclosed embodiments, the actuator is the gate valve, and the gate valve is configured to bear against a cover member of a container when a container is received by the port and the gate valve is in the closed position, and movement of the gate valve to the open position allows the cover member of the container to open.

[013] In any or all of the disclosed embodiments, the port comprises at least one flow directing device configured to direct a flow of powder from a container received in the port toward the powder supply assembly.

[014] In any or all of the disclosed embodiments, the transfer system is located above the powder supply assembly such that powder from a container coupled to the transfer system flows to the powder supply assembly by gravity.

[015] In any or all of the disclosed embodiments, the actuator is configured to open a container received by the transfer system by moving a closure of the container to the open position when activated.

[016] In any or all of the disclosed embodiments, the transfer system comprises a load lock chamber configured to receive a container, and a gate valve movable between a closed position and an open position to selectively place the load lock chamber in communication with the environmental chamber, and wherein when the gate valve is in the closed position, the gate valve is configured to bear against a cover member of a container when a container is received in the load lock chamber, and further configured to allow the cover member of the container to open when the gate valve is moved to the open position.

[017] In another representative embodiment, a method comprises filling a container with additive manufacturing powder material, reducing a pressure in the container to a first pressure that is below ambient atmospheric pressure, and sealing the container so that the container remains at the first pressure.

[018] In any or all of the disclosed embodiments, the method further comprises heating the powder material in the container or agitating the powder material in the container at the first pressure. [019] In any or all of the disclosed embodiments, reducing the pressure in the container further comprises placing the container in an environmental chamber and reducing the pressure in the environmental chamber, or reducing the pressure in the container with a vacuum pump system coupled to a valve port of the container.

[020] In any or all of the disclosed embodiments, sealing the container further comprises closing a cover member of the container and fastening a fastening device to secure the cover member closed.

[021] In any or all of the disclosed embodiments, the method further comprises closing the cover member and fastening the fastening device with an actuator in an environmental chamber at the first pressure.

[022] In any or all of the disclosed embodiments, the method further comprises venting the environmental chamber to ambient atmospheric pressure after the cover member is closed and the fastening device is fastened.

[023] In any or all of the disclosed embodiments, the first pressure is 1 x 10^-3 Pa or less.

[024] In any or all of the disclosed embodiments, the method further comprises coupling the container to a transfer system of an additive manufacturing system, the transfer system being coupled to an environmental chamber in which a powder supply assembly of the additive manufacturing system is located, an interior of the environmental chamber being at the first pressure, reducing a pressure in the transfer system to the first pressure, and opening the container to allow powder in the container to flow to the powder supply assembly.

[025] In another representative embodiment, a method comprises supplying powder material to an additive manufacturing system in a vacuum environment while maintaining the vacuum environment.

[026] In another representative embodiment, supplying powder material to an additive manufacturing system comprises coupling a container to a transfer system of the additive manufacturing system, the transfer system being coupled to an environmental chamber in which a powder supply assembly of the additive manufacturing system is located, an interior of the environmental chamber being at a first pressure that is less than ambient atmospheric pressure, reducing a pressure in the transfer system to the first pressure, and opening the container to allow powder in the container to flow to the powder supply assembly. [027] In any or all of the disclosed embodiments, prior to opening the container, the interior of the container is at the first pressure.

[028] In any or all of the disclosed embodiments, the transfer system further comprises a port configured to be selectively placed in fluid communication with the interior of the environmental chamber, and coupling the container to the transfer system further comprises forming a seal between the port and a body of the container.

[029] In any or all of the disclosed embodiments, the transfer system comprises a load lock chamber configured to receive the container, and coupling the container to the transfer system further comprises placing the container in the load lock chamber.

[030] In any or all of the disclosed embodiments, opening the container further comprises unfastening a fastening device of the container.

[031] In any or all of the disclosed embodiments, the method further comprises opening a valve of the transfer system such that the transfer system communicates with the interior of the environmental chamber.

[032] In any or all of the disclosed embodiments, the valve is a gate valve configured to bear against the container when the gate valve is in a closed position, and opening the container further comprises moving the gate valve to an open position.

[033] In any or all of the disclosed embodiments, the container comprises a main body portion, a tapered outlet portion defining an opening, and a closure, the main body portion coupled to the tapered outlet portion, the closure comprising a cover member coupled to the tapered outlet portion and movable between an open position and closed position, the cover member being configured to close the opening in the closed position, a bias coupled to the tapered outlet portion and to the cover member and configured to bias the cover member toward the closed position, and a fastening device configured to secure the cover member in the closed position, and wherein a sealing member is coupled to the tapered outlet portion or to the cover member.

[034] In another representative embodiment, a container comprises a main body portion and a tapered outlet portion, the outlet portion defining an opening, and a closure comprising a cover member coupled to the tapered outlet portion and movable between an open position and closed position, the cover member being configured to close the opening in the closed position, a bias coupled to the tapered outlet portion and to the cover member, and configured to bias the cover member toward the closed position, a fastening device configured to secure the cover member in the closed position, and a sealing member coupled to the tapered outlet portion or to the cover member.

[035] In any or all of the disclosed embodiments, the container is configured to maintain an internal pressure of 1 x 10^-3 Pa or less.

[036] In any or all of the disclosed embodiments, the fastening device comprises a latch, a hasp, a buckle, a clasp, a pin, or any combination thereof.

[037] In any or all of the disclosed embodiments, the cover member is pivotable between the position and the closed position.

[038] In any or all of the disclosed embodiments, the cover member comprises a gate valve member.

[039] In another representative embodiment, a container comprises a main body portion configured to contain a powder material, and a closure configured to maintain a first pressure that is below ambient atmospheric pressure.

[040] In any or all of the disclosed embodiments, the first pressure is a vacuum environment.

[041] In any or all of the disclosed embodiments, the container is configured to maintain an internal pressure of 1 x 10^-3 Pa or less.

[042] In any or all of the disclosed embodiments, the container further comprises a tapered outlet portion defining an opening.

[043] In any or all of the disclosed embodiments, the closure comprises a cover member coupled to the tapered outlet portion and movable between an open position and a closed position, the cover member being configured to close the opening in the closed position, a bias coupled to the tapered outlet portion and to the cover member, and configured to bias the cover member toward the closed position, a fastening device configured to secure the cover member in the closed position, and a sealing member coupled to the tapered outlet portion or to the cover member.

[044] In any or all of the disclosed embodiments, the fastening device comprises a latch, a hasp, a buckle, a clasp, a pin, or any combination thereof. [045] In any or all of the disclosed embodiments, the cover member is pivotable between the open position and the closed position.

[046] hi any or all of the disclosed embodiments, the cover member comprises a gate valve member.

[047] The foregoing and other objects, features, and advantages of the disclosed technology will become more apparent from the following detailed description, which proceeds with reference to the accompanying figures.

BRIEF DESCRIPTION OF THE DRAWINGS

[048] FIG. 1A is a schematic side view of an implementation of a processing machine having features of the present embodiment.

[049] FIG. IB is a schematic top view of a portion of the processing machine of FIG. 1 A.

[050] FIG. 2 is a schematic side view of another implementation of a processing machine having features of the present embodiment.

[051] FIG. 3 is a schematic side view of still another implementation of a processing machine having features of the present embodiment.

[052] FIG. 4 is a schematic top view of a powder bed assembly.

[053] FIG. 5 is a schematic top view of another implementation of a powder bed assembly.

[054] FIG. 6A is a perspective view of a portion of a powder bed assembly and a powder supply assembly.

[055] FIG. 6B is a cut-away view taken on line 6B-6B in FIG. 6A.

[056] FIG. 6C is a cut-away view of the powder supply assembly of FIG. 6B at a different time. [057] FIG. 6D is a cut-away view taken from line 6D-6D in FIG. 6A.

[058] FIG. 6E is a schematic top view of the powder supply assembly without powder.

[059] FIG. 6F is a top view of a flow controller.

[060] FIG. 6G is a side view of another flow controller. [061] FIG. 7 is a schematic diagram illustrating a container and a filling system, according to one embodiment.

[062] FIGS. 8A-8E are side elevation views schematically illustrating embodiments of containers with various closures.

[063] FIG. 9 is a schematic diagram illustrating a vacuum dryer system, according to one embodiment.

[064] FIG. 10 is a schematic diagram illustrating another embodiment of a vacuum dryer system.

[065] FIG. 11 is a schematic diagram illustrating an additive manufacturing system including a transfer system configured as a selectively sealable access port, and a container coupled to the port, according to one embodiment.

[066] FIG. 12 is a schematic diagram illustrating powder flowing from the container into the environmental chamber of the additive manufacturing system of FIG. 11.

[067] FIG. 13 is a schematic diagram of another embodiment of an additive manufacturing system including a gate valve configured to bear against a cover member of a container.

[068] FIG. 14 illustrates movement of the gate valve of FIG. 13 to allow the cover member of the container to open.

[069] FIG. 15 is a schematic diagram of another embodiment of an additive manufacturing system in which the transfer system includes multiple flow control devices.

[070] FIG. 16A-16C schematically illustrate another embodiment of a container including a pivotable cover member and a valve port.

[071] FIG. 17 is a schematic diagram of another embodiment of an additive manufacturing system including a transfer system configured as a load lock chamber configured to receive the container of FIGS. 16A-16C.

DETAILED DESCRIPTION

[072] The present disclosure pertains to additive manufacturing systems such as three- dimensional printing systems that are configured to create/build/print a solid object by depositing layers of powder material onto the object, and fusing or sintering the powder to the object by application of heat. In certain embodiments, the powder material (also referred to as additive manufacturing powder material) can comprise any of various metals or metal alloys (e.g., steel, aluminum, titanium, etc.), or can comprise polymeric materials or ceramic materials. In certain embodiments, the heat source can be a high energy beam, such as an electron beam or other charged particle beam, which can be quickly and accurately directed over the surface of the object to fuse sequential layers of powder to the object.

[073] In certain embodiments, the systems described herein can be operated in a vacuum environment to facilitate generation of the electron beam. Accordingly, certain embodiments described herein pertain to systems and methods of delivering powder material or other consumable materials to an additive manufacturing system operating in a vacuum environment while maintaining the vacuum environment, that is, without substantially increasing the pressure in the vacuum environment. For example, certain embodiments of the disclosure pertain to containers configured to be filled with powder in a vacuum environment and sealed such that the interior of the container is at a pressure below ambient atmospheric pressure. In this manner, when the containers are opened in the vacuum environment to dispense powder material to the additive manufacturing system, any gas introduced into the environmental chamber by opening the containers can be kept within prescribed limits.

[074] In certain embodiments, such containers can include a closure including a cover member movable between an open position and a closed position, one or a plurality of sealing members configured to seal the interior of the container from the ambient, a bias that biases the cover member toward the open position or toward the closed position, a releasable fastening device such as a latch, pin, hasp, or the like, and/or a single-use barrier to aid in keeping the cover member closed. In certain embodiments, the containers described herein can be configured to maintain an internal pressure of, for example, 1 x 10^-3 Pa for days, weeks, months, or years. Systems and methods of filling the containers and processing the powder to drive off water and other undesirable substances before sealing the containers are also described.

[075] Certain embodiments of the disclosure also pertain to additive manufacturing systems that operate in a vacuum environment maintained in an environmentally controlled chamber, and which include transfer systems configured to receive a powder- filled container and transfer the powder from the container to a powder supply assembly of the additive manufacturing system while maintaining the vacuum environment. In certain embodiments, the transfer system can comprise a port that can be selectively placed in fluid communication with the interior of the environmentally controlled chamber, for example, by a valve. In certain embodiments, the port can comprise a tubular body having a diameter less than a diameter of the container such that the container can be placed on the tubular body or at least partially within the tubular body of the port. In certain embodiments, the port can be configured to form a seal with the container when the container is coupled to or received by the port. In certain embodiments, when a container is coupled to the port, the valve of the port, the wall of the tubular body, and the container can define a sealed volume. A vacuum pump system can be coupled to the sealed volume, and can draw a vacuum in the sealed volume prior to opening the container. When the sealed volume is at a selected pressure (e.g., at or near the pressure inside the environmental chamber), the container can be opened, for example, with an actuator, or by opening the valve and allowing the cover member of the container to open under the influence of gravity, and/or by the influence of a bias such as a spring. This can allow powder within the container to flow through the port and to the powder supply assembly of the additive manufacturing system to replenish the powder supply.

[076] In certain embodiments, the transfer system can be positioned above the powder supply assembly such that powder can flow from the container to the powder supply assembly by gravity. In certain embodiments, the transfer system can comprise one or a series of flow-directing devices such as funnels, conduits, or the like to direct powder flow from the container to the powder reservoir of the powder supply assembly. In certain embodiments, the transfer system can comprise a load lock vacuum chamber configured to receive a powder-filled container.

[077] The features of any of the embodiments described herein can be combined in any combination to provide additive manufacturing systems with the capability to operate in a vacuum environment and replenish consumable materials such as powder while maintaining the vacuum environment (e.g., without venting the vacuum environment to atmosphere).

[078] Example 1: Additive Manufacturing System

[079] FIG. 1 A is a schematic side illustration of a processing machine 10 that can be used to manufacture one or more three-dimensional objects 11. As provided herein, the processing machine 10 can be an additive manufacturing system, e.g., a three-dimensional printer, in which a portion of the powder 12 (powder particles illustrated as small circles) in a series of powder layers 13 (illustrated as dashed horizontal lines) is joined, melted, solidified, and/or fused together to manufacture one or more three-dimensional object(s) 11. In FIG. 1A, the object 11 includes a plurality of small squares that represent the joining of the powder 12 to form the object 11.

