Surface level control systems and material recycling systems for use with programmable material consolidation apparatus

Abstract

A surface level control system for use with a fabrication tank of a programmable material consolidation apparatus includes at least one aperture with a lowermost edge located at about the same elevation as a desired surface level for unconsolidated material within the fabrication tank. The surface level control system may also include a receptacle for receiving unconsolidated material that has been removed from the fabrication tank. The surface level control system may be configured to constantly allow for the removal of unconsolidated material, or it may be configured to selectively remove unconsolidated material. One or more sensors may be used to monitor the surface level and provide information that may be used in maintaining the surface level at a substantially constant elevation. A recycling system may be used in conjunction with or separately from a surface level control system to reintroduce unconsolidated material back into the fabrication tank.

1 . A surface level control system for a fabrication tank of a programmable material consolidation apparatus, comprising: 
 at least one aperture defined in a wall of the fabrication tank; and    at least one receptacle in communication with the at least one aperture for receiving unconsolidated material therefrom.    
   
   
       2 . The surface level control system of  claim 1 , wherein the at least one aperture and the at least one receptacle are configured to maintain a level of unconsolidated material within the fabrication tank at a substantially constant elevation.  
   
   
       3 . The surface level control system of  claim 1 , wherein the at least one aperture is configured and located so as to remove a displaced volume of the unconsolidated material from the fabrication tank.  
   
   
       4 . The surface level control system of  claim 1 , wherein a lowermost edge of the at least one aperture is positioned at about the same elevation as a desired surface level for unconsolidated material within the fabrication tank.  
   
   
       5 . The surface level control system of  claim 1 , wherein a lowermost edge of the at least one aperture is positioned at about the same elevation as a focal point plane for consolidating radiation within the fabrication tank.  
   
   
       6 . The surface level control system of  claim 1 , wherein the at least one aperture is in constant communication with the at least one receptacle.  
   
   
       7 . The surface level control system of  claim 1 , wherein the at least one aperture is in selective communication with the at least one receptacle.  
   
   
       8 . The surface level control system of  claim 7 , further comprising: 
 at least one sensor for monitoring a surface level of unconsolidated material within the fabrication tank.    
   
   
       9 . The surface level control system of  claim 1 , wherein the at least one receptacle comprises a container.  
   
   
       10 . The surface level control system of  claim 1 , wherein the receptacle comprises or is in communication with a material recycling element for reintroducing unconsolidated material into the fabrication tank.  
   
   
       11 . The surface level control system of  claim 10 , wherein the material recycling element communicates with a fluid inflow element in communication with the fabrication tank.  
   
   
       12 . A programmable material consolidation apparatus, comprising: 
 a fabrication tank for containing unconsolidated material, the fabrication tank including a fabrication elevation; and    a surface level control system in communication with the fabrication tank and comprising at least one aperture including a lowermost edge positioned so as to maintain a surface level of the unconsolidated material substantially at the fabrication elevation of the fabrication tank.    
   
   
       13 . The programmable material consolidation apparatus of  claim 12 , wherein the surface level control system further comprises at least one receptacle in communication with the at least one aperture.  
   
   
       14 . The programmable material consolidation apparatus of  claim 12 , wherein the at least one aperture of the surface level control system constantly remains open.  
   
   
       15 . The programmable material consolidation apparatus of  claim 12 , wherein the surface level control system is configured to selectively remove unconsolidated material from the fabrication tank.  
   
   
       16 . The programmable material consolidation apparatus of  claim 15 , wherein the surface level control system includes at least one sensor for monitoring the surface level of the unconsolidated material.  
   
   
       17 . The programmable material consolidation apparatus of  claim 12 , wherein surface level control system comprises or communicates with a material recycling system.  
   
   
       18 . The programmable material consolidation apparatus of  claim 17 , wherein the material recycling system is configured to reintroduce unconsolidated material into the fabrication tank.  
   
   
       19 . A material recycling system for use with a fabrication tank of a programmable material consolidation apparatus, comprising: 
 a receptacle for unconsolidated material from the fabrication tank; and    an input element for returning the unconsolidated material to the fabrication tank.    
   
   
       20 . The material recycling system of  claim 19 , further comprising: 
 at least one sensor for monitoring a surface level of unconsolidated material within the fabrication tank.    
   
   
       21 . The material recycling system of  claim 20 , wherein the at least one sensor provides information useful in determining a volume of unconsolidated material to be removed from the fabrication tank or introduced into the fabrication tank to maintain the surface level at a substantially constant elevation.