Apparatus and methods for fabricating components
An additive manufacturing method for fabricating a component having a surface substantially free of imperfections may include providing a mold having a configuration corresponding to the component, and depositing a material on at least one surface of the mold to fabricate the component having the surface substantially free of imperfections.
1. An additive manufacturing apparatus, comprising:
a pair of side walls spaced apart along a horizontal direction;
a gantry supported on the pair of side walls;
a carriage movably supported on the gantry;
a carrier movably supported on the carriage and movable along a vertical direction orthogonal to the horizontal direction;
an applicator head supported on and movable with the carrier;
a nozzle within the applicator head, the nozzle shaped to deposit a molten material on a surface; and
a servomotor configured to rotate a bracket disposed on the applicator head.
2. The additive manufacturing apparatus of claim 1 , further including a worktable having a surface that extends between the pair of side walls, and wherein the surface of the worktable extends within in a horizontal plane.
3. The additive manufacturing apparatus of claim 1 , further including a roller configured to compress the molten material, the roller being rotatable about the vertical direction.
4. The additive manufacturing apparatus of claim 3 , wherein, during an additive manufacturing process, the roller is configured to be disposed between the applicator head and the surface.
5. The additive manufacturing apparatus of claim 1 , wherein the gantry is supported on respective upper ends of the pair of side walls.
6. The additive manufacturing apparatus of claim 1 , wherein the nozzle extends through a passage within the applicator head.
7. The additive manufacturing apparatus of claim 1 , further including a roller rotatable with the bracket by the servomotor.
8. An additive manufacturing system including the additive manufacturing apparatus of claim 1 , further including a mold, and wherein the surface is a surface of the mold.
9. The additive manufacturing system of claim 8 , wherein the mold extends below the applicator head and the carrier in the vertical direction.
10. An additive manufacturing apparatus, comprising:
an applicator head movable with a carrier along a vertical direction;
a nozzle coupled to the applicator head, the nozzle configured to extrude a molten material; and
a roller configured to compress the molten material, the roller being rotatable about the vertical direction with respect to the nozzle.
11. The additive manufacturing apparatus of claim 10 , wherein the nozzle is configured to extrude a heated thermoplastic material that forms the molten material.
12. The additive manufacturing apparatus of claim 10 , wherein the applicator head, the nozzle, and the roller are translatable along a first horizontal direction orthogonal to the vertical direction and a second horizontal direction orthogonal to the vertical direction.
13. The additive manufacturing apparatus of claim 10 , further including a surface configured to receive the molten material from the nozzle, the surface being a coated surface and/or a polished surface.
14. An additive manufacturing system including the additive manufacturing apparatus of claim 10 , further including a mold having a surface configured to receive the molten material, and wherein the roller is positionable between the surface and the applicator head.
15. The additive manufacturing system of claim 14 , wherein the applicator head includes a bracket that supports the roller, the bracket facing the surface of the mold during an additive manufacturing process.
16. An additive manufacturing system, comprising:
a pair of side walls spaced apart from each other in a first direction;
a gantry extending along the first direction and supported on the pair of side walls;
an applicator head movable with respect to the gantry along a second direction that is different from the first direction;
a nozzle coupled to the applicator head, the nozzle configured to extrude a flowable material;
a mold having a surface configured to receive the flowable material; and
a roller configured to compress the flowable material deposited on the surface of the mold, wherein the roller is translatable within the first direction and rotatable about the second direction.
17. The additive manufacturing system of claim 16 , further including a servomotor configured to rotate the roller about the second direction.
18. The additive manufacturing system of claim 16 , wherein the mold is disposed between the pair of side walls when flowable material is deposited on the surface of the mold.