[080] The type of three-dimensional object(s) 11 manufactured with the processing machine 10 may be almost any shape or geometry. As a non-exclusive example, the three-dimensional object 11 may be a metal part, or another type of part, for example, a resin (plastic) part or a ceramic part, etc. The three-dimensional object 11 may also be referred to as a “built part”.

[081] The type of powder 12 joined and/or fused together may be varied to suit the desired properties of the object(s) 11. As a non-exclusive example, the powder 12 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 12 may be non-metal powder, a plastic, polymer, glass, ceramic powder, organic powder, an inorganic powder, or any other material known to people skilled in the art. The powder 12 may also be referred to as “material,” “powder particles,” “granules,” “granular material,” etc.

[082] A number of different designs of the processing machine 10 are provided herein. In certain implementations, the processing machine 10 includes (i) a powder bed assembly 14; (ii) a pre-heat device 16; (iii) a powder supply assembly 18 (illustrated as a box); (iii) a measurement device 20 (illustrated as a box); (iv) an energy system 22 (illustrated as a box); and (v) a control system 24 (illustrated as a box) that cooperate to make each three-dimensional object 11. 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. 1. Moreover, the processing machine 10 can include more components or fewer components than illustrated in FIG. 1A. For example, the processing machine 10 can include a cooling device (not shown in FIG. 1A) that uses radiation, conduction, and/or convection to cool the powder 12. Alternatively, for example, the processing machine 10 can be designed without the pre-heat device 16 and/or the measurement device 20.

[083] A number of different powder supply assemblies 18 are disclosed herein. As an overview, these powder supply assemblies 18 are uniquely designed to accurately, efficiently, evenly, and quickly distribute the powder layers 13 onto the powder bed assembly 14. Further, in certain implementations, the powder supply assembly 18 is centerless, and uniformly distributes a fine layer of the powder 12 over a large and broad powder bed assembly 14. This will improve the accuracy of the built object 11, and reduce the time required to form the built object 11.

[084] The thickness of each powder layer 13 can be varied to suit the manufacturing requirements. In alternative, non-exclusive examples, one or more (e.g. all) of the powder layers 13 can have a uniform layer thickness (along the Z axis) of twenty, thirty, forty, fifty, sixty, seventy, eighty, or ninety, or one hundred microns. However other layer thicknesses are possible. Particle sizes of the powder 12 can be varied. In one implementation, a common particle size is fifty microns. Alternatively, in other non-exclusive examples, the particle size can be twenty, thirty, forty, sixty, seventy, eighty, or ninety, or one hundred microns.

[085] A number of figures include an orientation system that illustrates an X axis, a Y axis that is orthogonal to the X axis, and a Z axis that is orthogonal to the X and Y axes. It should be noted that any of these axes can also be referred to as the first, second, and/or third axes. Further, as used herein, movement with six degrees of freedom shall mean along and about the X, Y, and Z axes.

[086] In FIG. 1A, a portion of the powder bed assembly 14 is illustrated in cut-away so that the powder 12, the powder layers 13 and the object 11 are visible. With the present design, one or more objects 11 can be simultaneously made with the processing machine 10. In FIG. 1A, only one object 11 is visible.

[087] It should be noted that any of the processing machines 10 described herein may be operated in a controlled environment, e.g. such as a vacuum, using an environmental chamber 23 (illustrated in FIG. 1 A as a box). For example, one or more of the components of the processing machine 10 can be positioned entirely or partly within the environmental chamber 23. Alternatively, at least a portion of one or more of the components of the processing machine 10 may be positioned outside the environmental chamber 23. Still alternatively, the processing machine 10 may be operated in non-vacuum environment such as inert gas (e.g., nitrogen gas or argon gas) environment.

[088] FIG. IB is a top view of a portion of the powder bed assembly 14 of FIG. 1 A and the three- dimensional object 11. FIG. IB also illustrates (i) the pre-heat device 16 (illustrated as box) and a pre-heat zone 16A (illustrated with dashed lines) which represents the approximate area in which the powder 12 can be pre-heated with the pre-heat device 16; (ii) the powder supply assembly 18 (illustrated as a box) and a deposit zone 18A (illustrated in phantom) which represents the approximate area in which the powder 12 can be added and/or spread to the powder bed assembly 14 by the powder supply assembly 18; (iii) the measurement device 20 (illustrated as a box) and a measurement zone 20A (illustrated in phantom) which represents the approximate area in which the powder 12 and/or the object 11 can be measured by the measurement device 20; and (iv) the energy system 22 (illustrated as a box) and an energy zone 22A which represents the approximate area in which the powder 12 can be melted and fused together by the energy system 22.

[089] It should be noted that these zones may be spaced apart different, oriented differently, or positioned differently from the non-exclusive example illustrated in FIG. IB. Additionally, the relative sizes of the zones 16A, 18 A, 20A, 22A may be different than what is illustrated in FIG. IB.

[090] In FIGS. 1A and IB, in certain implementations, the processing machine 10 can be operated so that there is substantially constant relative motion along a moving direction 25 (illustrated by an arrow) between the object 11 being formed and one or more of the pre-heat device 16, the powder supply assembly 18, the measurement device 20, and the energy system 22. The moving direction 25 may include a rotation direction about a rotation axis 25A. With this design, the powder 12 may be deposited and fused relatively quickly. This allows for the faster forming of the objects 11, increased throughput of the processing machine 10, and reduced cost for the objects 11.

[091] In the implementation illustrated in FIG.1A and IB, the powder bed assembly 14 includes (i) a powder bed 26 that supports the powder 12 and the object 11 while being formed, and (ii) a device mover 28 (e.g. one or more actuators) that selectively moves the powder bed 26. In this implementation, the device mover 28 rotates the powder bed 26 about the rotation axis 25A relative to the pre-heat device 16 (and the pre-heat zone 16A), the powder supply assembly 18 (and the deposit zone 18A), the measurement device 20 (and the measurement zone 20A), and the energy system 22 (and the irradiation zone 22A). This allows nearly all of the rest of the components of the processing machine 10 to be fixed while the powder bed 26 is moved.

[092] In the schematic diagram illustrated in FIG. 1A and IB, the powder bed 26 includes a build platform 26 A and a support side wall 26B. In this embodiment, the build platform 26A is flat disk shaped and has a support surface, and the support side wall 26B is tubular shaped and extends upward from a perimeter of the support surface 26A. Alternatively, other shapes of the build platform 26A and the support side wall 26B may be utilized. In some implementations, the build platform 26A is moved somewhat similar to a piston relative to the support side wall 26B which act like as the piston’s cylinder wall. For example, a platform mover (not shown) can selectively move the build platform 26 A downward as each subsequent powder layer 13 is added.

[093] In another implementation, the build platform 26A is flat, rectangular shaped, and the support side wall assembly 26B are rectangular tube shaped and extends upward around the build platform 26A. Alternatively, other shapes of the build platform 26A and/or support side wall assembly 26B may be utilized. As non-exclusive examples, the build platform 26A can be polygonal- shaped, with the support side wall assembly 26B having the corresponding tubular- shape. In another implementation, the support side wall can be built concurrently as a custom shape around the object 11, while the object 11 is being built.

[094] The device mover 28 can move the powder bed 26 at a substantially constant or variable angular velocity about the rotation axis 25 A. As alternative, non- exclusive examples, the device mover 28 may move the powder bed 26 at a substantially constant angular velocity of at least 1, 2, 5, 10, 20, 30, 60, 100 or more revolutions per minute (RPM). Stated in a different fashion, the device mover 28 may move the powder bed 26 at a substantially constant angular velocity of between one and one hundred revolutions per minute. As used herein, the term “substantially constant angular velocity” shall mean a velocity that varies less than 10% over time. In one embodiment, the term “substantially constant angular velocity” shall mean a velocity that varies less 0.2% from the target velocity. The device mover 28 may also be referred to as a “drive device”.

[095] Additionally or alternatively, the device mover 28 may move the powder bed 26 at a variable velocity or in a stepped or other fashion. For example, it may be desired to speed up or slow down the rotation of the powder bed 26 for some sections, either as part of a normal cycle like increase time under pre-heater, or as a smart corrective action during the build (e.g. to repair a defect). The rotation axis 25 A may be aligned along with gravity direction, and may be along with an inclination direction about the gravity direction.

[096] In FIG. 1A, the device mover 28 includes a motor 28A (e.g., a rotary motor) and a device connector 28B (e.g., a rigid shaft) that fixedly connects the motor 28A to the powder bed 26. In other embodiments, the device connector 28B may include a transmission device such as at least one gear, belt, chain, or friction drive. [097] The powder 12 used to make the object 11 is deposited onto the powder bed 26 in a series of powder layers 13. Depending upon the design of the processing machine 10, the powder bed 26 with the powder 12 may be very heavy. With the present design, this large mass may be rotated at a constant or substantially constant speed to avoid accelerations and decelerations, and the required motion is a continuous rotation of a large mass, with no non-centripetal acceleration other than at the beginning and end of the entire exposure process. The melting process may be performed during the period when the motion is constant velocity motion.

[098] The pre-heat device 16 selectively preheats the powder 12 in the pre-heat zone 16A that has been deposited on the powder bed 26 during a pre-heat time. In certain embodiments, the pre-heat device 16 heats the powder 12 to a desired preheated temperature in the pre-heat zone 16A when the powder 12 is moved through the pre-heat zone 16A. The number of the pre-heat devices 16 may be one or plural.

[099] In one embodiment, the pre-heat device 16 is positioned along a pre-heat axis (direction)

16B and is arranged between the measurement device 20 and the energy system 22. However, the pre-heat device 16 can be positioned at another location.

[0100] The design of the pre-heat device 16 and the desired preheated temperature may be varied. In one embodiment, the pre-heat device 16 may include one or more pre-heat energy source(s) 16C that direct one or more pre-heat beam(s) 16C at the powder 12. Each pre-heat beam 16D may be steered as necessary. As alternative, non-exclusives examples, each pre-heat energy source 16C may be an electron beam system, a mercury lamp, an infrared laser, a supply of heated air, thermal radiation system, a visual wavelength optical system or a microwave optical system. The desired preheated temperature may be 50% 75% 90% or 95% of the melting temperature of the powder material used in the printing. It is understood that different powders have different melting points and therefore different desired pre-heating points. As non-exclusive examples, the desired preheated temperature may be at least 300, 500, 700, 900, or 1000 degrees Celsius. Energy input may also vary dependent on melt duty of previous layers, specific regions on a layer, or progress though the build.

[0101] The powder supply assembly 18 deposits the powder 12 onto the powder bed 26. In certain embodiments, the powder supply assembly 18 supplies the powder 12 to the powder bed 26 in the deposit zone 18A while the powder bed 26 is being moved to form each powder layer 13 on the powder bed 26.

[0102] In one implementation, the powder supply assembly 18 extends along a powder supply axis (direction) 18B and is arranged between the measurement device 20 and the energy system 22. The powder supply assembly 18 can include one or more powder containers (not shown in FIGS. 1A and IB). The number of the powder supply assemblies 18 may be one or plural.

[0103] With the present design, the powder supply assembly 18 deposits the powder 12 onto the powder bed assembly 14 to sequentially form each powder layer 13. Once a portion of the powder layer 13 has been melted with the energy system 22, the powder supply assembly 18 evenly and uniformly deposits another (subsequent) powder layer 13.

[0104] It should be noted that the three-dimensional object 11 is formed through consecutive fusions of consecutively formed cross sections of powder 12 in one or more powder layers 13. For simplicity, the example of FIG. 1A illustrates only a few, separate, stacked powder layers 13. However, it should be noted that depending upon the design of the object 11, the building process will require numerous powder layers 13.

[0105] A number of alternative powder supply assemblies 18 are described in more detail below. In these embodiments, the powder supply assembly 18 is an overhead powder supply that supplies the powder 12 onto the top of the powder bed assembly 14.

[0106] The measurement device 20 inspects and monitors the melted (fused) layers of the object 11 as they are being built, and/or the deposition of the powder layers 13. The number of the measurement devices 20 may be one or plural. For example, the measurement device 20 can measure both before and after the powder 12 is distributed.

[0107] 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.

[0108] In one implementation, the measurement device 20 is arranged between the powder supply assembly 18 and the pre-heat device 16, however, the measurement device 20 may be alternatively located. [0109] The energy system 22 selectively heats and melts the powder 12 in the energy zone 22 A to sequentially form each of the layers of the object 11 while the powder bed 26 and the object 11 are being moved. The energy system 22 can selectively melt the powder 12 at least based on a data regarding to the object 11 to be built. The data may be corresponding to a computer-aided design (CAD) model data. The number of the energy systems 22 may be one or plural.

[0110] In one embodiment, the energy system 22 is positioned along an energy axis (direction) 22B and is arranged between the pre-heat device 16 and the powder supply assembly 18. The design of the energy system 22 can be varied. In one embodiment, the energy system 22 may include one or more energy source(s) 22C (“irradiation systems”) that direct one or more irradiation (energy) beam(s) 22D at the powder 12. The one or more energy sources 22C can be controlled to steer the energy beam(s) 22D to melt the powder 12.

