US 12,269,091 B2
System and method for multimaterial powder bed patterning for use in additive manufacturing
Nikola Dudukovic, Hayward, CA (US); Alexander Baker, Livermore, CA (US); Joshua R. Deotte, Livermore, CA (US); Eric B. Duoss, Danville, CA (US); and Scott McCall, Livermore, CA (US)
Assigned to Lawrence Livermore National Security, LLC, Livermore, CA (US)
Filed by Lawrence Livermore National Security, LLC, Livermore, CA (US)
Filed on Nov. 30, 2020, as Appl. No. 17/106,251.
Prior Publication US 2022/0168814 A1, Jun. 2, 2022
Int. Cl. B22F 10/38 (2021.01); B22F 10/28 (2021.01); B22F 10/85 (2021.01); B22F 12/30 (2021.01); B22F 12/53 (2021.01); B33Y 10/00 (2015.01); B33Y 30/00 (2015.01); B33Y 50/02 (2015.01)
CPC B22F 10/38 (2021.01) [B22F 10/28 (2021.01); B22F 10/85 (2021.01); B22F 12/30 (2021.01); B22F 12/53 (2021.01); B33Y 10/00 (2014.12); B33Y 30/00 (2014.12); B33Y 50/02 (2014.12)] 18 Claims
OG exemplary drawing
 
1. An additive manufacturing system, comprising:
a nozzle having a body with a tip, and configured to receive a quantity of feedstock material including granular metal powder particles, and further configured to release the granular metal powder particles out through the tip into an ambient environment, through which the deposited granular metal powder particles fall onto at least one of a build plate or a previously formed material layer, to form at least one layer of a part;
a magnetic field generator subsystem including a processor for producing a controlled magnetic field configured to orient the granular metal powder particles on at least one of the build plate or the previously formed metal layer, after the granular metal powder particles have been released from the nozzle, and exited the tip of the nozzle and are falling through the ambient environment, in a desired orientation, before fusing of the granular metal powder particles occurs; and
the processor controlled, magnetic field generator subsystem further being spaced at least partially elevationally below the tip of the nozzle, laterally of the tip so as to generate the controlled magnetic field in a space below the nozzle tip and outside of the nozzle body, between the nozzle tip and the build plate, to enable alignment of the granular metal powder particles along two or more axes as the granular metal powder particles are falling towards and onto the build plate, and further being arranged adjacent to the build plate to produce a magnet field encompassing the build plate.