Granted Patent B2

US 12,654,227 · App. 18/250,846 · Granted Jun 16, 2026

Inventors: Jacob Mayer (Cincinnati, OH); Victor Fulton (West Chester, OH); Carlos H. Bonilla (West Chester, OH)

Assignee: General Electric Company

B22F12/38B22F12/222B22F12/53B22F12/90B33Y30/00

Abstract

Claims (29)

1 . An apparatus for forming a three-dimensional article having successive layers of a powder material, which layers correspond to successive cross-sections of the three-dimensional article, the apparatus comprising:

a process chamber comprising a process chamber floor having an opening therethrough, the opening defining a part processing area; and

a lid management system comprising:

an actuator comprising a movable arm that moves between retracted and extended positions; and

a machine lid connected to the movable arm by a connector located on a top face of the machine lid, the machine lid sized and configured to sealingly engage a perimeter of the opening of the process chamber floor with the movable arm in the extended position.

2 . The apparatus of claim 1 further comprising a build head that deposits a layer of binder material in a predetermined pattern on a layer of powder material that has been distributed on a build platform located within the opening of the process chamber floor.

3 . The apparatus of claim 1 , wherein the machine lid comprises a clamping device configured to clamp onto a build box lid of a build box that comprises the build platform.

4 . The apparatus of claim 1 , wherein the machine lid comprises a seal that seals against the perimeter of the opening of the process chamber floor.

5 . The apparatus of claim 4 , wherein the seal is inflatable having an inflated configuration of increased dimension and a deflated configuration of decreased dimension.

6 . The apparatus of claim 1 further comprising an actuator mounting assembly comprising a mounting bracket that mounts the actuator above a top plate that forms a ceiling of the process chamber.

7 . The apparatus of claim 6 , wherein the mounting bracket comprises mounting legs that extend alongside the actuator and a laterally extending mount that extends between the mounting legs, the laterally extending mount connected to the actuator.

8 . The apparatus of claim 7 , wherein each mounting leg includes an end flange that mounts to a support structure using one or more adjustable fasteners, the adjustable fasteners providing for height adjustment of the mounting bracket.

9 . The apparatus of claim 1 further comprising a build box that is located under the process chamber floor and comprises a build platform located within the opening of the process chamber floor.

10 . The additive manufacturing apparatus of claim 9 , wherein the build box comprises a build box lid that seals against an enclosure body of the build box.

11 . A build box for an apparatus for forming a three-dimensional article having successive layers of a powder material, which layers correspond to successive cross-sections of the three-dimensional article, the build box comprising:

an enclosure body forming a build volume;

a build platform slidably disposed in the build volume; and

a build box lid covering the build volume that is removable from the enclosure body, the build box lid comprising a connector located on a top face of the machine lid.

12 . The build box of claim 11 , wherein the build box lid comprises one or more clamping structures on a face of the build box lid that are grasped by a clamping device of the additive manufacturing apparatus for removing the build box lid from the enclosure body.

13 . The build box of claim 11 further comprising a top flange plate having an opening therethrough with a perimeter that extends around the enclosure body.

14 . The build box of claim 13 further comprising a bottom flange plate having a channel formed therein that receives a bottom edge of the enclosure body.

15 . The build box of claim 11 , wherein the build platform comprises multiple, stacked plates that form a groove having a seal located therein that maintains a pressure against an inner surface of the enclosure body.

16 . The build box of claim 11 , wherein the enclosure body and build platform are formed of different materials.

17 . A method of sealing a process chamber of an apparatus, the apparatus for forming a three-dimensional article having successive layers of a powder material, which layers correspond to successive cross-sections of the three-dimensional article, the method comprising:

sealing an opening that defines a part processing area in a process chamber floor using a machine lid, the machine lid connected to a movable arm of an actuator for moving the machine lid toward and away from the opening in the process chamber floor, the movable arm connected to a connector located on a top face of the machine lid; and

removing the machine lid from the opening.

18 . The method of claim 17 further comprising introducing an inert gas to the process chamber with the machine lid sealing the opening.

19 . The method of claim 17 further comprising sealing around the opening using a build box, the build box comprising a build box lid.

20 . The method of claim 19 further comprising raising a build platform using a lift platform assembly, wherein the build platform engages and raises the build box lid.

Assignments (1)

Continuity (2)

References Cited (287)