Powder removal system for powder based manufacturing methods

1 . A powder removal system for removing powder from an additive manufacturing component with a plurality of component voids therein, comprising:

a flat build plate;

the flat build plate comprising a block of solid metal with a top side and a bottom side;

the flat build plate comprising a plurality of build plate conduits that aligns with the plurality of component voids in the additive manufacturing component positioned on the top side of the flat build plate;

a powder removal plate positioned on the bottom side of the flat build plate;

the powder removal plate comprising a first side and a second side and a plurality of powder removal plate conduits that aligns with the plurality of build plate conduits;

wherein the plurality of build plate conduits extend along the first side of the powder removal plate; and

a pressurized fluid system in communication with the plurality of powder removal plate conduits such that a fluid extends through the powder removal plate, into the flat build plate, and into the additive manufacturing component.

2 . The powder removal system of claim 1 , wherein the pressurized fluid system comprises a source of the fluid.

3 . The powder removal system of claim 2 , wherein the source of a fluid comprises a gas or a liquid.

4 . The powder removal system of claim 2 , wherein the source of a fluid is in communication with a pressurizing device.

5 . The powder removal system of claim 1 , wherein the pressurized fluid system pulls a vacuum.

6 . The powder removal system of claim 1 , wherein the powder removal plate comprises a fluid distribution system.

7 . The powder removal system of claim 1 , wherein the powder removal plate comprises a sidewall.

8 . The powder removal system of claim 7 , wherein the powder removal plate comprises a plurality of internal channels.

9 . The powder removal system of claim 8 , wherein the plurality of internal channels comprises a plurality of input ports positioned on the sidewall.

10 . The powder removal system of claim 9 , wherein the plurality of internal channels extends from the plurality of input ports.

11 . The powder removal system of claim 8 , wherein the plurality of internal channels extends to a plurality of fluid plenums.

12 . The powder removal system of claim 11 , wherein a number of the plurality of powder removal plate conduits are positioned in each of the plurality of fluid plenums.

13 . The powder removal system of claim 1 , wherein the flat build plate is clamped to the powder removal plate.

14 . The powder removal system of claim 1 , further comprising a build platform and wherein the build platform vibrates.

15 . A method of removing residual powder from an additive manufacturing component with a plurality of component voids therein, comprising:

positioning a flat build plate with a plurality of build plate conduits on top of a powder removal plate with a plurality of powder removal plate conduits such the plurality of build plate conduits aligns with the plurality of powder removal plate conduits;

wherein the powder removal plate comprises a first side, a second side, and a side wall therebetween, wherein the powder removal plate comprises a fluid distribution system formed therein, the fluid distribution system including a number of internal channels, wherein the internal channels extend from a number of input ports positioned about the side wall of the powder removal plate to a number of internal fluid plenums provided in the powder removal plate, wherein each internal fluid plenum has one or more of the powder removal plate conduits formed therein, and wherein at least some of the internal channels fluidly connect two fluid plenums with each other;

manufacturing the component on the flat build plate such the plurality of component voids aligns with the plurality of build plate conduits;

after manufacturing the component, flowing a pressurized fluid through the plurality of powder removal plate conduits and the plurality of build plate conduits and into the plurality of component voids; and

forcing the residual powder out of the plurality of component voids.

16 . An additive manufacturing system for manufacturing a component with a plurality of component voids therein, comprising:

a source of powder;

a printer for manufacturing the component from the source of powder;

a flat build plate comprising a block of solid metal with a top side and a bottom side for building the component on the top side thereof;

the flat build plate comprising a plurality of build plate conduits that aligns with the plurality of component voids;

a powder removal plate positioned on the bottom side of the flat build plate;

the powder removal plate comprising a first side and a second side and a plurality of powder removal plate conduits that aligns with the plurality of build plate conduits;

wherein the plurality of build plate conduits extend along the first side of the powder removal plate; and

a pressurized fluid system in communication with the plurality of powder removal plate conduits such that a fluid extends through the powder removal plate, into the flat build plate, and into the component.

17 . The additive manufacturing system of claim 16 , wherein the pressurized fluid system comprises a source of a gas fluid or a liquid fluid.

18 . The additive manufacturing system of claim 17 , wherein the source of the gas fluid or the liquid fluid is in communication with a pressurizing device.

19 . The additive manufacturing system of claim 16 , wherein the pressurized fluid system pulls a vacuum.

20 . The additive manufacturing system of claim 16 , further comprising a build platform and wherein the build platform vibrates.