US 12,485,617 B2
Systems and methods for creating a powder removal tool via additive manufacturing
Adam McFarland, Royal Oak, MI (US); Adam John Campbell, Rochester, MI (US); Steven Lewis Corzyk, Farmington Hills, MI (US); Patrick J. Eding, Fremont, MI (US); and Dale Miller, Rochester, MI (US)
Assigned to GM Global Technology Operations LLC, Detroit, MI (US)
Filed by GM Global Technology Operations LLC, Detroit, MI (US)
Filed on Sep. 26, 2023, as Appl. No. 18/474,652.
Prior Publication US 2025/0100224 A1, Mar. 27, 2025
Int. Cl. B29C 64/35 (2017.01); B29C 64/141 (2017.01); B29C 64/386 (2017.01); B33Y 10/00 (2015.01); B33Y 40/20 (2020.01); B33Y 50/00 (2015.01)
CPC B29C 64/35 (2017.08) [B29C 64/386 (2017.08); B33Y 10/00 (2014.12); B33Y 40/20 (2020.01); B33Y 50/00 (2014.12); B29C 64/141 (2017.08)] 20 Claims
OG exemplary drawing
 
1. A method for removing excess powder from a part during an additive manufacturing process, the method comprising:
defining parameters for a part;
defining parameters for a removal tool comprising a plurality of links to create a chain-like structure, each of the links having a spherical body defining a central aperture and being joined to an adjacent link by a linkage having a first head disposed at a first end and a second head disposed at a second end opposite the first end, the first head and the second head having a larger diameter than a diameter of the central aperture;
simultaneously creating the part and the removal tool via additive manufacturing, wherein the part defines an interior passageway and the removal tool is created within the interior passageway and, upon completion of the creation of the part and the removal tool, the removal tool is surrounded by excess powder in the interior passageway, and wherein each link of the plurality of links is created with a gap between adjacent links of the plurality of links;
removing the removal tool from the interior passageway, forcing at least some of the excess powder out of the interior passageway; and
performing at least one of the following operations to remove any remaining excess powder from the interior passageway:
providing a robotic appendage for powder removal;
vibration powder removal;
air blasting in the interior passageway; or
media blasting in the interior passageway.