Additively manufactured rotors for superchargers and expanders

1. A method of making a rotor comprising:

(a) defining a printing order for the application of a first material;

(b) creating a first rotor end face by adding the first material in the printing order;

(c) creating a plurality of lobes arranged helically about a central opening or a shaft by adding the first material in the printing order, each of the plurality of lobes defining an interior cavity;

(d) creating a second rotor end face by adding the first material in the printing order to at least partially enclose the interior cavity defined by each of the plurality of lobes; and

(e) creating an abradable coating by adding material onto the outer surface of the plurality of lobes.

2. The method of making a rotor of claim 1 , wherein the step of creating the plurality of lobes includes first printing a base.

3. The method of making a rotor of claim 1 , further including the step of creating a reaming hole in the first rotor end face for each of the plurality of lobes.

4. The method of making a rotor of claim 1 , wherein the step of creating the plurality of lobes includes creating a lattice structure within the interior cavity of each of the plurality of lobes.

5. The method of making a rotor of claim 1 , further including the step of mounting the printed rotor onto a shaft, wherein the shaft is formed from a metal material and the first material is a metal material.

6. The method of making a rotor of claim 1 , wherein the first material is one or more of a steel, a stainless steel, an aluminum alloy.

7. The method of making a rotor of claim 1 , wherein each of the plurality of lobes has a wall thickness that is 20 percent or less of a maximum width of the plurality of lobes.

8. The method of making a rotor of claim 5 , wherein the first material is added to the shaft to form each of the plurality of lobes by one of selective laser sintering, selective laser melting, stereolithography, fused deposition modeling, coaxial powder feeding, and wire feeding.

9. The method of making a rotor of claim 1 , wherein the step of creating the second rotor end face includes adding material on an inside surface of each of the plurality of lobes defining the interior cavity at an angle between 30 to 60 degrees with respect to a longitudinal axis of the rotor to close off the interior cavity.

10. The method of making a rotor of claim 1 , wherein the step of creating the abradable coating includes by adding a second material, different from the first material, onto the outer surface of the plurality of lobes.

11. The method of making a rotor of claim 10 , wherein the second material is added at a second material porosity that is higher than a first material porosity at which the first material is added.

12. The method of making a rotor of claim 1 , wherein the abradable coating is applied with the first material in a matrix pattern onto the outer surface of the plurality of lobes.

13. The method of making a rotor of claim 10 , wherein the second material has a lower hardness and abradability than that of the first material.

14. The method of making a rotor of claim 4 , further including the step of injecting a foam or polymer into the lattice structure.

15. A method of making a rotor comprising:

(e) defining a printing order for the application of a first material and a second material;

(f) creating a first rotor end face by adding the first material in the printing order;

(g) creating a plurality of lobes arranged about a central opening or a shaft by adding the first material in the printing order, each of the plurality of lobes defining a convex shaped outer perimeter and defining an interior cavity located at least partially within the convex shaped outer perimeter;

(h) creating a second rotor end face by adding the first material in the printing order to at least partially enclose the interior cavity defined by each of the plurality of lobes; and

(i) creating an abradable coating by adding the second material onto an outer surface of the plurality of lobes.

16. The method of making a rotor of claim 15 , wherein the step of creating the plurality of lobes includes creating a lattice structure within the interior cavity of each of the plurality of lobes.

17. The method of making a rotor of claim 15 , further including the step of mounting the printed rotor onto a shaft, wherein the shaft is formed from a metal material and the first material is a metal material.

18. The method of making a rotor of claim 15 , wherein the first material is one or more of a steel, a stainless steel, and an aluminum alloy.

19. The method of making a rotor of claim 15 , wherein each of the plurality of lobes has a wall thickness that is 20 percent or less of a maximum width of the plurality of lobes.

20. The method of making a rotor of claim 19 , wherein the first material is added to the shaft to form each of the plurality of lobes by one of selective laser sintering, selective laser melting, stereolithography, fused deposition modeling, coaxial powder feeding, and wire feeding.

21. The method of making a rotor of claim 15 , wherein the step of creating the second rotor end face includes adding material on an inside surface of each of the plurality of lobes defining the interior cavity at an angle between 30 to 60 degrees with respect to a longitudinal axis of the rotor to close off the interior cavity.

22. The method of making a rotor of claim 15 , wherein the second material is added at a second material porosity that is higher than a first material porosity at which the first material is added.

23. The method of making a rotor of claim 15 , wherein the second material is applied in a matrix pattern onto the outer surface of the plurality of lobes.

24. The method of making a rotor of claim 15 , wherein the second material has a lower hardness and abradability than that of the first material.

25. The method of making a rotor of claim 16 , further including the step of injecting a foam or polymer into the lattice structure.