Thermal control for additive manufacturing

Abstract

An additive manufacturing system for building a product includes a base plate for mounting the product thereon, and at least one heating element shaped to at least partially conform to the product and configured to apply heat to at least a portion of the product as the product is additively manufactured to reduce thermal gradients in the product.

What is claimed is: 
     
         1 . An additive manufacturing system for building a product, comprising:
 a base plate for mounting the product upon; and   at least one heating element shaped to at least partially conform to the product and configured to apply heat to at least a portion of the product as the product is additively manufactured to reduce thermal gradients in the product.   
     
     
         2 . The system of  claim 1 , wherein the base plate is configured to be heated. 
     
     
         3 . The system of  claim 1 , wherein the heating element includes an electric coil. 
     
     
         4 . The system of  claim 1 , wherein the heating element is conformal to an outer shape of the product. 
     
     
         5 . The system of  claim 1 , further comprising a thermal imaging device positioned to view the product within the heating element for thermal monitoring of the product as it is additively manufactured. 
     
     
         6 . The system of  claim 5 , further comprising a control unit operatively connected to the thermal imaging device and the heating element to control the heating element as a function of feedback from the thermal imaging device to reduce thermal gradients in the product. 
     
     
         7 . The system of  claim 1 , further comprising an energy applicator positioned to apply energy within the heating element for layer-wise powder fusion. 
     
     
         8 . A method for additively manufacturing a product, comprising:
 additively manufacturing a product on a base plate and within a heating element; and   applying heat to a portion of the product during additive manufacturing to reduce thermal gradients in the product, wherein heating the product occurs within a heating element configured to at least partially conform to the product.   
     
     
         9 . The method of  claim 8 , wherein additive manufacturing the product includes depositing powder within the heating element. 
     
     
         10 . The method of  claim 9 , further comprising applying energy from an energy applicator to the powder within the heating element to sinter the powder within the heating element. 
     
     
         11 . The method of  claim 8 , further comprising controlling the heating element as a function of feedback from a thermal imaging device to reduce thermal gradients in the product. 
     
     
         12 . The method of  claim 8 , further comprising heating the base plate that the product is mounted on.