Apparatus and methods for optimization of powder removal features in additively manufactured components

Abstract

Techniques for optimizing powder hole removal are disclosed. In one aspect, an apparatus for inserting powder removal features may identify what powder removal features are optimal for a given AM component, as well as the optimal location and physical characteristics of these features. The features are automatedly added to the component, and an FEA test is run. In the event of failure, the offending feature is removed and the process is repeated. If successful then the loose powder may be removed in a post-processing step following AM.

What is claimed is: 
     
         1 . A method for automatedly inserting powder removal features in an additively manufactured component, the method comprising:
 receiving a model of a component to be additively manufactured;   automatedly determining optimal size and location of one or more apertures in the component for powder removal; and   updating the model to include the one or more determined powder removal apertures.   
     
     
         2 . The method of  claim 1 , further comprising additively manufacturing the component based on the updated model. 
     
     
         3 . The method of  claim 2 , further comprising removing trapped powder from the additively manufactured component using the one or more powder removal apertures. 
     
     
         4 . The method of  claim 1 , wherein the automatedly determining optimal size and location of the one or more apertures comprises evaluating potential gravitational advantages for facilitating powder removal. 
     
     
         5 . The method of  claim 1 , wherein the automatedly determining optimal size and location of the one or more apertures comprises selecting an aperture size based at least in part on a type of material to be used as powder particles in the additive manufacturing of the component. 
     
     
         6 . The method of  claim 1 , wherein the automatedly determining optimal size and location of the one or more apertures comprises evaluating loading and boundary conditions for the component. 
     
     
         7 . The method of  claim 1 , further comprising automatedly determining geometry and location of one or more powder channels for removing powder after additively manufacturing the component. 
     
     
         8 . The method of  claim 7 , wherein the automatedly determining geometry and location of the one or more powder channels comprises identifying a shortest removal path. 
     
     
         9 . The method of  claim 7 , wherein the automatedly determining geometry and location of the one or more powder channels comprises identifying a path of least material resistance. 
     
     
         10 . The method of  claim 7 , wherein the automatedly determining geometry and location of the one or more powder channels comprises evaluating potential gravitational advantages for facilitating powder removal. 
     
     
         11 . The method of  claim 1 , wherein the automatedly determining optimal size and location of the one or more apertures comprises specifying an aerodynamic contour for the aperture to facilitate subsequent powder removal through air flow. 
     
     
         12 . The method of  claim 7 , wherein the automatedly determining geometry and location of the one or more powder channels comprises specifying an aerodynamic contour for the one or more powder channels to facilitate subsequent powder removal through air flow. 
     
     
         13 . The method of  claim 1 , wherein the automatedly determining optimal size and location of the one or more apertures comprises evaluating at least one of powder material, powder particle size distribution, average powder flow rate, and powder type. 
     
     
         14 . The method of  claim 7 , wherein the automatedly determining size and placement of the one or more powder channels comprises evaluating at least one of powder material, powder particle size distribution, average powder flow rate, and powder type. 
     
     
         15 . A method for removing powder from an additively manufactured component having at least one aperture, comprising:
 receiving a data model of the component;   additively manufacturing the component based on the data model;   removing trapped powder from the additively manufactured component using the at least one aperture; and   performing a layup process using at least one material to seal the aperture.