System And Method For Additive Manufacturing

Abstract

An additive manufacturing system may include a table, a supporting structure, a first powder dispenser, and a second powder dispenser. The table is rotatable about a first rotational axis. The supporting structure may be mounted for movement relative to the table. The first powder dispenser may be mounted to the supporting structure and may extend radially across the table. The first powder dispenser includes a first outlet disposed vertically above the table. The second powder dispenser may be mounted to the supporting structure and may extend radially across the table. The second powder dispenser includes a second outlet disposed vertically above the table. The table is rotatable about the first rotational axis relative to the supporting structure and the first and second powder dispensers. The first and second powder dispensers may be movable with the supporting structure relative to the table in a direction parallel to the first rotational axis.

What is claimed is: 
     
         1 . A system comprising:
 a table rotatable about a first rotational axis;   a supporting structure mounted for movement relative to the table;   a first powder dispenser mounted to the supporting structure and extending radially across the table, the first powder dispenser having a first outlet disposed vertically above the table; and   a second powder dispenser mounted to the supporting structure and extending radially across the table, the second powder dispenser having a second outlet disposed vertically above the table,   wherein the table is rotatable about the first rotational axis relative to the supporting structure and the first and second powder dispensers, and wherein the first and second powder dispensers are movable with the supporting structure relative to the table in a direction parallel to the first rotational axis.   
     
     
         2 . The system of  claim 1 , further comprising a binder dispenser mounted to the supporting structure and extending radially across the table, the binder dispenser having a third outlet disposed vertically above the table, wherein the binder dispenser is circumferentially spaced apart from the first and second powder dispensers, wherein the binder dispenser is movable with the supporting structure relative to the table in the direction parallel to the first rotational axis. 
     
     
         3 . The system of  claim 2 , further comprising a compacting roller mounted to the supporting structure and disposed vertically above the table, wherein the compacting roller is rotatable relative to the supporting structure and the table about a second rotational axis that is angled relative to the first rotational axis. 
     
     
         4 . The system of  claim 3 , wherein the compacting roller includes a frustoconical rolling surface. 
     
     
         5 . The system of  claim 3 , wherein the compacting roller is disposed circumferentially between the second powder dispenser and the binder dispenser. 
     
     
         6 . The system of  claim 2 , further comprising a curing element attached to the supporting structure and extending radially across the table, wherein the curing element is disposed vertically above the table, and wherein the binder dispenser is disposed circumferentially between the curing element and the second powder dispenser. 
     
     
         7 . The system of  claim 6 , wherein the curing element includes at least one of a heat source and an ultraviolet light source. 
     
     
         8 . The system of  claim 1 , further comprising a third powder dispenser mounted to the supporting structure and extending radially across the table, the third powder dispenser having a fourth outlet disposed vertically above the table, wherein the third powder dispenser is circumferentially spaced apart from the first and second powder dispensers, wherein the third powder dispenser is movable with the supporting structure relative to the table in the direction parallel to the first rotational axis. 
     
     
         9 . The system of  claim 1 , wherein the first and second powder dispensers are rotationally fixed relative to the first rotational axis. 
     
     
         10 . A system comprising:
 a table rotatable about a first rotational axis;   a first powder dispenser extending radially across the table, the first powder dispenser having a first outlet disposed vertically above the table;   a second powder dispenser extending radially across the table, the second powder dispenser having a second outlet disposed vertically above the table; and   a binder dispenser extending radially across the table, the binder dispenser having a third outlet disposed vertically above the table, wherein the binder dispenser is circumferentially spaced apart from the first and second powder dispensers,   wherein the table is rotatable about the first rotational axis relative to the first and second powder dispensers and the binder dispenser, wherein the first and second powder dispensers and the binder dispenser are movable relative to the table in a direction parallel to the first rotational axis, and wherein the first and second powder dispensers and the binder dispenser are rotationally fixed relative to each other.   
     
     
         11 . The system of  claim 10 , further comprising a supporting structure supporting the first and second powder dispensers and the binder dispenser and movable with the first and second powder dispensers and the binder dispenser in the direction parallel to the first rotational axis. 
     
     
         12 . The system of  claim 11 , further comprising a compacting roller mounted to the supporting structure and extending radially across the table from the supporting structure, wherein the compacting roller is disposed vertically above the table, wherein the compacting roller is rotatable relative to the supporting structure and the table about a second rotational axis that is angled relative to the first rotational axis. 
     
     
         13 . The system of  claim 12 , wherein the second rotational axis is disposed at a non-perpendicular angle relative to the first rotational axis. 
     
     
         14 . The system of  claim 12 , wherein the supporting structure is disposed radially inward relative to an inner diameter of the table, and wherein the first and second powder dispensers, the binder dispenser and the compacting roller extend radially outward from the supporting structure. 
     
     
         15 . The system of  claim 12 , wherein the compacting roller includes a frustoconical rolling surface. 
     
     
         16 . The system of  claim 12 , wherein the compacting roller is disposed circumferentially between the second powder dispenser and the binder dispenser. 
     
     
         17 . The system of  claim 10 , further comprising a curing element extending radially across the table, wherein the curing element is disposed vertically above the table, and wherein the binder dispenser is disposed circumferentially between the curing element and the second powder dispenser. 
     
     
         18 . The system of  claim 10 , further comprising a third powder dispenser extending radially across the table, the third powder dispenser having a fourth outlet disposed vertically above the table, wherein the third powder dispenser is circumferentially spaced apart from the first and second powder dispensers and the binder dispenser, and wherein the third powder dispenser is movable with the first and second powder dispensers and the binder dispenser relative to the table in the direction parallel to the first rotational axis. 
     
     
         19 . A manufacturing method comprising:
 rotating a table about a first rotational axis;   dispensing a powdered magnetically susceptible material onto the table while the table is rotating;   dispensing a powdered insulating material onto the table while the table is rotating;   dispensing a binder material onto the table while the table is rotating;   forming a plurality of first layers of the magnetically susceptible material on the table; and   forming a plurality of second layers of the insulating material on the table, wherein each of the second layers is disposed axially between adjacent first layers.   
     
     
         20 . The method of  claim 19 , further comprising removing the first and second layers from the table and subsequently heating the first and second layers in an oven. 
     
     
         21 . The method of  claim 19 , wherein the first and second layers are discrete layers. 
     
     
         22 . The method of  claim 19 , wherein the first and second layers cooperate to form a single, continuous helical coil. 
     
     
         23 . The method of  claim 19 , further comprising:
 compacting the powdered magnetically susceptible material on the table using a compacting roller; and   curing the binder material after compacting the powdered magnetically susceptible material.   
     
     
         24 . The method of  claim 19 , further comprising forming apertures in the first and second layers by ceasing dispensation of the powdered magnetically susceptible material and the powdered insulating material at selected locations radially between inner and outer diameters of the first and second layers. 
     
     
         25 . The method of  claim 19 , further comprising forming an electrically conductive path through the plurality of first and second layers by dispensing powdered conductive material at selected locations on each of the first and second layers.