REDUCED BUILD MASS ADDITIVE MANUFACTURING CHAMBER
A disclosed additive manufacturing machine includes a work surface for supporting fabrication of part and a housing defining a chamber over the work surface. A material applicator supported on the housing deposits material onto the work surface and a blocker plate disposed between the material applicator and the work surface for blocking a portion of material deposited by the material applicator. An energy directing device is supported on the housing and directing energy within the chamber to form the part.
1 . An additive manufacturing process comprising:
defining a work surface;
depositing material over a portion of the work surface;
directing energy on portions of the deposited material according to a defined part geometry; and
moving the work surface relative to the blocker plate to maintain a distance for incremental deposition of material.
2 . The additive manufacturing process as recited in claim 1 , including blocking material from the work surface with the blocking plate.
3 . The additive manufacturing process as recited in claim 1 , including removing excess material from the blocker plate.
4 . The additive manufacturing process as recited in claim 1 , including defining an outer perimeter of the part with a sidewall barrier defining an opening through the blocker plate.
5 . The additive manufacturing process as recited in claim 4 , wherein the sidewall barrier includes a vertical length greater than a thickness of the blocker plate.
6 . The additive manufacturing process as recited in claim 5 , including a working surface movable relative to the blocker plate within the contour of the sidewall barrier.
7 . The additive manufacturing process as recited in claim 5 , including a material storage container receiving material removed from the blocker plate.
8 . The additive manufacturing process as recited in claim 1 , including fixing the blocker plate relative to movement of the material applicator.
9 . An additive manufacturing machine comprising:
a work surface for supporting fabrication of a desired part geometry;
a housing defining a chamber over the work surface;
a material applicator for depositing material onto the work surface;
a blocker plate disposed between the material applicator and the work surface for blocking a portion of material deposited by the material applicator; and
an energy directing device directing energy within the chamber to form a desired part geometry.
10 . The additive manufacturing machine as recited in claim 9 , including an actuator for moving the work surface relative to the housing.
11 . The additive manufacturing machine as recited in claim 9 , including a controller governing movement of the work surface relative to the housing.
12 . The additive manufacturing machine as recited in claim 11 , wherein the blocker plate includes an opening corresponding to at least the outer perimeter of the part.
13 . The additive manufacturing machine as recited in claim 12 , including a sidewall barrier extending through the opening of the blocker.
14 . The additive manufacturing machine as recited in claim 13 , wherein the plunger includes a length greater than a thickness of the blocker plate.
15 . The additive manufacturing machine as recited in claim 13 , wherein the plunger extends downward into a space between the blocker plate and the work surface.
16 . The additive manufacturing machine as recited in claim 9 , including a material removal device for removing material deposited on the blocker plate.