Method of forming an article

Abstract

A method of making an article includes determining the greatest dimension of an article along a selected axis, and manufacturing a first part of the article between an end and a face lying in the laterally extending plane containing the dimension. The method further includes placing the article on the support of direct layer deposition (DLD) apparatus with the face upwards, and forming the remaining part of the article using the DLD apparatus.

1 . A method of making an article including:
 (a) determining the greatest dimension of an article along a selected axis;   (b) manufacturing a first part of the article between an end and a face lying in the laterally extending plane containing the dimension;   (c) placing the article on the support of direct layer deposition (DLD) apparatus with the face upwards; and   (d) forming the remaining part of the article using the DLD apparatus.   
     
     
         2 . A method as claimed in  claim 1 , wherein the part is clamped to the support. 
     
     
         3 . A method as claimed in  claim 1  wherein the DLD apparatus is by either a selective laser sintering apparatus or a selective laser melt apparatus. 
     
     
         4 . A method as claimed in  claim 2  wherein the DLD apparatus is by either a selective laser sintering apparatus or a selective laser melt. 
     
     
         5 . A method as claimed in  claim 1 , wherein the step (d) joins the forming remaining part to the first part. 
     
     
         6 . A method as claimed in  claim 2  wherein the step (d) joins the remaining part to the first part. 
     
     
         7 . A method as claimed in  claim 1 , wherein the parts are of different materials. 
     
     
         8 . A method of making a complex object by joining an already built part to a further part by using the same method for joining as to build that further part. 
     
     
         9 . A method as claimed in  claim 8  where the further part is made by Direct Laser Deposition 
     
     
         10 . A method as claimed in  claim 9  where the Direct Laser Deposition method is a selective laser sintering or melting method. 
     
     
         11 . A method as claimed in  claim 1  where the material melted or sintered is a metal or metal alloy. 
     
     
         12 . A method as claimed in  claim 11  where the material of either or both the already built and further parts is a high temperature metal or alloy such as titanium or a ‘super alloy’ such as cobalt chrome or a nickel or nickel/iron based alloy. 
     
     
         13 . A method as claimed in  claim 1  wherein an attachment part for the first part is formed at the same time and by the same means as the first part whereby the first part, once removed can be relocated and clamped to this attachment part to provide accurate location during the building of the second part. 
     
     
         14 . A method as claimed in  claim 8  wherein an attachment part for the first part is formed at the same time and by the same means as the first part whereby the first part, once removed can be relocated and clamped to this attachment part to provide accurate location during the building of the second part.