[0111] As alternative, non-exclusives examples, each of the energy sources 22C can be designed to include one or more of the following: (i) an electron beam generator that generates a charged particle electron beam; (ii) an irradiation system that generates an irradiation beam; (iii) an infrared laser that generates an infrared beam; (iv) a mercury lamp; (v) a thermal radiation system; (vi) a visual wavelength system; (vii) a microwave wavelength system; or (viii) an ion beam system.

[0112] Different powders 12 have different melting points. As non-exclusive examples, the desired melting temperature may be at least 1000, 1400, 1700, 2000, or more degrees Celsius.

[0113] The control system 24 controls the components of the processing machine 10 to build the three-dimensional object 11 from the computer-aided design (CAD) model by successively melting portions of one or more of the powder layers 13. For example, the control system 24 can control (i) the powder bed assembly 14; (ii) the pre-heat device 16; (iii) the powder supply assembly 18; (iii) the measurement device 20; and (iv) the energy system 22. The control system 24 can be a distributed system.

[0114] The control system 24 may include, for example, a CPU (Central Processing Unit) 24A, a GPU (Graphics Processing Unit) 24B, and electronic memory 24C. The control system 24 functions as a device that controls the operation of the processing machine 10 by the CPU executing the computer program. This computer program is a computer program for causing the control system 24 (for example, a CPU) to perform an operation to be described later to be performed by the control system 24 (that is, to execute it). That is, this computer program is a computer program for making the control system 24 function so that the processing machine 10 will perform the operation to be described later. A computer program executed by the CPU may be recorded in a memory (that is, a recording medium) included in the control system 24, or an arbitrary storage medium built in the control system 24 or externally attachable to the control system 24, for example, a hard disk or a semiconductor memory. Alternatively, the CPU may download a computer program to be executed from a device external to the control system 24 via the network interface. Further, the control system 24 may not be disposed inside the processing machine 10, and may be arranged as a server or the like outside the processing machine 10, for example. In this case, the control system 24 and the processing machine 10 may be connected via a communication line such as a wired communications line (cable communications), a wireless communications line, or a network. In case of physically connecting with wired, it is possible to use serial connection or parallel connection of IEEE1394, RS-232x, RS- 422, RS-423, RS-485, USB, etc. or 10BASE-T, 100BASE-TX, 1000BASE- T or the like via a network. Further, when connecting using radio, radio waves such as IEEE 802. lx, OFDM, or the like, radio waves such as

Bluetooth (registered trademark), infrared rays, optical communication, and the like may be used.

In this case, the control system 24 and the processing machine 10 may be configured to be able to transmit and receive various types of information via a communication line or a network. Further, the control system 24 may be capable of transmitting information such as commands and control parameters to the processing machine 10 via the communication line and the network. The processing machine 10 may include a receiving device (receiver) that receives information such as commands and control parameters from the control system 24 via the communication line or the network. As a recording medium for recording the computer program executed by the CPU, a CD-

ROM, a CD-R, a CD-RW, a flexible disk, an MO, a DVD-ROM, a DVD-RAM, a DVD-R, a DVD

+ R, a DVD-RW, a magnetic medium such as a magnetic disk and a magnetic tape such as DVD +

RW and Blu-ray (registered trademark), a semiconductor memory such as an optical disk, a magneto- optical disk, a USB memory, or the like, and a medium capable of storing other programs. In addition to the program stored in the recording medium and distributed, the program includes a form distributed by downloading through a network line such as the Internet. Further, the recording medium includes a device capable of recording a program, for example, a general- purpose or dedicated device mounted in a state in which the program can be executed in the form of software, firmware or the like. Furthermore, each processing and function included in the program may be executed by program software that can be executed by a computer, or processing of each part may be executed by hardware such as a predetermined gate array (FPGA, ASIC) or program software, and a partial hardware module that realizes a part of hardware elements may be implemented in a mixed form.

[0115] It should also be noted that with the unique designs provided herein, multiple operations may be performed at the same time (simultaneously) to improve the throughput of the processing machine 10. Stated in another fashion, one or more of (i) pre-heating with the pre-heat device 16, (ii) measuring with the measurement device 20, (iii) depositing powder 12 with the powder supply assembly 18, and (iv) melting the powder with the energy system 22 may be partly or fully overlapping in time on different parts of the powder bed 26 to improve the throughput of the processing machine 10. For example, two, three, four, or all five of these functions may be partly or fully overlapping.

[0116] In certain implementations, the powder bed 26 may be moved down with the device mover 28 along the rotation axis 25A in a continuous rate via a fine pitch screw or some equivalent method. With this design, a height 29 between the most recent (top) powder layer 13 and the powder supply assembly 18 (and other components) may be maintained substantially constant for the entire process. Alternatively, the powder bed 26 may be moved down in a step down fashion at each rotation, which could lead to the possibility of a discontinuity at one radial position in the powder bed 26. As used herein, “substantially constant” shall mean the height 29 varies by less than a factor of three, since the typical thickness of each powder layer is less than one millimeter.

In another embodiment, “substantially constant” shall mean the height 29 varies less than ten percent of the height 29 during the manufacturing process.

[0117] In this implementation, only the powder bed 26 is primarily moved, while everything else (pre-heat device 16, powder supply assembly 18, measurement device 20, energy system 22) are all fixed, making the overall system simpler. Also, the throughput of a rotary based powder bed 26 system is much higher since one or more steps can be performed in parallel rather than serially.

[0118] In the example of FIG. 1A, the processing machine 10 additionally includes a component housing 30 that retains the pre-heat device 16, the powder depositor 18, the measurement device 20, and the energy system 22. Collectively these components may be referred to as the top assembly. Further, the processing machine 10 can include a housing mover 32 that can be controlled to selectively move the top assembly. The housing mover 32 and the device mover 28 may each include one or more actuators (e.g. linear or rotary). The housing mover 32 and/or the device mover 28 may be referred to as a first mover or a second mover.

[0119] It should be noted that processing machine 10 can be designed to have one or more of the following features: (i) one or more of the pre-heat device 16, the powder supply assembly 18, the measurement device 20, and the energy system 22 can be selectively moved relative to the component housing 30 and/or the powder bed 26 with one or more of the six degrees of freedom; (ii) the component housing 30 with one or more of the pre-heat device 16, the powder supply assembly 18, the measurement device 20, and the energy system 22 can be selectively moved relative to the powder bed 26 with one or more of the six degrees of freedom; and/or (iii) the powder bed 26 can be selectively moved relative to the component housing 30 with one or more of the six degrees of freedom.

[0120] In a specific, alternative implementation, the housing mover 32 can move the top assembly (or a portion thereof) upward (e.g. along and/or transverse to the rotation axis 25 A) relative to the powder bed 26 at a continuous (or stepped) rate while the powder 12 is being deposited to maintain the desired height 29.

[0121] Additionally, or alternatively, the housing mover 32 can rotate the top assembly (or a portion thereof) relative to the powder bed 26 about the rotation axis 25A relative to the powder bed 26 during the printing of the object 11. In this implementation, the powder bed 26 can be stationary, rotated about the rotation axis in the clockwise direction, rotated about the rotation axis in the counterclockwise direction, and/or or moved linearly along and/or transverse to the rotation axis 25 A.

[0122] Stated in another fashion, the processing machine 10 illustrated in FIGS. 1A and IB may be designed so that (i) the powder bed 26 is rotated about the Z axis and moved along the rotation axis 25A; or (ii) the powder bed 26 is rotated about the rotation axis 25 A, and the component housing 30 and the top assembly are moved along the rotation axis 25A only to maintain the desired height 29. In certain embodiments, it may make sense to assign movement along the rotation axis 25A to one component and rotation about the rotation axis 25A to the other.

[0123] FIG. 2 is a schematic side view of another embodiment of a processing machine 210 for making the object 211 with a portion of the powder bed assembly 214 illustrated in cut-away. In this embodiment, the three-dimensional printer 210 includes (i) a powder bed assembly 214; (ii) a pre-heat device 216 (illustrated as a box); (iii) a powder supply assembly 218 (illustrated as a box); (iv) a measurement device 220 (illustrated as a box); (v) an energy system 222 (illustrated as a box); (vi) an environmental chamber 223; and (vii) a control system 224 that are somewhat similar to the corresponding components described above. However, in this embodiment, the powder bed 226 of the powder bed assembly 214 can be stationary, and the housing mover 232 moves the component housing 230 with one or more of the pre-heat device 216, the powder supply assembly 218, the measurement device 220, and the energy system 222 relative to the powder bed 226.

[0124] As a non-exclusive example, the housing mover 232 may rotate the component housing 230 with the pre-heat device 216, the powder supply assembly 218, the measurement device 220, and the energy system 222 (collectively “top assembly”) at a constant or variable velocity about the rotation axis 225A. Additionally or alternatively, the housing mover 232 may move the top assembly along the rotation axis 225A.

[0125] It should be noted that the processing machine 210 of FIG. 2 may be designed so that (i) the top assembly is rotated about the Z axis and moved along the Z axis to maintain the desired height 233 with the housing mover 232; or (ii) the top assembly is rotated about the Z axis, and the powder bed 226 is moved along the Z axis only with a device mover 228 to maintain the desired height 229. In certain embodiments, it may make sense to assign Z movement to one component and rotation to the other.

[0126] In this embodiment, the powder bed assembly 214 can be generally circular disk shaped or rectangular shaped.

[0127] FIG. 3 is a side view of another embodiment of a processing machine 310 for making one or more object(s) 11 (two are illustrated) with a portion of the powder bed assembly 314 illustrated in cut-away. In this implementation, the three- dimensional printer 310 includes (i) a powder bed assembly 314; (ii) a pre-heat device 316 (illustrated as a box); (iii) a powder supply assembly 318 (illustrated as a box); (iv) a measurement device 320 (illustrated as a box); (v) an energy system 322 (illustrated as a box); (vi) an environmental chamber 323; and (vii) a control system 324 that are somewhat similar to the corresponding components described above. However, in this embodiment, the powder bed 326 includes a platform mover 326C in addition to the build platform 326A and the support side wall 326B. In this implementation, the build platform 326A can be moved linearly downward as each subsequent powder layer is added relative to the support side wall 326B with the platform mover 326C.

[0128] In alternative, non-exclusive implementations, the build platform 326A can have a build area 326D that is (i) flat, circular disk shaped for use with a corresponding support side wall 326B that is circular tube shaped; (ii) flat rectangular shaped for use with a corresponding support side wall 326B that is rectangular tube shaped, or (iii) polygonal- shaped for use with a corresponding support side wall 326B that is polygonal tube shaped.

[0129] It should be noted that the processing machine 310 of FIG. 3 may be designed so that (i) one or more of the pre-heat device 316, the powder supply assembly 318, the measurement device 320, and the energy system 322 can be selectively moved relative to the component housing 330 and/or the powder bed 326 with one or more of the six degrees of freedom; (ii) the component housing 330 with one or more of the pre-heat device 316, the powder supply assembly 318, the measurement device 320, and the energy system 322 can be selectively moved relative to the powder bed 326 with one or more of the six degrees of freedom; and/or (iii) the powder bed 326 can be selectively moved relative to the component housing 330 with one or more of the six degrees of freedom.

[0130] FIG. 4 is a schematic top illustration of a powder bed assembly 414 that can be used in any of the processing machines 10, 210, 310 disclosed herein. In this embodiment, the powder bed assembly 414 can be used to make multiple objects 411 substantially simultaneously. The number of objects 411 that may be made concurrently can vary according the type of object 411 and the design of the processing machine 10, 210, 310. In FIG. 4, six objects 411 are made simultaneously. Alternatively, more than six or fewer than six objects 411 may be made simultaneously.

[0131] In FIG. 4, each of the objects 411 is the same design. Alternatively, for example, the processing machine 10, 210, 310 may be controlled so that one or more different types of objects 411 are made simultaneously.

[0132] In FIG. 4, the powder bed assembly 414 includes a relatively large support platform 426A, and a plurality of separate, spaced apart, build assemblies 434 that are positioned on and supported by the support platform 426A. The number of separate build assemblies 434 can be varied. In FIG. 4, the powder bed assembly 414 includes six separate build assemblies 414, one for each object 411. With this design, a single object 411 is made in each build assembly 434. Alternatively, more than one object 411 may be built in each build assembly 434. Still alternatively, the powder bed assembly 414 can include more than six or fewer than six separate build assemblies 434.

[0133] In one, non-exclusive embodiment, the support platform 426A with the build assemblies 434 can be rotated like a turntable during printing of the objects 411 in a moving direction 425 about a support rotation axis 425A (illustrated with a “+”, e.g. the Z axis). With this design, each build assembly 434 is rotated about at least one axis 425A during the build process. Further, in this embodiment, the separate build assemblies 434 are spaced apart on the large common support platform 426A. The build assemblies 434 can be positioned on or embedded into the support platform 426A. As non-exclusive examples, the support platform 426A can be disk shaped or rectangular shaped.

[0134] As provided herein, each of the build assemblies 434 defines a separate, discrete build region. For example, each build assembly 434 can include a build platform 434A, and a sidewall assembly 434B. In one embodiment, each build assembly 434 is an open container in which the object 411 can be built. In this design, after the object 411 is printed, the build assembly 434 with the printed object 411 can be removed from the support platform 426A via a robotic arm (not shown in FIG. 4) and replaced with an empty build assembly 434 for subsequent fabrication of the next object 411.

