Apparatus and methods for production additive manufacturing

1. An additive manufacturing apparatus, comprising:

a build module comprising:

a build chamber;

a powder recovery chamber; and

a build-module worksurface including a build chamber opening communicating with the build chamber; and

at least one of but less than all of the following elements:

(a) a directed energy source;

(b) a powder supply; and

(c) a powder applicator; and

a workstation comprising:

the remainder of elements (a)-(c) not included in the build module; and

an enclosure sized to enclose the build module, the directed energy source, the powder supply, and the powder applicator; and

a transport mechanism comprising a conveyor or a turntable disposed partially within the enclosure and defining a transport-mechanism worksurface configured to receive the build module therein, the transport-mechanism worksurface being coplanar with the build-module worksurface so as to define a virtual workplane, and the transport mechanism being configured to move the build module in to and out of the workstation.

2. The apparatus of claim 1 wherein the build module includes:

a peripheral wall extending past the build-module worksurface opposite the build chamber to define a workspace; and

a window transparent to radiant energy that spans across the peripheral wall to close off the workspace.

3. The apparatus of claim 2 wherein the enclosure comprises one or more seals configured to allow the build module to pass therethrough.

4. An additive manufacturing apparatus, comprising:

a plurality of workstations and build modules according to claim 1 ; and

an electronic central controller operably connected to each of the workstations.

5. An additive manufacturing apparatus, comprising:

a plurality of workstations and build modules according to claim 1 ; and

a central shielding gas supply coupled to each of the workstations.

6. An additive manufacturing apparatus, comprising:

a plurality of workstations and build modules according to claim 1 ; and

a central cooling fluid supply coupled to each of the workstations.

7. An additive manufacturing apparatus, comprising:

a plurality of workstations and build modules according to claim 1 ; and

a central ventilation system coupled to each of the workstations.

8. An additive manufacturing apparatus, comprising:

a workstation comprising:

a directed energy source;

an enclosure sized to enclose a build module;

a powder supply contained within the enclosure;

a build module, comprising:

a first build chamber;

a powder recovery chamber;

a build-module worksurface including a build chamber opening communicating with the first build chamber; and

a peripheral wall extending past the build-module worksurface opposite the first build chamber to define a workspace; and

a transport mechanism operable to move the build module into and out of the workstation, the transport mechanism comprising a turntable or a conveyor disposed partially within the enclosure and defining a transport-mechanism worksurface configured to receive the build module therein, the transport-mechanism worksurface being coplanar with the build-module worksurface so as to define a virtual workplane;

wherein the powder supply is configured to drop powder onto the transport-mechanism worksurface; and

wherein the workstation further comprises a moveable powder applicator disposed in the workspace and contacting the transport-mechanism worksurface.

9. The apparatus of claim 8 wherein each module includes a window transparent to radiant energy that spans across the peripheral wall to close off the workspace.

10. The apparatus of claim 8 wherein the enclosure comprises one or more seals configured to allow the build module to pass therethrough.