Method and system for hybrid direct manufacturing
A method for hybrid direct manufacturing is provided. The method involves depositing a foundation of material onto a substrate platform or base plate. The foundation serves as a foundation for a block of material (a monolith) to be welded thereon. Once the foundation is created, the monolith or block of material may be placed against the foundation. The foundation may be created such that its boundary matches with the boundary of the monolith that will be welded on top of the foundation. Next, the monolith is welded to the foundation using a high energy beam such as an electron beam. The method may also involve depositing a layer of material on or adjacent to the monolith.
1. A method for hybrid direct manufacturing, the method comprising:
depositing, using a direct manufacturing process, a first foundation of material on a substrate such that a boundary of the first foundation matches the boundary of a first monolith;
positioning the first monolith against the first foundation; and
welding, using an energy beam, the first foundation and the first monolith together;
wherein a height of the first monolith is greater than a height of the first foundation.
2. The method of claim 1 , wherein a height of the first foundation is at least half of a diameter of the energy beam.
3. The method of claim 1 , further comprising depositing a second foundation on the substrate platform prior to the positioning of the first monolith, wherein the second foundation has a height that is different than a height of the first foundation, and wherein a boundary of the second foundation matches with the boundary of the second monolith.
4. The method of claim 3 , wherein the second foundation is higher than the first foundation by at least half of the diameter of the energy beam.
5. The method of claim 3 , further comprising:
positioning a second monolith against the second foundation; and
welding the second monolith to the second foundation.
6. The method of claim 1 , further comprising face milling a top surface of the first foundation to match a mating surface of the first monolith.
7. The method of claim 1 , further comprising machining the boundary of the first foundation to match with details of the boundary of the first monolith.
8. The method of claim 5 , further comprising depositing a layer of material on the first or second monolith to create a component on top of the first or second monolith.
9. The method of claim 5 , further comprising depositing a layer of material adjacent to the first or second monolith.
10. The method of claim 5 , wherein the energy beam used to weld each of the monoliths to its respective foundation is parallel to a working surface of the substrate platform.
11. The method of claim 1 , wherein the energy beam is an electron beam.
12. A method for hybrid direct manufacturing, the method comprising:
depositing, using a direct manufacturing process, a first foundation of material on a substrate platform such that a boundary of the first foundation matches with a boundary of a first monolith;
depositing a second foundation of material on a substrate platform such that a boundary of the second foundation matches with a boundary of a second monolith, wherein the second foundation is higher than the first foundation;
placing the first and second monoliths against the first and second foundations, respectively; and
welding, using an energy beam, the first monolith to the first foundation and the second monolith to the second foundation;
wherein a height of the first monolith is greater than a height of the first foundation.
13. The method of claim 12 , wherein the welding comprises creating a vacuum in a vacuum chamber, wherein the energy beam and the first and second monoliths are disposed inside the vacuum chamber, wherein the first and second monoliths are moved from a first position to a second position against the first and second foundations, respectively, without interrupting the vacuum in the vacuum chamber.
14. The method of claim 12 , wherein a height of the first foundation is at least half of a diameter of the energy beam.
15. The method of claim 12 , wherein the second foundation is higher than the first foundation by at least half of the diameter of the energy beam.
16. The method of claim 12 , further comprising face milling surfaces of each of the first and second foundations.
17. The method of claim 12 , further comprising machining the boundaries of the first and second foundations to match with details of the boundaries of the first and second monoliths.
18. The method of claim 12 , further comprising depositing layers of material on the first or second monolith to create geometry on top of the first or second monolith or joining adjacent monoliths.
19. The method of claim 12 , further comprising depositing layers of material adjacent to the first or second monolith to join the first or second monolith.
20. The method of claim 12 , wherein the energy beam used to weld each of the monoliths to its respective foundation is parallel to the substrate platform.
21. The method of claim 12 , wherein the energy beam is an electron beam.
22. A direct manufacturing system comprising:
means for depositing a first foundation of material on a substrate platform such that a boundary of the first foundation matches with a boundary of a first monolith;
means for depositing a second foundation of material on a substrate platform such that a boundary of the second foundation matches with a boundary of a second monolith, wherein the second foundation is higher than the first foundation;
means for placing the first and second monoliths against the first and second foundations, respectively; and
means for welding, using an energy beam, the first monolith to the first foundation and the second monolith to the second foundation;
wherein a height of the first monolith is greater than a height of the first foundation.
23. The direct manufacturing system of claim 22 , wherein a height of the first foundation is at least half of a diameter of the energy beam.
24. The direct manufacturing system of claim 22 , wherein the second foundation is higher than the first foundation by at least half of the diameter of the energy beam.
25. The direct manufacturing system of claim 22 , wherein the means for welding comprises creating a vacuum in a vacuum chamber, wherein the energy beam and the first and second monoliths are disposed inside the vacuum chamber, wherein the first and second monoliths are moved from a first position to a second position against the first and second foundations, respectively, without interrupting the vacuum in the vacuum chamber.