Method for controlling a fluid flow during an additive manufacturing process
Methods for controlling a fluid flow during an additive manufacturing process are provided. The method may comprise causing a fluid flow to move across a build volume and forming a component. The component may comprise a plurality of layers of material in the build volume and at least one directional portion comprising a plurality of layers of material in the build volume. The component includes at least one critical zone and the at least one direction portion is configured to at least in part direct the fluid flow to for block the fluid flow from the at least one critical zone.
1 . A method for controlling a fluid flow during an additive manufacturing process comprising:
causing the fluid flow to continuously move across a build volume including at least one directional portion;
forming at least one component comprising a first plurality of layers of material in the build volume, the at least one component having at least one zone comprising a feature; and
forming the at least one directional portion comprising a second plurality of layers of the material in the build volume, the at least one directional portion separate and spaced from the at least one component to form a space between the at least one directional portion and the at least one component, the at least one directional portion directing at least a portion of the fluid flow to or blocking at least a portion of the fluid flow from the at least one zone comprising the feature;
wherein the space between the at least one directional portion and the at least one component is void of the material, and
wherein the fluid flow is directed towards the at least one directional portion and the at least one component.
2 . The method of claim 1 , wherein the at least one directional portion is a wall configured to direct the fluid flow relative to the at least one zone comprising the feature.
3 . The method of claim 1 , wherein the at least one directional portion is configured to direct the fluid flow to the at least one zone to increase convection to transfer heat between the at least one zone comprising the feature and the fluid flow.
4 . The method of claim 1 , wherein the additive manufacturing process uses a Fused Filament Fabrication method.
5 . The method of claim 1 , wherein the space between the at least one component including the at least one zone comprising the feature and the at least one directional portion defines at least one separation layer.
6 . The method of claim 5 , wherein the at least one separation layer is sized to stagnate the fluid flow.
7 . The method of claim 5 , wherein the at least one separation layer has a thickness of at least 0.25″.
8 . The method of claim 1 , wherein the at least one directional portion causes the fluid flow to move from a first path to a second path.
9 . The method of claim 1 , wherein the at least one directional portion blocks the fluid flow from the at least one zone comprising the feature.
10 . The method of claim 1 , wherein the at least one zone comprising the feature of the component has a cooling rate that is affected by the fluid flow to the at least one zone.
11 . The method of claim 1 , wherein the fluid flow is at least one of a gas flow or a liquid flow.
12 . The method of claim 1 , wherein the at least one directional portion is configured to block the fluid flow from the at least one zone comprising the feature.
13 . The method of claim 1 , further comprising discarding the at least one directional portion following forming the at least one component.
14 . A method for forming a component with controlled heat transfer, comprising:
receiving instructions in a three-dimensional printer for forming in a build volume, using a nozzle, the component comprising a first plurality of layers of material and including at least one critical zone of material, and at least one directional portion comprising a second plurality of layers of material on a base;
causing a fluid circulator to cause a cooling fluid to flow across the base, the fluid circulator positioned adjacent to the base and directing the cooling fluid flow across the base; and
causing the three-dimensional printer to form the directional portion, the directional portion separate and spaced from the component to form a space between the directional portion and the component, the directional portion causing at least one of directing the cooling fluid flow to or blocking the cooling fluid flow from the at least one critical zone of material, where the temperature of material in the at least one critical zone is controlled differently than material of the component not in the critical zone;
wherein the nozzle moves independently of the fluid circulator,
wherein the directional portion causes the cooling fluid flow to move from a first direction to a second direction, and
wherein the space between the directional portion and the component is void of the material.
15 . The method of claim 14 , wherein the three-dimensional printer forms the component and the directional portion after causing the fluid circulator to cause the cooling fluid to flow across the base.
16 . The method of claim 14 , wherein the three-dimensional printer causing the fluid circulator to cause the cooling fluid to flow across the base occurs after forming the component and the directional portion.
17 . The method of claim 14 , wherein the causing the fluid circulator to cause the cooling fluid flow occurs at least partially simultaneously with causing the three-dimensional printer to form the component and the directional portion.
18 . The method of claim 14 , wherein the first plurality of layers of material comprises at least one of sintered powder, wire, paste, slurry, or liquid and the second plurality of layers comprises at least one of sintered powder, wire, slurry, or liquid.
19 . The method of claim 14 , wherein the directional portion is a wall configured to block the cooling fluid flow or to direct the cooling fluid flow relative to the at least one critical zone of material.
20 . The method of claim 19 , wherein the component and the directional portion are formed on the base in the build volume, and wherein causing the three-dimensional printer to form the component and the directional portion comprises moving at least one of the base or the nozzle in a direction perpendicular to the base.
21 . The method of claim 14 , wherein when the cooling fluid flow is caused to move from a first direction to a second direction, the second direction is directed to the at least one critical zone comprising the feature.
22 . The method of claim 14 , wherein when the cooling fluid flow is caused to move from a first direction to a second direction, the cooling fluid flow is directed away from the at least one critical zone comprising the feature.
23 . The method of claim 14 , wherein the at least one directional portion is a wall configured to block the cooling fluid flow to the at least one critical zone comprising the feature.
24 . A method for controlling a fluid flow during an additive manufacturing process comprising:
causing, using a fluid circulator, a fluid flow to continuously move across a plurality of objects formed on a build surface of a build volume in a first direction, the fluid circulator positioned adjacent to the build surface, wherein the plurality of objects includes a component and a directional portion;
forming, using a nozzle, the component comprising a first plurality of layers of material in the build volume, the component having at least one zone comprising a feature; and
forming, using the nozzle, the directional portion comprising a second plurality of layers of material in the build volume, the directional portion forming at least one of a baffle or a wall, the directional portion separate and spaced from the component to form a space between the directional portion and the component, the directional portion directing cooling fluid to or blocking the cooling fluid flow from the at least one zone comprising the feature, where the temperature of material in the zone comprising the feature is controlled differently than material not in the zone comprising the feature,
wherein the fluid circulator is independent of the nozzle,
wherein the directional portion is not attached to or part of the component,
wherein the space between the directional portion and the component is void of the material, and
wherein a first layer of material of the component and the first layer of material of the directional portion]are formed on the build surface and subsequent layers are formed by moving at least one of the nozzle or the build surface.