[0135] As non-exclusive examples, each build platform 434A can define a build area 434C that is rectangular, circular, or polygonal shaped.

[0136] In an alternative embodiment, one or more of the build platforms 434A can be moved somewhat like an elevator vertically (along the Z axis) relative to its side wall assembly 434B with a platform mover assembly 434D (illustrated in phantom with a box) during fabrication of the objects 411. Each platform mover assembly 434D can include one or more actuators. Fabrication can begin with the build platform 434 A placed near the top of the side wall assembly 434B. The powder supply assembly (not shown in FIG. 4) deposits a thin layer of powder into each build assembly 434 as it is moved (e.g. rotated) below the powder supply assembly. At an appropriate time, the build platform 434A in each build assembly 434 is stepped down by one layer thickness so the next layer of powder may be distributed properly.

[0137] In some embodiments, one or more platform mover assemblies 434D can also or alternatively be used to move (e.g. rotate) one or more of the build assemblies 434 relative to the support platform 426A and each other in a platform direction 434E about a platform rotation axis 434F (illustrated with a “+”, e.g. the Z axis). With this design, each build platform 434A can be rotated about two, separate, spaced apart and parallel axes 425A, 434F during the build process.

[0138] In one, non-exclusive example, the support platform 426A can be rotated (e.g., at a substantially constant rate) in the moving direction 425 (e.g. counterclockwise), and one or more of the build assemblies 434 can be moved (e.g. rotated) relative to the support platform 426A in the opposite direction 434E (e.g. clockwise) during the printing process. In this example, the rotational speed of the support platform 426A about the support rotational axis 425A can be approximately the same or different from the rotational speed of each build assembly 434 relative to the support platform 426A about the platform rotational axis 434F.

[0139] Alternatively, the support platform 426 A can be rotated (e.g., at a substantially constant rate) in the moving direction 425 (e.g. counterclockwise), and one or more of the build assemblies 434 can be moved (e.g. rotated) relative to the support platform 426A in the same direction 434E (e.g. counterclockwise) during the printing process.

[0140] FIG. 5 is a schematic top illustration of another implementation of a powder bed assembly 514 that can be used in any of the processing machines 10, 210, 310 disclosed herein. In this implementation, the powder bed assembly 514 can be used to make multiple objects (not shown in FIG. 5) substantially simultaneously.

[0141] In FIG. 5, the powder bed assembly 514 includes a relatively large support platform 526A, and a plurality of separate, spaced apart, build assemblies 534 that are integrated into the support platform 526A. The number of separate build assemblies 534 can be varied. In FIG. 5, the powder bed assembly 514 includes four separate build assemblies 534. With this design, one or more objects can be made on each build assembly 534. Alternatively, the powder bed assembly 514 can include more than four or fewer than four separate build assemblies 534.

[0142] In FIG. 5, each build assembly 534 defines a separate build platform 534A that is selectively lowered like an elevator with a platform mover assembly 534D (illustrated in phantom with a box) into the support platform 526A during the manufacturing process. With this design, the support platform 526A can define the support side wall for each build platform 534 A. Fabrication can begin with the build platform 534 A placed near the top of the support platform 526A. The powder supply assembly (not shown in FIG. 5) deposits a thin layer of powder onto each build platform 534A as it is moved (e.g. rotated) below the powder supply assembly. At an appropriate time, each build platform 534A is stepped down by one layer thickness so the next layer of powder may be distributed properly. Alternatively, each build platform 534 A can be moved in steps that are smaller than the powder layer or moved in a continuous fashion, rather than in discrete steps.

[0143] In this FIG. 5, each build platform 534A defines a circular shaped build area 534C that receives the powder (not shown in FIG. 5). Alternatively, for example, each build area 534C can have a different configuration, e.g. rectangular or polygonal shaped.

[0144] Additionally, the support platform 526A can be annular shaped and powder bed 526 can include a central, support hub 526D. In this implementation, there can be relative movement (e.g. rotation) between the support platform 526A and the support hub 526D. As a result thereof, one or more of the other components (e.g. the powder supply assembly) of the processing machine (not shown in FIG. 5) can be coupled to the support hub 526D.

[0145] In one, non-exclusive embodiment, the support platform 526A with the build assemblies 534 can be rotated like a turntable during printing of the objects in a moving direction 525 about the support rotation axis 525A (illustrated with a “+”) relative to the support hub 526D. With this design, each build platform 534A is rotated about at least one axis 525A during the build process.

[0146] In some embodiments, one or more platform mover assemblies 534D can be used to move (e.g. rotate) one or more of the build assemblies 534 relative to the support platform 526A and each other in a platform direction 534E about a platform rotational axis 534F (illustrated with a “+”, e.g. along the Z axis). With this design, each build platform 534A can be rotated about two, separate, spaced apart and parallel axes 525A, 534F during the build process.

[0147] In one, non-exclusive example, the support platform 526A can be rotated (e.g., at a substantially constant rate) in the moving direction 525 (e.g. counterclockwise), and one or more of the build assemblies 534 can be moved (e.g. rotated) relative to the support platform 526A in the opposite, platform direction 534E (e.g. clockwise) during the printing process. In this example, the rotational speed of the support platform 526A about the support rotational axis 525A can be approximately the same or different from the rotational speed of each build assembly 534 relative to the support platform 526A about the platform rotational axis 434F.

[0148] Alternatively, the support platform 526A and one or more of the build assemblies 534 can be rotated in the same rotational direction during the three-dimensional printing operation. [0149] It should be noted that in FIGS. 4 and 5, a separate platform mover assembly 434D, 534D is used for each build assembly 434, 534. Alternatively, one or more of the platform mover assemblies 434D, 534D can be designed to concurrently move more than one build assembly 434,534.

[0150] FIG. 6 A is a perspective view of a portion of a powder bed assembly 614 including at least one build platform 634A, and a powder supply assembly 618 that can be integrated into in any of the processing machines 10, 210, 310 described above. For example, the powder bed assembly 614 and the powder supply assembly 618 can be designed to have one or more the following movement characteristics while powder 612 is being deposited on the build platform 634A: (i) the build platform 634A is stationary; (ii) the build platform 634A is moved relative to the powder supply assembly 618; (iii) the build platform 634A is moved linearly (along one or more axes) relative to the powder supply assembly 618; (iv) the build platform 634A is rotated (about one or more axes) relative to the powder supply assembly 618; (v) the powder supply assembly 618 is stationary; (vi) the powder supply assembly 618 is moved relative to the build platform 634A; (vii) the powder supply assembly 618 is moved linearly (along one or more axes) relative to the build platform 634A; and/or (viii) the powder supply assembly 618 is rotated (about one or more axes) relative to the build platform 634A. These can be collectively referred to as “Movement Characteristics (i)- (viii)”.

[0151] It should be noted that the powder bed assembly 614 and the powder supply assembly 618 can be designed to have any combination of the Movement Characteristics (i)-(viii). For example, the powder bed assembly 614 and the powder supply assembly 618 can be designed to have one, two, three, four, five, six, seven, or all eight of the Movement Characteristics (i)-(viii). Further, the build platform 634A can be circular, rectangular or other suitable shape.

[0152] In the implementation illustrated in FIG. 6 A, the powder bed assembly 614 is somewhat similar to the implementation illustrated in FIG. 5, and includes a relatively large support platform 626A, a central support hub 626D, and a plurality of separate, spaced apart, build assemblies 634 (only one is illustrated) that are integrated into the support platform 626A. With this design, the support platform 626A with the build assemblies 634 can rotate relative to the support hub 626D, and/or the build assemblies 634 can rotate relative to the support platform 626A. [0153] Further, in FIG. 6A, the powder supply assembly 618 is secured to the support hub 626D, and cantilevers and extends radially over the support platform 626A to selectively deposit the powder 612 (illustrated with small circles) onto the moving build assemblies 634. Alternatively, or additionally, the powder supply assembly 618 could be designed to be moved (e.g. linearly or rotationally) relative to the build assemblies 634. Still alternatively, the powder supply assembly 618 can be retained in another fashion than via the support hub 626D. For example, the powder supply assembly 618 can be coupled to the upper component housing 30 illustrated in FIG. 1A.

[0154] FIG. 6B is a cut-away view of the powder supply assembly 618 taken on line 6B-6B in FIG. 6A.

[0155] With reference to FIGS. 6A and 6B, the powder supply assembly 618 is a top-down, gravity driven system that is shown with a circular shaped build platform 634A. In one implementation, the powder supply assembly 618 includes a supply frame assembly 638, a powder container assembly 640, and a flow control assembly 642 that is controlled by the control system 624 to selectively and accurately deposit the powder 612 onto the build platform(s) 634A. The design of each of these components can be varied to suit the design requirements of processing machine 10, 210, 310. In FIGS. 6 A and 6B, the flow control assembly 642 is illustrated as being recently activated and the powder supply assembly 618 is releasing the powder 612 towards the build platform 634A.

[0156] The supply frame assembly 638 supports and couples the powder container assembly 640 and the flow control assembly 642 to the rest of the processing machine 10, 210, 310. The supply frame assembly 638 can fixedly couple these components to the support hub 626D. In one, non exclusive implementation, the supply frame assembly 638 includes (i) a riser frame 638 A that is fixedly coupled to and extends upwardly along the Z axis from the support hub 626D; and (ii) a transverse frame 638B that is fixedly coupled to and cantilevers radially away from the riser frame 638 A. It should be noted that either the riser frame 638 A, and the transverse frame 638B can be referred to as a first frame or a second frame.

[0157] The riser frame 638A is rigid and includes (i) a riser proximal end 638C that is secured to the support hub 626D, and (ii) a riser distal end 638D that is positioned above the support hub 626D. Further, the transverse frame 638B is rigid and includes (i) a transverse proximal end 638E that is secured to the riser distal end 638D, and (ii) a transverse distal end 638F that extends over an outer perimeter of the build platform 634A. In one, non-exclusive implementation, the riser frame 638A is right cylindrical shaped (e.g. hollow or solid), and the transverse frame 638A is rectangular beam shaped. However, other shapes and configurations can be utilized.

[0158] Additionally, the transverse frame 638B can include a frame passageway 638G that allows the powder 612 from the flow control assembly 642 to flow therethrough. For example, the frame passageway 638G can be rectangular shaped. Further, the frame passageway 638G can define the supply outlet 639 of the powder 612 from the powder supply assembly 618. The supply outlet 639 is in fluid communication with the powder container assembly 640 and the flow control assembly 642.

[0159] In one embodiment, the supply outlet 639 is positioned above and spaced apart a separation distance 643 from the build platform(s) 634A or uppermost powder layer on the build platform 634A. The size of the separation distance 643 can vary depending on the environment around the powder supply assembly 618. For example, the separation distance 643 can be larger if operated in a vacuum environment. As a non-exclusive embodiment, the separation distance 643 can be as small as the largest powder particle size. As a non-exclusive example, the separation distance 643 can be between zero to fifty millimeters.

[0160] Alternatively, the powder supply assembly 618 can be designed so that the supply outlet 639 is directly adjacent to and/or against the build platform(s) 634A or uppermost powder layer on the build platform 634A.

[0161] The powder container assembly 640 retains the powder 612 prior to being deposited onto the build platform(s) 634A. The powder container assembly 640 can be positioned above and coupled to the transverse frame 638B of the supply frame assembly 638. In one nonexclusive implementation, the powder container assembly 640 is open at the top and the bottom, and can include a powder container 640A that retains the powder 612, and a container base 640B that couples the powder container 640A to the transverse frame 638B with the flow control assembly 642 positioned therebetween. For example, the powder container 640A and the container base 640B can be integrally formed or secured together during assembly. In this implementation, the opening at the top of the powder container assembly 640 is larger than the opening at its bottom.

[0162] The size and shape of the powder container 640A can be varied to suit the powder 612 supply requirements for the system. In one non-exclusive implementation, the powder container 640A is tapered, rectangular tube shaped (V shaped cross- section) and includes (i) a bottom, container proximal end 640C that is coupled to the container base 640B, and that is an open, rectangular shape; (ii) a top, container distal end 640D that is an open, rectangular tube shaped and positioned above the proximal end 640C; (iii) a front side 640E; (iv) a back side 640F; (v) a left side 640G; and (vi) a right side 640H. Any of these sides can be referred to as a first, second, third, etc side. The powder container 640A can function as a funnel that uses gravity to urge the powder 612 against the flow control assembly 642.

[0163] In one design, the left side 640G and the right side 640H extend substantially parallel to each other; while the front side 640E and a back side 640F taper towards each other moving from the container distal end 640D to the container proximal end 640C. The sides 640E, 640F can be steep (near vertical). As non-exclusive examples, the angle of taper relative to normal (vertical) can be at 0, 0.5, 1, 2, 4, 6, 8, 10, 20, 30 degrees or other angles. The angle of taper can be determined based upon the characteristics (e.g. size) of the powder particles, the material of the powder particles, the amount of powder to be retained in the powder container 640 A and other factors. In certain implementations, the powder container 640A comprises two slopes (walls 640E, 640F) getting closer to each other from one end (top 640D) to the other end (bottom 640C) on which the flow controller 642A is provided, and the at least one vibration generator 642C is provided on the at least one wall 640E, 640F. Stated in another fashion, the powder container 640A comprises two walls 640E, 640F that slope towards each other from a first end 640D to the second end 640C in which the flow controller 642A is located. An angle between two slopes of the walls 640E, 640F can be determined based upon a type of powder 612. As provided herein, the plurality of vibration generators 642C are provided at the both of two walls 640E, 640F. Further, in certain implementations, the flow controller 642A is elongated a first direction (e.g. along the Y axis) that crosses the build platform 634A, and the plurality of vibration generators 642C are provided at the both of two walls 640E, 640F along the first direction.

