US 12,330,371 B2
Rotating relative recoater and part orientation
Lawrence Binek, Glastonbury, CT (US); and David W. Morganson, Marlborough, CT (US)
Assigned to Hamilton Sundstrand Corporation, Charlotte, NC (US)
Filed by Hamilton Sundstrand Corporation, Charlotte, NC (US)
Filed on May 5, 2023, as Appl. No. 18/144,002.
Application 17/724,183 is a division of application No. 16/166,958, filed on Oct. 22, 2018, abandoned.
Application 18/144,002 is a continuation in part of application No. 17/724,183, filed on Apr. 19, 2022.
Prior Publication US 2023/0330932 A1, Oct. 19, 2023
Int. Cl. B29C 64/241 (2017.01); B22F 10/28 (2021.01); B22F 10/32 (2021.01); B22F 10/38 (2021.01); B22F 12/00 (2021.01); B22F 12/37 (2021.01); B22F 12/47 (2021.01); B22F 12/67 (2021.01); B22F 12/70 (2021.01); B29C 64/153 (2017.01); B29C 64/255 (2017.01); B29C 64/268 (2017.01); B29C 64/321 (2017.01); B29C 64/393 (2017.01); B33Y 10/00 (2015.01); B33Y 30/00 (2015.01); B33Y 40/00 (2020.01)
CPC B29C 64/241 (2017.08) [B22F 10/28 (2021.01); B22F 10/32 (2021.01); B22F 10/38 (2021.01); B22F 12/226 (2021.01); B22F 12/37 (2021.01); B22F 12/47 (2021.01); B22F 12/67 (2021.01); B22F 12/70 (2021.01); B29C 64/153 (2017.08); B29C 64/255 (2017.08); B29C 64/268 (2017.08); B29C 64/321 (2017.08); B29C 64/393 (2017.08); B33Y 10/00 (2014.12); B33Y 30/00 (2014.12); B33Y 40/00 (2014.12)] 17 Claims
OG exemplary drawing
 
1. A method of additive manufacturing comprising:
selectively sintering at least a portion of a part and one or more indexing features onto a build plate disposed in a build area of a feedstock powder bed;
determining, using the one or more indexing features, an actual orientation of the part and the build plate relative to a recoater prior to recoating;
storing the actual orientation of the part and the build plate relative to the recoater in a memory;
comparing the actual orientation of the part and the build plate relative to the recoater with a predicted orientation of the part and the build plate relative to the recoater; and
recoating the build area with feedstock powder when the actual orientation of the part and the build plate relative to the recoater matches the predicted orientation of the part and the build plate relative to the recoater or when a difference between the actual and predicted orientation of the part and the build plate relative to the recoater is within a predetermined error threshold to achieve a predetermined build quality for a respective layer of the part, wherein:
when the actual orientation of the part and the build plate relative to the recoater matches the predicted orientation of the part and the build plate relative to the recoater or a difference between the actual and predicted orientation of the part and the build plate relative to the recoater is within a predetermined error threshold:
after recoating, selectively sintering a portion of the feedstock powder deposited by the recoater to the part; and
when the actual orientation of the part and the build plate relative to the recoater does not match the predicted orientation of the part and the build plate relative to the recoater and the difference between the actual and predicted orientation of the part and the build plate relative to the recoater exceeds the error threshold:
rotating the build plate and part together to change the orientation relative to the recoater such that the difference between the actual and the predicted orientation of the part and the build plate relative to the recoater is at least within the error threshold;
recoating the build area with feedstock powder after rotating the part to the predicted orientation; and
selectively sintering the feedstock powder to the part after recoating the build area.