Abstract: A method that includes additively manufacturing with an additive manufacturing (AM) system a sub-component that has a locator element. Using a control system of the AM system for positioning a first location of the locator element. Selectively placing a portion of another sub-component adjacent to the locator element, based on the positioning. Then attaching the second sub-component to the first sub-component in a region, wherein the region is based on the positioning knowledge from the control system so as to make a component. A component that comprises a first sub-component that has an AM locator element; and a second sub-component attached to the first sub-component, wherein the locator element is attached to the second sub-component within the same additive manufacturing build chamber as the first sub-component.
WE CLAIM:
1. A method comprising:
additively manufacturing with an additive manufacturing system a first sub-component having at least one locator element, thereby using a control system of the additive manufacturing system for positioning a first location of the at least one locator element;
selectively placing a portion of a second sub-component adjacent to the at least one locator element of the first sub-component, based on the positioning; and
attaching the second sub-component to the first sub-component in a region, wherein the region is based on the positioning from the control system of said additive manufacturing system, thereby defining a component.
2. The method as claim in claim 1, wherein the attaching comprises welding with a welding source.
3. The method as claim in claim 2, wherein the welding source comprises a laser.
4. The method as claim in claim 2, wherein the welding comprises one of: gas welding, e-beam welding, friction stir welding, ultrasonic welding, and thermal welding.
5. The method as claim in claim 1, wherein the second sub-component is additively manufactured.
6. The method as claim in claim 3, wherein the additively manufacturing further comprises additively manufacturing the first sub-component and the second sub-component as a monolithic workpiece.
7. The method as claim in claim 6, wherein the selectively placing further comprises rotating the second sub-component from the monolithic workpiece towards the first sub-component.
8. The method as claim in claim 7, wherein during the rotating the second sub-component remains attached to the first sub-component.
9. The method as claim in claim 1, wherein the second sub-component is manufactured via at least one of: casting, extrusion, rolling, forging, and machining.
10. The method as claim in claim 1, wherein the additively manufacturing, selectively placing, and attaching are done in a common build chamber.
11. The method as claim in claim 1, wherein the additively manufacturing comprises direct metal laser melting (DMLM).
12. The method as claim in claim 5, wherein the first sub-component and the second sub-component are additively manufactured on a shared build plate in a common build chamber.
13. The method as claim in claim 1, wherein at least one locator element further comprises at least one support element.
14. The method as claim in claim 13, wherein a portion of the second sub-component comprises a bearing surface configured to bear at least in part on said at least one support element.
15. The method as claim in claim 1, wherein the selectively placing comprises manually or robotically placing the second sub-component on the first sub-component.
16. The method as claim in claim 4, wherein the thermally welding comprises laser welding in a pulsed-mode.
17. The method as claim in claim 1, wherein a portion of the component comprises a substantially horizontal surface.
18. The method as claim in claim 17, wherein the substantially horizontal surface comprises a substantially downward facing surface.
19. The method as claim in claim 1, wherein a portion of the component comprises one of: a tube, an arch, and an overhang.
20. The method as claim in claim 1, wherein the component comprises one of: an open chamber and a closed chamber.
21. The method as claim in claim 1, after attaching further comprising one of:
additively manufacturing the component;
attaching a third sub-component to the component; and
attaching the component to a second component.
22. A component manufactured by the method as claim in claim 1.
23. A component comprising:
a first sub-component, wherein the first sub-component has an additively manufactured locator element; and
a second sub-component attached to the first sub-component, wherein the additively manufactured locator element is attached to the second sub-component within the same additive manufacturing build chamber as the first sub-component.
24. The component as claim in claim 23, wherein at least one of the first and second sub-components has at least one substantially downward facing surface.
25. The component as claim in claim 24, wherein the at least one substantially downward facing surface comprises a portion of one of: a tube, an arch, a sculpted surface, and an overhang.
26. The component as claim in claim 23, the first sub-component comprises a support element and the second sub-component comprises a bearing surface configured to bear on the support element.
27. The component as claim in claim 26, the support element and the bearing surface define a connection region, wherein the connection region is thermally welded.
28. The component as claim in claim 27, wherein the connection region is thermally welded with a laser operating in a pulsed-mode.