[0164] The container base 640B can be rectangular tube shaped to allow the powder 612 to flow therethrough.

[0165] It should be noted that other shapes and configurations of the powder container 640 A can be utilized. For example, the powder container 640A can have a tapering, oval tube shape, or another suitable shape. [0166] The control system 424 controls the flow control assembly 642 to selectively and accurately control the flow of the powder 612 from the supply outlet 639 onto the build platform(s) 634 A. In one implementation, the flow control assembly 642 includes a flow controller 642A and an activation system 642B. In this implementation, (i) the flow controller 642 A can be a flow restrictor such as one or more mesh screen(s) or other porous structure; and (ii) the activation system 642B can include one or more vibration generators 642C that are controlled by the control system 624 to selectively vibrate the powder container 640A. Each vibration generator 642C can be a vibration motor.

[0167] With this design, sufficient vibration of the powder container 640A by the vibration generator(s) 642C causes the powder 612 to flow through the flow controller 642A to the build platform(s) 634A. In contrast, if there is insufficient vibration of the powder container 640A by the vibration generator(s) 642C, there is no flow through the flow controller 642A. Stated in another fashion, the rate (amplitude and frequency) of vibration by the vibration generator(s) 642C can control the flow rate of the powder 612 through the flow controller 642 A to the build platform(s) 634 A. Generally speaking, no vibration results in no flow of the powder 612, while the flow rate of the powder 612 increases as vibration rate increases. Thus, the vibration generator(s) 642C can be controlled to precisely control the flow rate of powder 612 to the build platform(s) 634A.

[0168] The location of the flow controller 642A can be varied. In FIGS. 6A and 6B, the flow controller 642 A is located between the powder container 640 A and the transverse frame 638B. Alternatively, for example, the flow controller 642A can be located below the transverse frame 638B near the supply outlet 639.

[0169] The number and location of the vibration generator(s) 642C can be varied. In the non exclusive implementation in FIGS. 6 A and 6B, the activation system 642B includes (i) five spaced apart vibration generators 642C that are secured to the front side 640E near the top, container distal end 640D; and (ii) five spaced apart vibration generators 642C (only one is visible in FIG. 6B) that are secured to the back side 640F near the container distal end 640D. These vibration generators 642C are located above the flow controller 642A to vibrate the powder 612 in the powder container 640A. Alternatively, the activation system 642B can include more than ten or fewer than ten vibration generators 642C, and/or one or more of the vibration generators 642C located at different positions than illustrated in FIGS. 6 A and 6B. [0170] The five vibration generators 642C on each side 640E, 640F can be spaced apart linearly moving left to right. In FIG. 6A, the individual vibration generators 642C on the front side 640E are labeled A-E moving left to right linearly for ease of discussion. With this design, the vibration generators 642C can be independently controlled to control the distribution rate of the powder 612 moving linearly along the power supply assembly 618. This allows for control of the powder distribution radially from near the center to near the edge of the powder bed assembly 614. For example, if more powder 612 is needed near the edge than the center, the vibration generators 642C labelled “D” and “E” can be activated more than the vibration generators 642C labelled “A” and “B”.

[0171] With the present design, when it is desired to deposit the powder 612 onto the build platform 634A, the vibration generator(s) is(are) 642C turned ON to start the vibration motion. At this time, the powder 612 will pass from the powder container 640A through the flow controller 642 A to deposit the powder 612. In contrast, when it is desired to stop the deposit of the powder 612, the vibration generators 642C are OFF, and the powder 612 will remain inside the powder container 640A.

[0172] With the present design, a thin, accurate, even layer of powder 612 can be supplied to the build platform(s) 634A without having to spread the powder 612 (e.g. with a rake) using the top- down vibration activated, powder supply assembly 618 disclosed herein. This powder supply assembly 618 is cost-effective, simple, and reliable method for delivering powder 612. Further, it requires a minimal amount of hardware to achieve even powder layers 612 on the build platform(s) 634A.

[0173] In certain embodiments, the flow controller 642 A can be grounded to reduce static charges of the metal powder 612.

[0174] Additionally, or alternatively, the powder supply assembly 618 can include one or more heating and/or cooling devices/systems referred to herein as temperature control elements. Representative temperature control elements are indicated at 645A-645D on the inner or outer surface of powder container 640, on the transverse frame 638B, and/or near the separation distance 643. The temperature control elements can comprise, for example, any of a variety of electronic heating and/or cooling devices such as thermoelectric heat pumps (e.g., Peltier devices, thermoelectric coolers (TECs), etc.), preheaters/heaters, fluid cooling systems or portions thereof, and/or combinations of any of the above. For example, in certain embodiments one or more of the temperature control elements can comprise an electronic cooling device such as a TEC device in combination with a preheater. In certain embodiments, different types of temperature control elements can be provided at different locations on the powder supply assembly 618, such as preheaters and/or TEC devices on the surfaces and outlet of the powder container 640, and a fluid cooling system (e.g., including coolant passages) coupled to or extending through the body of the powder container as described in greater detail below.

[0175] The non-exclusive implementation illustrated in FIG. 6B includes (i) one or more temperature control elements (e.g., preheaters) 645A that are positioned near the inner surface of the powder container 640; (ii) one or more temperature control elements (e.g., preheaters) 645B that are positioned near the outer surface of the powder container 640; (iii) one or more temperature control elements (e.g., preheaters) 645C that are positioned on the transverse frame 638B; and (iv) one or more temperature control elements (e.g., preheaters) 645D that are positioned on the transverse frame 638B near the supply outlet 639. With this design, the temperature control elements 645A-645D can be controlled to control the temperature (e.g., preheat) the powder 612 before, during, and/or after passing through the flow controller 642A. Stated in another fashion, the powder container temperature control elements 645A-645D (different from the build pre-heater) can be located around the body of the powder container 640, or possibly, within the container 640. Another option might be an “on-demand” variant that either separately, or in addition to a bulk container 640 temperature control element or heater, locally pre-heats the powder further somewhere near the dispensing process.

[0176] Additionally, or alternatively, the powder supply assembly 618 can be used with a powder recoater (not shown) such as a rake, roller, wiper, squeegee, and/or a brush to further improve the flat powder surface.

[0177] FIG. 6C is a cut-away view of the powder supply assembly 618 similar to FIG. 6B, except in FIG. 6C, the vibration generators 642C are turned off. At this time, no powder 612 is flowing through the flow controller 642A.

[0178] FIG. 6D is a cut-away view taken from line 6D-6D in FIG. 6A, without the powder. Basically, FIG. 6D illustrates the powder supply assembly 618, including a portion of the supply frame assembly 638, the powder container assembly 640, and the flow control assembly 642. [0179] FIG. 6E is a schematic top view of the powder supply assembly 618, without the powder. FIG. 6D illustrates the powder supply assembly 618, including the powder container assembly 640, and the flow controller 642 A and the vibration generators 642C of the flow control assembly 642.

[0180] FIG. 6F is a top view of one implementation of the flow controller 642A. In this implementation, the flow controller 642A includes a flow structure 642D, and a plurality of flow apertures 642E that extend through the flow structure 642D. In this embodiment, the flow structure 642D is rectangular plate shaped to correspond to the bottom container end 640C (illustrated in FIG. 6B). However, other shapes are possible. For example, the flow structure 642D can be shaped the same as the build platform 634A (illustrated in FIG. 6A) to allow fast and efficient supply of powder to the build platform 634A.

[0181] The flow apertures 642E can have a circular, oval, square, polygonal, or other suitable shape. Further, flow apertures 642E can follow a straight or curved path through the flow structure 642D. Moreover, in this implementation, one or more (typically all) of the flow apertures 642E have an aperture size that is larger than a nominal powder particle size of each of the powder particles 612. In alternative, non- exclusive examples, the aperture size is at least 1, 1.25, 1.5, 1.7,

2, 2.5, 3 or 4 times the nominal powder particle size. Further, in alternative, non-exclusive examples, the aperture size is less than 5, 6, 7, 8 or 10 times the nominal powder particle size. Stated in a different fashion, one or more (typically all) of the flow apertures 642E have an aperture cross-sectional area that is larger than a nominal powder particle cross sectional area of the individual particles of powder 612 (illustrated in FIG. 6A). In alternative, non-exclusive examples, one or more (typically all) of the flow apertures 642E have an aperture cross-sectional area is equal to or larger than the nominal powder cross sectional area of the individual particles of powder 612 by at least, but not limited to, 1, 2, 3, 5, 10, 20, 40, 50, 60, 70, 80, 90, 100, 150, or 200 percent. Stated differently, as non-exclusive examples, the aperture cross- sectional area can be at least ten, twenty, fifty, one hundred, or one thousand times the nominal powder cross-sectional area. Stated in yet another fashion, one or more (typically all) of the flow apertures 642E have an aperture diameter that is larger than a nominal powder particle diameter of the powder particles 612. In alternative, non-exclusive examples, the aperture diameter is at least 1, 1.25, 1.5, 1.75, 2, 3 or 4 times the nominal powder particle diameter. Further, in alternative, non-exclusive examples, the aperture diameter is less than 5, 6, 7, 8 or 10 times the nominal powder particle diameter. However, depending upon the design, other aperture sizes, diameters or cross-sectional areas are possible. [0182] FIG. 6G is a side view the flow structure 642D of the flow controller 642A. In this implementation, the flow structure 642D includes one or more mesh screens 642F. In FIG. 6G, the flow structure 642D includes four mesh screens 642F. Alternatively, it can include more than four or fewer than four mesh screens 642F. In this design, the mesh screens 642F combine to define the plurality of spaced apart flow apertures 642E (illustrated in FIG. 6F).

[0183] With reference to FIGS. 6A-6G, in certain implementations, the sizes of flow apertures 642E, the vibration amplitude and/or the vibration directionality of the vibration generator(s) 642C may be adjusted to control the amount of the powder 612 supplied over the build platform 634A. The control system 624 may control the vibration generators 642C based on feedback results from the measurement device 20 (illustrated in FIG. 1A). For example, the measurement device 20 measures (monitors) the condition of the build platform(s) 634A (e.g., the topography of the powder layer, the irregularity of the surface of the powder layer, the geometry of the as-built object 11, the powder quality, the powder temperature, etc.) and the control system 624 controller controls the vibration generator(s) 642C so as to individually adjust the amount and location of powder 612 deposited on the build platform(s) 634A. The powder supply assembly 618 is designed to supply arbitrary amounts of the powder 612 in every area including individual sub-areas (along the radial direction perpendicular to the z-axis) of each build platform 634A. Additional details regarding the three-dimensional printing systems described herein can be found in U.S. Application No. 17/624,191, which is incorporated herein by reference.

[0184] Example 2: Consumable Materials Container and Vacuum Dryer System

[0185] In certain embodiments, it can be advantageous to provide consumable materials to the additive manufacturing system in the environmental chamber while maintaining the vacuum environment. Stated differently, it can be advantageous to provide consumable materials to the additive manufacturing system without raising the pressure in the environmental chamber, such as by venting the environmental chamber, or otherwise exposing the interior of the chamber to the ambient. In certain embodiments, it can be also be advantageous to provide consumable materials to the additive manufacturing system in a manner that limits introduction of undesirable substances such as water molecules, gas, etc., into the environmental chamber. Additionally, although the following description proceeds with reference to powder for convenience, it should be understood that the container embodiments, systems, and methods described herein can be applicable to other forms of consumable materials, such as particles or particulate material of different sizes including granules, sand, etc., and/or material formed in different shapes including sheets, cylinders or rods, spherules, disks, etc.

[0186] In certain embodiments, consumable materials such as powder material can be provided to an additive manufacturing system in pre-filled containers or canisters. For example, in certain embodiments the container can include a closure configured to seal the interior of the container from the ambient. The closure can take many forms. For example, in certain embodiments the closure can include a closure member (such as a lid, cap, etc.) that closes an opening of the container, a sealing member configured to form a seal between the closure member and the body of the container, any of a variety of biases for biasing the closure member to the open or closed position, and/or any of a variety of fastening devices for fastening or securing the closure member in the closed position.

[0187] For example, beginning with the closure member, in certain embodiments the closure can be resealable or re-closeable such that the container can be refilled and used to deliver powder to the additive manufacturing system multiple times. Resealable closures can include a member that is movable (e.g., by pivoting or sliding) between an open position and a closed position.

[0188] In certain embodiments, the container, closure, or portions of the container and/or the closure, can be configured for a single use. In such embodiments, opening the closure can result in permanent deformation or damage to elements of the closure (e.g., such as by tearing, puncturing, etc.). For example, in certain embodiments the closure can include a seal, barrier, membrane, weakened area (e.g., a pre-scored area or tab), etc., that can be ruptured, punctured, torn, opened, etc., in order to access the contents of the container. In certain embodiments, one or more of such elements can be replaced after use and the container refilled and resealed.

[0189] In certain embodiments, the closure can include one or more sealing members, such as seals, gaskets, O-rings, etc. In certain embodiments, the closure can form a gas tight seal or substantially gas tight seal with the body of the container.

[0190] In certain embodiments, the container can be filled with powder, and sealed with an internal pressure below ambient atmospheric pressure (e.g., below 101 kPa). For example, in certain embodiments the container can be sealed with an internal pressure of 1 x 10^-5 Pa to 1 kPa,

1 x 10^-3 Pa to 1 kPa, 1 x 10^-5 Pa to 1 x 10^-3 Pa, 1 kPa or less, 1 x 10^-3 Pa or less, etc. This can limit any pressure increase in the environmental chamber and/or limit the introduction of undesirable substances (e.g., by outgassing) to within specified ranges when the container is opened and placed in communication with the environmental chamber in which the additive manufacturing system operates. In certain embodiments, the container can be configured to maintain a specified internal pressure for a specified period of time (e.g., hours, days, weeks, months, years, etc.) to facilitate storage and shipment to additive manufacturing system operators.

[0191] For example, FIG. 7 illustrates a representative example of a container 700 that can be used to deliver a predefined quantity of powdered material to the additive manufacturing system in the environmental chamber. The container 700 can include a plurality of walls 702 defining an internal volume 704. In the illustrated embodiment, the container 700 includes a main body portion 706 and a tapered inlet/outlet portion referred to herein as an outlet portion 708 for convenience. The main body portion 706 can be coupled to the tapered outlet portion 708. The outlet portion 708 can define an opening 710 in communication with the interior volume 704, and closable by a closure 712. The container 700 is shown partially filled with a powder material 714, which can be dispensed into the container through a dispensing system including a funnel 716.

[0192] As noted above, the closure 712 can take many forms. In the embodiment of FIG. 7, the closure 712 comprises a closure member configured as a hinged lid or cap referred to herein as a cover member 718. The cover member 718 can pivot between an open position and a closed position. In certain embodiments, the closure 712 can further comprise a bias such as a spring configured to bias the cover member 718 toward the open position or toward the closed position. FIG. 8A schematically illustrates a spring member 736 coupled to the outlet portion of the container and to the cover member 718. In certain embodiments, the spring member 736 can be configured to bias the cover member 718 toward the closed position.

[0193] In certain embodiments, the closure 712 can further comprise a releasable retaining, locking, and/or fastening device such as, for example, a latch, a hasp, a buckle, a clasp, a pin, or combinations thereof. For example, FIG. 8B illustrates a fastening device configured as a latch or pin member 738 of the cover member 718 received in a corresponding opening in the outlet portion 708 of the container. FIG. 8C illustrates a pair of hasps 740 assembled on the outlet portion 708 of the container and on the cover member 718 to hold the cover member in place. In certain embodiments, the closure can comprise a bias such as the spring 736 in combination with any of the fastening devices described herein. For example, in certain embodiments the closure 712 can comprise a spring such as the spring 736 configured to bias the cover member 718 toward the closed position, and a fastening device to maintain the cover member 718 in the closed position until released. In other embodiments the spring can be configured to bias the cover member toward the open position, and the fastening device can mechanically hold the cover member in place until released.

[0194] Returning to FIG. 7, the closure 712 can also include any of various sealing elements, such as elastomeric seals, gaskets, O-rings, metal knife edge and gasket combinations, etc., to seal the interior of the container when in the closed position. For example, one or more sealing elements can be disposed around the perimeter of the opening 710, and/or on the cover member 718. FIG. 7 schematically illustrates a seal member 742 disposed around the perimeter of the cover member 718. Any of the biasing members and/or fastening devices described herein can be configured to compress the sealing elements to seal the inside of the container from the ambient. Thus, any of the container embodiments of FIGS. 8A-8E can include a sealing member similar to the sealing member 742 of FIG. 7.

[0195] FIG. 8D illustrates another embodiment in which the closure 712 comprises a gate valve member 720 that opens and closes, for example, by moving across the outlet portion 708 of the container as indicated by double-headed arrow 721. The gate valve member 720 can be on the exterior of the container as shown in FIG. 8D, or can be incorporated into the structure of the outlet portion 708. In yet other embodiments, the closure 712 can comprise a threaded lid or cap.

[0196] FIG. 8E illustrates an example of a single-use closure 730 including a member 732 that is configured to be ruptured by a tool, such as a probe 734. In such configurations, the member 732 and/or the outlet portion 708, for example, can be detached from the remainder of the container and replaced to facilitate reuse of the container or portions thereof.

[0197] In certain embodiments, the container can be recyclable. As used herein, “recyclable” means that 90% or more of the material of the container by mass can be recovered and processed into a new container or other product.

[0198] In certain embodiments, the container 700 can be cylindrical, or any other suitable shape. For example, in certain embodiments the container 700 can be rectangular, or can comprise a combination of curved sides and straight/planar sides, depending upon the particular requirements of the system. [0199] In certain embodiments, the container 700 can comprise any of a variety of metals, such as aluminum, steel, etc. The container 700 can also comprise any of various polymeric materials and/or composite materials (e.g., carbon fiber, fiberglass, etc.) with suitable heat resistance and strength properties. In certain embodiments, the container 700 can be configured to maintain or withstand an external pressure of one atmosphere (101 kPa) with an internal pressure of 1 x 10^-3 Pa or less. In certain embodiments, the container 700 can be configured to be repeatedly evacuated to a pressure of 1 x 10^-3 Pa and pressurized to atmospheric pressure (101 kPa) over multiple filling cycles.

[0200] In certain embodiments, the container and/or the powder can be processed/treated to limit outgassing into the vacuum environment of the environmental chamber when the container is opened. For example, in certain embodiments the container and/or the powder can be heated to drive off water and/or other volatile substances. In certain embodiments, the powder and the container can be heated separately before the container is filled. In certain embodiments, the powder can be heated in the container. In certain embodiments, the powder-filled container can be heated and/or agitated in a low-pressure/vacuum environment. In certain embodiments, after heating and/or agitation, the powder-filled container can be sealed in the low-pressure/vacuum environment such that the interior of the container remains at a pressure lower than ambient atmospheric pressure.

[0201] For example, FIG. 9 illustrates a representative embodiment of a vacuum dryer or vacuum oven, referred to hereinafter as a vacuum dryer system 800. The vacuum dryer system 800 can include an environmental chamber 802 configured to receive the container 700. For purposes of illustration, the container 700 is shown with a pivotable closure member 718 according to the embodiment of FIG. 7, although the general principles of the following description can be adapted to any of the closure and/or container configurations described herein. The environmental chamber 802 can comprise a plurality of walls 804, and an opening or access closeable by a cap, door, hatch or other suitable closure, configured in the non-limiting example of FIG. 8 as a lid or cover member 806. A sealing member 808 can be positioned between the cover member 806 and the walls 804, and can seal the interior of the environmental chamber 802 from the ambient when the cover member is in place. In the illustrated example, the sealing member 808 extends around the perimeter of the walls 804 along their upper surfaces, but can be positioned at any suitable location depending upon the shape/orientation of the opening and/or the configuration of the access. [0202] A hose or conduit 810 is shown in fluid communication with the interior of the environmental chamber 802 through a port 812 defined in one wall, and can be connected to a vacuum pump.

[0203] The environmental chamber 802 can comprise a variety of tools to heat and/or agitate the container 700 and the powder 714 contained therein. For example, in certain embodiments the environmental chamber 802 can comprise an agitator configured to shake the container, rotate the container, stir the contents of the container, swirl the contents of the container, etc. The environmental chamber 802 can also include a heater. The heater can take many forms, including an electrical resistance heating element, a radiator, a magnetic induction heater, etc. For example, in FIG. 9 the environmental chamber 802 includes a movable agitator platform 814. The agitator platform 814 can be configured to shake the container 700, such as by rapidly moving it along any of the X-, y-, and/or z-axes. The agitator platform 814 can also be configured as a heater or “hot plate,” and can heat the container 700 and the powder 714 before, during, and/or after agitation.

[0204] In certain embodiments, the agitator platform 814 can be configured to rotate or tilt the container 700 about one or both of the x-axis and/or the y-axis, which can aid in mixing or swirling the powder to bring water and/or other substances to the surface, where they can be volatized and removed through the vacuum hose 810. For example, FIG. 10 illustrates another embodiment of an agitator 816 configured to incline the container 700 relative to the z-axis and rotate it. The agitator 816 can also include a heater.

[0205] In certain embodiments, the agitator/heater 814 can be configured to heat the powder to a temperature of 100° C to 900° C, such as 100° C to 700° C, 100° C to 500° C, 100° C to 300° C, 900° C or less, 700° C or less, 500° C or less, 300° C or less, etc., depending upon the particular material. In certain embodiments, the agitator/heater 814 can heat the powder material to a temperature less than the sintering temperature of the material.

[0206] In certain embodiments, the vacuum dryer system 800 can be configured to produce powder with a moisture/water content of 1% or less by volume, 1 ppm to 100 ppm, 1 ppm to 10 ppm, 100 ppm or less, 10 ppm or less, 1 ppm or less, etc. In certain embodiments, the vacuum dryer system 800 can be configured to heat the powder material to 300° C in a vacuum environment of 1 x 10^-5 Pa, and seal the container such that when it is opened/exposed to the environmental chamber of the additive manufacturing system any water that outgases from the container is not sufficient to raise the pressure beyond 1 x 10^-3 Pa in the environmental chamber.

[0207] In certain embodiments, the vacuum dryer system 800 can include an actuator or other tool configured to move the closure 712 of the container 700 to the closed position. In certain embodiments the actuator can be a linear actuator or a rotary actuator, or combinations thereof. In certain embodiments, the actuator can be an electric actuator, a pneumatic actuator, a hydraulic actuator, or combinations thereof. For example, referring again to FIG. 9, the environmental chamber 802 includes an actuator 818 configured to close the closure member 718 by extending from a first, short length to a second, increased length causing the closure member 718 to pivot downwardly to the closed position. In certain examples, the actuator 818 can be configured as an electric actuator, such as a voice coil motor, a linear motor, a piezoelectric actuator/motor, a stepper motor, a linear servo motor, a solenoid, a variable reluctance actuator, a rotary electric motor and a leadscrew, a capstan drive, or rack and pinion, or any other type of electric actuator. In certain embodiments, the actuator can be configured to close the closure member 718 against the force exerted by a bias such as the spring member 736 of FIG. 8A, or with the assistance of such a bias.

In certain embodiments, the actuator 818 can be configured to fasten or secure any fastening devices of the container.

[0208] When processing of the powder has concluded, the actuator 818 can be activated to close the closure member 718 and seal the dry powder 714 in a low-pressure environment inside the container 700. The container 700 can then be removed from the environmental chamber 802. In certain embodiments, the pressure difference between the interior of the container and the ambient can hold the closure member in the closed position. Stated differently, when the environmental chamber 802 is pressurized or vented and returns to ambient atmospheric pressure, the relatively higher ambient pressure can help to keep the container closed and sealed.

[0209] Example 3: Additive Manufacturing System with Transfer System

[0210] In certain embodiments, the additive manufacturing systems described herein can operate in a vacuum environment, and can be configured to receive consumable materials such as powder in pre-prepared, sealed pods or containers, such as any of the containers described herein with reference to FIGS. 7-8E. The additive manufacturing systems can be configured to receive the containers in a manner that does not substantially compromise the vacuum environment in which the additive manufacturing system is operating. For example, in certain embodiments the environmental chamber in which the additive manufacturing system operates can comprise an introduction system or transfer system, such as a sealable access chamber, interlock, airlock, port, etc., configured to receive the container, and seal at least the outlet portion of the container from the ambient. For example, in certain embodiments the system can comprise a transfer system including a port, socket, or receptacle configured to receive at least the outlet portion of the container and form a seal with the container. The port can comprise a vacuum pump system in fluid communication with sealed volume around the outlet portion of the container. The sealed volume around the outlet portion of the container can then be pumped down to at or near the pressure of the environmental chamber, and the closure of the container can be opened to provide powder from the container to the additive manufacturing system. In certain embodiments, the pressure inside the environmental chamber can be from 1 x 10^-3 Pa to 1 x 10^-5 Pa, or 1 x 10^-3 Pa or less.

[0211] In certain other embodiments, the system can comprise a transfer system including a load lock vacuum chamber referred to herein as a load lock chamber. The load lock chamber can include first and second airtight doors, valves, or other sealable accesses to selectively isolate the high vacuum environmental chamber from the load lock chamber. In certain embodiments, the load lock chamber can be coupled to a vacuum pump system. The powder- filled container can be received in the load lock chamber at ambient pressure through a first door or other access. The load lock chamber can then be sealed and pumped down to at or near the pressure of the environmental chamber. The container can then be placed in communication with the interior of the environmental chamber (e.g., through the second door) in order to deliver the contents of the container to the additive manufacturing system.