29. The component as claim in claim 27, further comprising a space beneath the connection region.
30. The component as claim in claim 27, wherein a portion of the connection region is recessed.
| # | Name | Date |
|---|---|---|
| 1 | 201644022415-IntimationOfGrant20-10-2022.pdf | 2022-10-20 |
| 1 | Power of Attorney [30-06-2016(online)].pdf | 2016-06-30 |
| 2 | 201644022415-PatentCertificate20-10-2022.pdf | 2022-10-20 |
| 2 | Form 5 [30-06-2016(online)].pdf | 2016-06-30 |
| 3 | Form 3 [30-06-2016(online)].pdf | 2016-06-30 |
| 3 | 201644022415-CLAIMS [15-05-2020(online)].pdf | 2020-05-15 |
| 4 | Form 18 [30-06-2016(online)].pdf_131.pdf | 2016-06-30 |
| 4 | 201644022415-COMPLETE SPECIFICATION [15-05-2020(online)].pdf | 2020-05-15 |
| 5 | Form 18 [30-06-2016(online)].pdf | 2016-06-30 |
| 5 | 201644022415-FER_SER_REPLY [15-05-2020(online)].pdf | 2020-05-15 |
| 6 | Drawing [30-06-2016(online)].pdf | 2016-06-30 |
| 6 | 201644022415-FORM 3 [15-05-2020(online)].pdf | 2020-05-15 |
| 7 | Description(Complete) [30-06-2016(online)].pdf | 2016-06-30 |
| 7 | 201644022415-Information under section 8(2) [15-05-2020(online)].pdf | 2020-05-15 |
| 8 | 201644022415-Power of Attorney-010816.pdf | 2016-08-23 |
| 8 | 201644022415-OTHERS [15-05-2020(online)].pdf | 2020-05-15 |
| 9 | 201644022415-PETITION UNDER RULE 137 [15-05-2020(online)].pdf | 2020-05-15 |
| 9 | abstract-201644022415-jpeg.jpg | 2016-10-05 |
| 10 | 201644022415-Proof of Right [15-05-2020(online)].pdf | 2020-05-15 |
| 10 | Notarial Certificate_As Filed_12-11-2016.pdf | 2016-11-12 |
| 11 | 201644022415-FER.pdf | 2019-11-22 |
| 11 | Form30_Notarial Certificate_12-11-2016.pdf | 2016-11-12 |
| 12 | Correspondence by Agent_Form26_14-03-2019.pdf | 2019-03-14 |
| 12 | Correspondence by Agent_Priority Document_17-11-2016.pdf | 2016-11-17 |
| 13 | 201644022415-FORM-26 [06-03-2019(online)].pdf | 2019-03-06 |
| 13 | 201644022415-RELEVANT DOCUMENTS [28-02-2019(online)].pdf | 2019-02-28 |
| 14 | 201644022415-FORM 13 [28-02-2019(online)].pdf | 2019-02-28 |
| 15 | 201644022415-FORM-26 [06-03-2019(online)].pdf | 2019-03-06 |
| 15 | 201644022415-RELEVANT DOCUMENTS [28-02-2019(online)].pdf | 2019-02-28 |
| 16 | Correspondence by Agent_Form26_14-03-2019.pdf | 2019-03-14 |
| 16 | Correspondence by Agent_Priority Document_17-11-2016.pdf | 2016-11-17 |
| 17 | Form30_Notarial Certificate_12-11-2016.pdf | 2016-11-12 |
| 17 | 201644022415-FER.pdf | 2019-11-22 |
| 18 | Notarial Certificate_As Filed_12-11-2016.pdf | 2016-11-12 |
| 18 | 201644022415-Proof of Right [15-05-2020(online)].pdf | 2020-05-15 |
| 19 | 201644022415-PETITION UNDER RULE 137 [15-05-2020(online)].pdf | 2020-05-15 |
| 19 | abstract-201644022415-jpeg.jpg | 2016-10-05 |
| 20 | 201644022415-OTHERS [15-05-2020(online)].pdf | 2020-05-15 |
| 20 | 201644022415-Power of Attorney-010816.pdf | 2016-08-23 |
| 21 | 201644022415-Information under section 8(2) [15-05-2020(online)].pdf | 2020-05-15 |
| 21 | Description(Complete) [30-06-2016(online)].pdf | 2016-06-30 |
| 22 | 201644022415-FORM 3 [15-05-2020(online)].pdf | 2020-05-15 |
| 22 | Drawing [30-06-2016(online)].pdf | 2016-06-30 |
| 23 | 201644022415-FER_SER_REPLY [15-05-2020(online)].pdf | 2020-05-15 |
| 23 | Form 18 [30-06-2016(online)].pdf | 2016-06-30 |
| 24 | 201644022415-COMPLETE SPECIFICATION [15-05-2020(online)].pdf | 2020-05-15 |
| 24 | Form 18 [30-06-2016(online)].pdf_131.pdf | 2016-06-30 |
| 25 | Form 3 [30-06-2016(online)].pdf | 2016-06-30 |
| 25 | 201644022415-CLAIMS [15-05-2020(online)].pdf | 2020-05-15 |
| 26 | Form 5 [30-06-2016(online)].pdf | 2016-06-30 |
| 26 | 201644022415-PatentCertificate20-10-2022.pdf | 2022-10-20 |
| 27 | Power of Attorney [30-06-2016(online)].pdf | 2016-06-30 |
| 27 | 201644022415-IntimationOfGrant20-10-2022.pdf | 2022-10-20 |
| 1 | 2019-09-2616-52-22_26-09-2019.pdf |