[0212] In certain embodiments, the additive manufacturing system can comprise any of a variety of tools (e.g., remotely operated actuators) configured to open the container. For example, in certain embodiments the transfer system can comprise an actuator or robotic arm configured to release or unfasten any fastening device(s) of the container and/or move the closure of the container to the open position. In certain embodiments, the transfer system can comprise a member, such as a valve member, configured to bear against the closure or cover member of the container to maintain the closure or cover member in the closed position until the valve member is moved to the open position. [0213] In certain embodiments, the additive manufacturing system can be configured to direct the contents of the sealed container to a storage, such as a hopper or reservoir of a powder supply assembly. In some embodiments, the additive manufacturing system can be configured to direct powder from the container to the powder supply assembly without flowing onto sensitive objects or surfaces such as seals. For example, in certain embodiments the additive manufacturing system can comprise one or a series of funnels, conduits, troughs, or other flow directing devices positioned between the port or load lock chamber and the powder supply assembly to direct powder from the container.

[0214] FIG. 11 schematically illustrates a representative additive manufacturing system 900, according to one embodiment. The additive manufacturing system 900 can comprise a main environmental chamber or vacuum chamber 902. A powder supply assembly generally indicated at 904, and including a powder container or hopper 906, is shown situated in the environmental chamber 902. Although not shown in FIG. 11 for convenience, the additive manufacturing system 900 can further include any or all of the subsystems and components of any of the additive manufacturing systems described herein. The additive manufacturing system can further comprise a transfer system in the form of a selectively sealable access port 908. The port 908 can comprise a hollow or tubular body configured as a pipe or conduit 910. A wall 938 (also referred to as a tubular body wall) of the conduit 910 defines a passage extending from a first end portion or inlet portion 912 to a second end portion or outlet portion 914 of the conduit. The first end portion 912 can be configured to receive a powder container, such as any of the powder containers described herein. For example, in the illustrated embodiment the first end portion 912 can comprise a sealing member 924, such as an O-ring or gasket, positioned along the perimeter of the first end portion. The second end portion 914 can be in fluid communication with the environmental chamber 902.

[0215] In the illustrated embodiment, the diameter of the conduit 910 is smaller than the diameter of the container 700 such that a portion of the outlet portion 708 of the container can be received within the inlet portion 912 and the sealing member 924 can form a seal with the outlet portion of the container, although other configurations are possible. In certain embodiments, the container 700 can be coupled to the inlet portion 912 in an inverted orientation with the outlet portion 708 oriented downwardly into the conduit 910.

[0216] The port 908 can further comprise a valve assembly 916 positioned between the first and second end portions 912, 914 of the conduit 910. The valve assembly 916 can be configured to isolate the first end portion 912 of the conduit from the second end portion 914 and from the environmental chamber 902. In the illustrated embodiment, the valve assembly 916 is configured as a gate valve including a valve member referred to herein as a gate member 918. The gate member 918 can be movable across the diameter of the conduit 910 between an open position, in which the gate member is at least partially received in a housing or bonnet 920, and a closed position in which the end portion of the gate member is received in a valve seat portion 922 to seal the second end portion 914 from the first end portion 912.

[0217] The port 908 can also be in fluid communication with a vacuum pump system through a hose or conduit 926. In the illustrated embodiment, the conduit 926 can be in fluid communication with the first end portion 912 through an aperture or port 928 defined in the wall 938 of the conduit 910.

[0218] In certain embodiments, the port 908 can be located above the powder supply assembly 904, and one or more flow directing devices can be positioned in the interior of the conduit 910 between the first end portion 912 of the conduit and the powder supply system. For example, in the embodiment of FIG. 11 a funnel 934 is positioned in the conduit 910 below the valve assembly 916 and above the powder container 906.

[0219] The port 908 can also include a tool or system configured to open containers received in the port 908. For example, in the illustrated embodiment the port includes an actuator 930 coupled to the interior of the conduit 910 at or above the level of the valve assembly 916, and configured to engage the closure of a container. The actuator 930 can be configured according to any of the actuator embodiments described herein. In certain embodiments, the actuator 930 can be an electric actuator such as a voice coil motor or a servo motor.

[0220] In use, a container 700 filled with powder 714 such as described above can be coupled to the port 908, such as by inserting the outlet portion 708 of the container 700 into the first end portion 912 of the conduit 910. The gate member 918 can be in the closed position. The sealing member 924 can form a seal with container 700 such that the portion of the conduit 910 above the gate member 918 defines a volume 932 enclosed by the gate member 918 at one end, and by the container 700 at the opposite end. In certain embodiments, the port 908 and/or the container 700 can comprise any of various engaging or locking mechanisms to mate or secure the container in place on the port, such as a bayonet mount, clasps, clamps, hasps, etc. The actuator 930 can engage the closure of the container 700, such as the closure member 718.

[0221] When the container 700 is first coupled to the port 908, the volume 932 can be at atmospheric pressure. When the container 700 is secured in place on the port 908, the gas (e.g., air) can be evacuated from the volume 932 through the conduit 926 by the associated vacuum pump system. Referring to FIG. 12, when the pressure in the volume 932 approaches or reaches the pressure in the environmental chamber 902, the valve assembly 916 can be opened such that the volume 932 communicates with the interior of the environmental chamber. The actuator 930 can then be operated to release or unfasten any fastening devices of the container and move the cover member 718 to the open position. This can allow powder 714 to flow (e.g., by gravity) out of the container 700, through the funnel 934, and into the powder container 906 of the powder supply assembly 904 (e.g., through the open top of the powder container 906).

[0222] FIG. 13 illustrates another embodiment of the additive manufacturing system 900 in which the port 908 is configured such that the gate member 918 of the valve assembly contacts, blocks, or bears against the closure member 718 of the container 700 when the gate member is in the closed position. In this manner, the gate member 918 can prevent the cover member 718 from opening as the pressure in the volume 932 approaches the pressure inside the container 700. Referring to FIG. 14, when the gate member 918 moves to the open position, the cover member 718 can move to its open position, allowing powder to flow out of the container 700 and into the powder container 906.

[0223] FIG. 15 illustrates another embodiment in which the port 908 includes two funnels 934 and 936 arranged in a vertical arrangement. The successive funnels 936 and 934 can constrain the powder flow out of the container 700 to avoid contaminating sensitive components such as seals, valves, etc. Any of the additive manufacturing systems described herein can include any number of funnels or other flow control devices, depending upon, for example, the lateral position of the port 908 relative to the powder supply assembly 904, the length of the conduit 910, etc.

[0224] FIGS. 16A-16C illustrate another embodiment of a container 1000 configured to be filled with powder and pumped down to a pressure below ambient atmospheric pressure. The container 1000 can comprise a cylindrical main container body 1002 defining an opening 1004 at one end, and a closure configured as a cover member 1006 pivotably coupled to the container body and configured to cover the opening 1004 when in the closed position. A sealing member 1008 can be disposed around the rim of the opening 1004, and can form a seal with the cover member 1006 when the cover member is in the closed position. The container 1000 can further comprise an opening or port 1010 defined in the wall of the container. In certain embodiments, the port 1010 can comprise a seal or a valve 1012. In certain embodiments, the valve 1012 can be a gate valve, a check valve, or any other type of valve. The port 1010 and/or valve 1012 can be couplable to a vacuum pump system generally indicated at 1014 in FIG. 16B.

[0225] The container 1000 can be filled with powder 1018, for example, through the opening 1004. The cover member 1006 can be moved to the closed position, the vacuum pump system 1014 can be connected to the port 1010 (FIG. 16B), and the gas (e.g., air) in the interior of the container can be removed. When the vacuum pump system 1014 is disconnected (FIG. 16C), the valve 1012 can prevent venting of the container, and the interior of the container can remain below ambient atmospheric pressure. The difference between the relatively higher ambient pressure and the relatively low pressure inside the container can hold the cover member 1006 in the closed position, and can compress the sealing member 1008 as indicated by arrows 1016. In certain embodiments, the container 1000 can have a modular design to facilitate storage or shipment in a stacked arrangement.

[0226] FIG. 17 schematically illustrates another embodiment of an additive manufacturing system 1100 configured to receive the container 1000. The additive manufacturing system 1100 as shown in FIG. 17 includes a powder supply assembly 1102 including a powder container 1116 situated in a first environmental chamber 1104. The first environmental chamber 1104 can be coupled to and in fluid communication with a second environmental chamber 1106 containing a powder bed assembly 1108. A transfer system 1118 comprising a load lock chamber 1110 can be coupled to the first environmental chamber 1104, and configured to receive the container 1000 of FIGS. 16A- 16C. In certain embodiments, the load lock chamber 1110 can be located above the powder supply assembly 1102.

[0227] The load lock chamber 1110 can be selectively placed in fluid communication with the first environmental chamber 1104 by way of a closeable hatch configured as a gate valve assembly schematically illustrated at 1112. The gate valve assembly 1112 can include a movable gate valve member 1114. In certain embodiments, the container 1000 can be positioned in the load lock chamber 1110 through an opening closable by a hatch 1130, which can be, for example, incorporated into the top or a sidewall of the chamber 1110. Further, in certain embodiments the container 1000 can be positioned in the load lock chamber 1110 with the cover member 1006 facing downwardly and in contact with the gate valve member 1114. When the container 1000 is secured in place in the load lock chamber 1110, any gas (e.g., air) in the load lock chamber can be evacuated through a conduit 1141 in fluid communication with a vacuum pump system 1140.

[0228] As the load lock chamber is pumped down, the cover member 1006 of the container 1000 can be maintained in the closed position by the gate valve member 1114 bearing against it. When the load lock chamber 1110 reaches a specified pressure (e.g., the pressure in the first environmental chamber 1104), the gate valve member 1114 can be moved to the open position, for example, by moving or translating in the direction of arrow 1120. This can unblock the cover member 1006, allowing it pivot/swing (e.g., by gravity) to the open position in the direction of arrow 1122 such that powder 1018 can flow out of the container 1000 and into the powder container 1116. In certain embodiments, the gate valve member 1114 can be coupled to the cover member 1006 and can pull the cover member to the open position. When the container 1000 has emptied, the gate valve member 1114 can be returned to the closed position, thereby contacting the cover member 1006 of the container 1000 and pivoting it to the closed position. The load lock chamber 1110 can then be vented, and the container 1000 removed.

[0229] In certain embodiments, the container 1000 can include any of the biasing members, fastening devices, and/or closure configurations described herein in lieu of, or in combination with, the features illustrated in FIGS. 16A-16C. Additionally, the transfer system 1118 can also include any of the actuator systems, flow control devices, etc., described herein in order to open the container 1000 and direct the powder contents to the powder container 1116. Thus, in certain embodiments, the gate valve member 1114 can be opened when the load lock chamber reaches a selected pressure, and the load lock chamber can be configured to open the container 1000 with, for example, an actuator system as described above with reference to FIGS. 11-12, an opening member or mechanism, or other opening means.

[0230] In another embodiment, any of the container configurations described herein can be filled with powder (or another consumable material) dried to a specified moisture content, and sealed at ambient atmospheric pressure. The container can then be coupled to or placed in a transfer system such as any of the transfer systems described herein, and opened while the transfer system is isolated from the environmental chamber of the additive manufacturing system. Gas released into the transfer system from inside the container upon opening the container can be pumped out of the transfer system prior to placing the transfer system in fluid communication with the environmental chamber. When the sealed volume of the transfer system reaches a specified vacuum pressure, the transfer system can be placed in fluid communication with the environmental chamber and the container can be emptied to supply powder to the powder supply assembly. In certain embodiments, the container can be placed in the transfer system with the outlet oriented downwardly as in FIGS. 11 and 17. In such embodiments, the container can be opened or vented by opening the closure of the outlet, or by opening a second closure located elsewhere on the container body. For example, in certain embodiments the container can include a valve, seal, etc., on the base of the container which can be opened when the container is inverted in the transfer system to vent gases from the container without allowing powder to flow out of the container. In certain embodiments, the container can be oriented upwardly when placed in the transfer system.

In such configurations, the container can be vented by opening the closure while in the upright orientation. The container can then be inverted (e.g., by an actuator system) to allow the powder contents to be emptied into the powder supply assembly of the additive manufacturing system.

[0231] In certain embodiments, any of the transfer systems described herein can comprise mechanical and/or electronic features such as shaped receptacles, mounts, identification chips (e.g., radio frequency identification (RFID) chips), etc., configured to interact with corresponding features on the containers to prevent the use of unauthorized containers/powder material, reducing the likelihood of supplying non-compatible powder to a manufacturing system and/or powder that does not meet quality specifications.

[0232] One or more of the container embodiments, vacuum dryer/oven embodiments, and/or additive manufacturing system embodiments with transfer systems described herein, and associated methods, can provide a number of significant advantages over existing systems. For example, by using a transfer system including a port or a load lock chamber configured as described herein, powder or other consumable materials can be supplied to an additive manufacturing system in a vacuum environment while maintaining the vacuum environment, that is, without venting the environmental chamber or otherwise significantly increasing the pressure in the environmental chamber. This can allow the additive manufacturing system to operate continuously without interruption while being resupplied with powder or other consumable supplies. Stated differently, this can avoid the need to shut down the additive manufacturing system, vent the environmental chamber to resupply the powder supply assembly, and re-evacuate/pump down the environmental chamber, a procedure which can require up to three hours or longer depending upon the volume of the chamber. The transfer system configurations described herein can also provide for powder delivery to the powder supply assembly without allowing powder to contact sensitive components such as seals, valves, pumps, and actuator mechanisms.

[0233] Agitating and/or heating the powder in a vacuum environment, such as in any of the vacuum dryer/oven embodiments described herein, before the container is sealed, can also avoid the need for long evacuation/pump down procedures to drive off water molecules and other substances when the powder is provided to the additive manufacturing system. Due to the particle size of the powder material (e.g., 50 pm), the powder has a large surface area to which water molecules or other substances may adhere. When placed in a vacuum environment, these molecules can volatize or outgas from the material, and must be removed by the vacuum pump system to maintain the vacuum environment within specified limits. Processing the powder in a separate vacuum dryer/oven at low pressure can drive off water molecules and other substances. Sealing the resulting dry powder in a container at low pressure can preserve the powder in this state, and can avoid the need for extended pumping time to remove volatized water molecules from the vacuum environment after powder is supplied to the additive manufacturing system, as must typically be done with existing systems.

[0234] The container embodiments described herein can also be reusable and/or recyclable, thereby reducing waste.

[0235] In any or all of the embodiments described herein, the powder bed assembly of the additive manufacturing system can be omitted, and the system can be configured to dispense/supply powder directly from the powder supply assembly to the powder bed (e.g., powder bed 26 of FIG. 1 A) without going through the powder supply assembly. In certain embodiments, the system can be configured to dispense/supply powder directly to the powder bed (e.g., powder bed 26 of FIG. 1 A) without going through the powder supply assembly.

[0236] Further, in any or all of the embodiments described herein, the powder bed need not translate in a plane parallel to the surface of the powder bed, nor rotate. In certain embodiments, the powder bed can be configured to move in a direction orthogonal to the surface of the powder bed. In certain embodiments, motion of the powder bed orthogonal to the surface of the powder bed can be combined with translation in a plane parallel to the surface of the powder bed and/or rotation of the powder bed.

[0237] In any or all of the embodiments described herein in which the transfer system includes a valve between the transfer system and the interior of the environmental chamber, the valve (e.g., the gate member 918) can act as an actuator that selectively allows the container to open when the valve is actuated (e.g., moved to the open position). Thus, the transfer systems described herein can include actuators such as the actuator 930 that selectively open the container (such as by pulling, pushing, retracting, unlocking, or detaching the closure) when activated, and/or actuators such as the valve assembly 916 that engage or bear against the closure of the container in the closed position and allow the container to open when activated by moving the gate member to the open position (e.g., allowing the closure/lid of the container to open into the interior of the transfer system). These systems can allow the powder container to remain closed after it is coupled to the transfer system and until the actuator is activated, improving control of the timing of opening the powder container.

[0238] It should be noted that any feature of any of the examples herein in isolation or more than one feature of any of the examples herein taken in any combination are further examples falling within the scope of this disclosure.

[0239] Explanation of Terms

[0240] For purposes of this description, certain aspects, advantages, and novel features of the embodiments of this disclosure are described herein. The disclosed methods, apparatus, and systems are not limiting in any way. Instead, the present disclosure is directed toward all novel features and aspects of the various disclosed embodiments, alone and in various combinations and sub-combinations with one another. The methods, apparatus, and systems are not limited to any specific aspect or feature or combination thereof, nor do the disclosed embodiments require that any one or more specific advantages be present or problems be solved. The scope of this disclosure includes any features disclosed herein combined with any other features disclosed herein, unless physically impossible.

[0241] Although the operations of some of the disclosed embodiments are described in a particular, sequential order for convenient presentation, it should be understood that this manner of description encompasses rearrangement, unless a particular ordering is required by specific language set forth herein. For example, operations described sequentially may in some cases be rearranged or performed concurrently. Moreover, for the sake of simplicity, the attached figures may not show the various ways in which the disclosed components can be used in conjunction with other components.

[0242] As used in this disclosure and in the claims, the singular forms “a,” “an,” and “the” include the plural forms unless the context clearly dictates otherwise. Additionally, the term “includes” means “comprises.” Further, the terms “coupled” and “associated” generally mean electrically, electromagnetically, and/or physically (e.g., mechanically or chemically) coupled or linked and does not exclude the presence of intermediate elements between the coupled or associated items absent specific contrary language.

[0243] In some examples, values, procedures, or apparatus may be referred to as “lowest,” “best,” “minimum,” or the like. Such descriptions are intended to indicate that a selection among many alternatives can be made, and such selections need not be better, smaller, or otherwise preferable to other selections.

[0244] In the description, certain terms may be used such as "up," "down," "upper," "lower," "horizontal," "vertical," "left," "right," and the like. These terms are used, where applicable, to provide some clarity of description when dealing with relative relationships. But, these terms are not intended to imply absolute relationships, positions, and/or orientations. For example, with respect to an object, an "upper" surface can become a "lower" surface simply by turning the object over. Nevertheless, it is still the same object.

[0245] Unless otherwise indicated, all numbers expressing material quantities, angles, pressures, molecular weights, percentages, temperatures, times, and so forth, as used in the specification or claims are to be understood as being modified by the term “about.” Accordingly, unless otherwise indicated, implicitly or explicitly, the numerical parameters set forth are approximations that can depend on the desired properties sought and/or limits of detection under test conditions/methods familiar to those of ordinary skill in the art. When directly and explicitly distinguishing embodiments from discussed prior art, the embodiment numbers are not approximates unless the word “about” is recited.

[0246] Although there are alternatives for various components, parameters, operating conditions, etc., set forth herein, that does not mean that those alternatives are necessarily equivalent and/or perform equally well. Nor does it mean that the alternatives are listed in a preferred order unless stated otherwise.

[0247] In view of the many possible embodiments to which the principles of the disclosed technology can be applied, it should be recognized that the illustrated embodiments are only examples and should not be taken as limiting the scope of the disclosure. Rather, the scope of the disclosure is at least as broad as the following claims and their equivalents. We therefore claim all that comes within the scope and spirit of these claims.

Claims

CLAIMS :

1. An additive manufacturing system, comprising: an environmental chamber configured to maintain a vacuum environment in an interior of the environmental chamber; a powder supply assembly situated in the environmental chamber; and a transfer system coupled to the environmental chamber and configured to receive a container containing a powder material and direct the powder material from the container to the powder supply assembly in the environmental chamber while maintaining the vacuum environment.

2. The additive manufacturing system of claim 1, wherein the transfer system further comprises an actuator configured to selectively open a container received by the transfer system, or allow the container to open, upon activation of the actuator.

3. The additive manufacturing system of claim 1 or claim 2, wherein the transfer system comprises a port configured to form a seal with a body of a container when a container is coupled to the port.

4. The additive manufacturing system of claim 3, wherein the port comprises a gate valve movable between an open position and a closed position, the gate valve being configured to seal the port from the environmental chamber when the gate valve is in the closed position.

5. The additive manufacturing system of claim 4, wherein: the port comprises a tubular body having a first end portion, a second end portion, and a tubular body wall extending between the first end portion and the second end portion; the gate valve extends across the tubular body in the closed position and seals the first end portion of the tubular body from the second end portion.

6. The additive manufacturing system of claim 5, wherein: the first end portion of the tubular body is configured to receive a container; and when a container is received by the first end portion, the gate valve, the tubular body wall, and the container define a sealed volume within the port.

7. The additive manufacturing system of claim 6, further comprising a vacuum pump system in fluid communication with the first end portion of the tubular body and configured to reduce a pressure in the sealed volume when a container is received by the first end portion.

8. The additive manufacturing system of any one of claims 4-7, wherein the actuator is the gate valve, and the gate valve is configured to bear against a cover member of a container when a container is received by the port and the gate valve is in the closed position, and movement of the gate valve to the open position allows the cover member of the container to open.

9. The additive manufacturing system of any one of claims 3-8, wherein the port comprises at least one flow directing device configured to direct a flow of powder from a container received in the port toward the powder supply assembly.

10. The additive manufacturing system of any one of claims 1-9, wherein the transfer system is located above the powder supply assembly such that powder from a container coupled to the transfer system flows to the powder supply assembly by gravity.

11. The additive manufacturing system of any one of claims 2-10, wherein the actuator is configured to open a container received by the transfer system by moving a closure of the container to the open position when activated.

12. The additive manufacturing system of claim 1, wherein the transfer system comprises a load lock chamber configured to receive a container, and a gate valve movable between a closed position and an open position to selectively place the load lock chamber in communication with the environmental chamber; and wherein when the gate valve is in the closed position and a container is received in the load lock chamber, a cover member of the container is in a closed position, and the load lock chamber is further configured to allow the cover member of the container to open when the gate valve is moved to the open position.

13. A method, comprising: filling a container with additive manufacturing powder material; reducing a pressure in the container to a first pressure that is below ambient atmospheric pressure; and sealing the container so that the container remains at the first pressure.

14. The method of claim 13, further comprising heating the powder material in the container or agitating the powder material in the container at the first pressure.

15. The method of claim 13 or claim 14, wherein: reducing the pressure in the container further comprises placing the container in an environmental chamber and reducing the pressure in the environmental chamber; or reducing the pressure in the container with a vacuum pump system coupled to a valve port of the container.

16. The method of any one of claims 13-15, wherein sealing the container further comprises closing a cover member of the container and fastening a fastening device to secure the cover member closed.

17. The method of claim 16, further comprising closing the cover member and fastening the fastening device with an actuator in an environmental chamber at the first pressure.

18. The method of claim 17, further comprising venting the environmental chamber to ambient atmospheric pressure after the cover member is closed and the fastening device is fastened.

19. The method of any one of claims 13-18, wherein the first pressure is 1 x 10^-3 Pa or less.

20. The method of any of claims 13-19, further comprising: coupling the container to a transfer system of an additive manufacturing system, the transfer system being coupled to an environmental chamber in which a powder supply assembly of the additive manufacturing system is located, an interior of the environmental chamber being at the first pressure; reducing a pressure in the transfer system to the first pressure; and opening the container to allow powder in the container to flow to the powder supply assembly.

21. A method of supplying powder material to an additive manufacturing system, comprising: coupling a container to a transfer system of the additive manufacturing system, the transfer system being coupled to an environmental chamber in which a powder supply assembly of the additive manufacturing system is located, an interior of the environmental chamber being at a first pressure that is less than ambient atmospheric pressure; reducing a pressure in the transfer system to the first pressure; and opening the container to allow powder in the container to flow to the powder supply assembly.

22. The method of claim 21, wherein prior to opening the container, the interior of the container is at the first pressure.

23. The method of claim 21 or claim 22, wherein the transfer system further comprises a port configured to be selectively placed in fluid communication with the interior of the environmental chamber, and coupling the container to the transfer system further comprises forming a seal between the port and a body of the container.

24. The method of claim 21 or claim 22, wherein the transfer system comprises a load lock chamber configured to receive the container, and coupling the container to the transfer system further comprises placing the container in the load lock chamber.

25. The method of any of claims 21-24, wherein opening the container further comprises unfastening a fastening device of the container.

26. The method of any of claims 21-25, further comprising opening a valve of the transfer system such that the transfer system communicates with the interior of the environmental chamber.

27. The method of claim 26, wherein the valve is a gate valve configured to bear against the container when the gate valve is in a closed position, and opening the container further comprises moving the gate valve to an open position.

28. The method of any of claims 21-27, wherein the container comprises a main body portion, a tapered outlet portion defining an opening, and a closure, the main body coupled to the tapered outlet portion, the closure comprising a cover member coupled to the tapered outlet portion and movable between an open position and closed position, the cover member being configured to close the opening in the closed position, a bias coupled to the tapered outlet portion and to the cover member and configured to bias the cover member toward the closed position, and a fastening device configured to secure the cover member in the closed position, and wherein a sealing member is coupled to the tapered outlet portion or to the cover member.

29. A container, comprising: a main body portion and a tapered outlet portion, the tapered outlet portion defining an opening; and a closure comprising: a cover member coupled to the tapered outlet portion and movable between an open position and closed position, the cover member being configured to close the opening in the closed position; a bias coupled to the tapered outlet portion and to the cover member, and configured to bias the cover member toward the closed position; a fastening device configured to secure the cover member in the closed position; and a sealing member coupled to the tapered outlet portion or to the cover member.

30. The container of claim 29, wherein the container is configured to maintain an internal pressure of 1 x 10^-3 Pa or less.

31. The container of claim 29 or claim 30, wherein the fastening device comprises a latch, a hasp, a buckle, a clasp, a pin, or any combination thereof.

32. The container of any one of claims 29-31, wherein the cover member is pivotable between the open position and the closed position.

33. The container of any one of claims 29-32, wherein the cover member comprises a gate valve member.

34. A container comprising: a main body portion configured to contain a powder material; and a closure configured to maintain a first pressure that is below ambient atmospheric pressure.

35. The container of claim 34, wherein the first pressure is a vacuum environment.

36. The container of claim 34, wherein the container is configured to maintain an internal pressure of 1 x 10^-3 Pa or less.

37. The container of any of claims 34-36, further comprising a tapered outlet portion defining an opening.

38. The container of any of claims 34-37, wherein the closure comprises: a cover member coupled to the tapered outlet portion and movable between an open position and a closed position, the cover member being configured to close the opening in the closed position; a bias coupled to the tapered outlet portion and to the cover member, and configured to bias the cover member toward the closed position; a fastening device configured to secure the cover member in the closed position; and a sealing member coupled to the tapered outlet portion or to the cover member.

39. The container of claim 38, wherein the fastening device comprises a latch, a hasp, a buckle, a clasp, a pin, or any combination thereof.

40. The container of any of claims 38-39, wherein the cover member is pivotable between the open position and the closed position.

41. The container of any of claims 38-40, wherein the cover member comprises a gate valve member.