WO2019014257A1

WO2019014257A1 - Systems and methods for automated powder handling and dispensing

Info

Publication number: WO2019014257A1
Application number: PCT/US2018/041495
Authority: WO
Inventors: David W. Heard; William J. STEINER
Original assignee: Arconic Inc
Current assignee: Howmet Aerospace Inc
Priority date: 2017-07-10
Filing date: 2018-07-10
Publication date: 2019-01-17
Anticipated expiration: 2020-01-10

Abstract

In some embodiments of the disclosure, an apparatus for dispensing a powder mixture is provided, comprising: a plurality of input containers configured to retain a source powder; a mixing container configured to mix the source powder received from the plurality of input containers into a powder bled; a feed system fluidly coupling the plurality of input containers to the mixing container, wherein the feed system is configured to feed source powder from the plurality of input containers to the mixing container; and output container fluidly coupled to the mixing container, wherein the output container is configured to receive the powder bled from the mixing container, and wherein the output container is configured to detachable from the apparatus; a control system configured to control powder blend characteristics.

Description

SYSTEMS AND METHODS FOR AUTOMATED POWDER HANDLING AND

DISPENSING

CROSS REFERENCE TO RELATED APPLICATIONS

[0001] This application claims benefit of U.S. provisional patent application Ser. No. 62/530,429 filed July 10, 2017.

FIELD OF THE INVENTION

[0002] Generally, the present disclosure is directed towards various embodiments of an automated powder handling and management system and methods of use thereof. More specifically the present disclosure is directed toward an automated system for handling and dispensing additive manufacturing powders that can be used in a three-dimensional (3D) printing process.

BACKGROUND

[0003] Powder handling and storage, for example, for additive manufacturing powders that can be used in a three-dimensional (3D) printing process can present challenges. For example, the high surface area of powders may result in absorption of water molecules to the surface of the powder when exposed to humidity, which can then have a negative effect on powder properties such as flow and tap density. In addition, accurate mixing, dispensing and inventory management of powders can help eliminate waste and improved safety.

SUMMARY OF THE INVENTION

[0004] In one or more embodiments of the present disclosure, systems and methods for powder mixing, handling, and dispensing are provided. For example, in one or more embodiments of the present disclosure, the systems and/or methods are specifically designed to enable tailored powder mixing at a point of sale, to supply a purchaser with a powdered metal alloy feedstock for additive manufacturing (e.g. 3D printing).

[0005] In some embodiments of the disclosure, an apparatus for dispensing a powder mixture is provided, comprising: a plurality of input containers configured to retain a source powder; a mixing container configured to mix the source powder received from the plurality of input containers into a powder blend; a feed system fluidly coupling the plurality of input containers to the mixing container, wherein the feed system is configured to feed source powder from the plurality of input containers to the mixing container; an output container fluidly coupled to the mixing container, wherein the output container is configured to receive the powder blend from the mixing container, and wherein the output container is configured to detachable from the apparatus; a control system configured to control powder blend characteristics.

[0006] In some embodiments, the source powder is a metal, a polymer, a thermoplastic, or a color pigments.

[0007] In some embodiments, each of the plurality of input containers comprises a body having a hollow volume to retain the source powder.

[0008] In some embodiments, each of the plurality of input containers retains an inert gas.

[0009] In some embodiments, each of the plurality of input containers further comprises an outlet.

[00010] In some embodiments, the body and the outlet are integrally formed.

[00011] In some embodiments, the body is coupled to the outlet via mechanical fasteners.

[00012] In some embodiments, the coupled body and outlet further comprise seals at coupling points to prevent exposure to the atmosphere. [00013] In some embodiments, the outlet comprises a sidewall having a slope configured to gravity feed source powder into the feed system.

[00014] In some embodiments, each of the input containers is sealed to prevent access to the powder inside except via connection to the feed system.

[00015] In some embodiments, each of the input containers comprises a metering valve to control the flow of powder from each input container.

[00016] In some embodiments, the apparatus further comprises a metering area configured to control the flow of powder from each input container to the feed system.

[00017] In some embodiments, the mixing container is fluidly coupled to the plurality of input containers.

[00018] In some embodiments, the mixing container is configured to homogenize one or more source powders into a powder blend.

[00019] In some embodiments, the mixing container comprises a body, an inlet in the body configured to receive source powder from the plurality of input containers, and an outlet in the body to discharge the powder blend.

[00020] In some embodiments, the body of the mixing container comprises a hollow volume to retain the powder blend.

[00021] In some embodiments, the body of the mixing container retains an inert gas.

[00022] In some embodiments, the feed system comprises a first end coupled to the input container.

[00023] In some embodiments, the first end of the feed system is coupled to an opening of the outlet.

[00024] In some embodiments, the feed system comprises a second end. [00025] In some embodiments, the second end of the feed system is coupled to the inlet of the mixing container.

[00026] In some embodiments, the second end of the feed system is coupled to an intermediate powder holder configured to receive source powder from the plurality of input containers via the feed system and transfer the source powder to the mixing container.

[00027] In some embodiments, the intermediate powder holder is configured to weigh source powder from the plurality of input containers.

[00028] In some embodiments, the apparatus further comprises a rotating carousel configured to retain the plurality of input containers.

[00029] In some embodiments, the rotating carousel is configured to position a selected input container to couple to the feed system.

[00030] In some embodiments, the output container comprises a body having a hollow volume to retain the powder blend, an inlet to receive the powder blend from the plurality of input containers, and an outlet to discharge the powder blend.

[00031] In some embodiments, the hollow volume of the mixing container retains an inert gas.

[00032] In some embodiments, the control system is configured to allow a user to select the powder blend composition and the amount (e.g. mass, volume) of powder blend to dispense to the output container.

[00033] In some embodiments, the control system is configured to maintain an inventory of the source powder levels.

[00034] In some embodiments, the control system is configured to alert a user to order more source powder based on powder usage rate. [00035] In some embodiments, the control system is configured to allow the user to save one or more specific predetermined powder blends within the control system.

[00036] In some embodiments, the control system is configured to provide a user with one or more pre-set powder blends.

[00037] In some embodiments, the control system is configured to recommend an amount of powder blend to be dispensed based on the additive manufacturing process used and the object to be additively manufactured.

[00038] In some embodiments, the control system is configured to print labels having barcodes that allow for powder lot tracking and inventory control.

[00039] In some embodiments, the control system is configured to prevent users from mixing potentially dangerous (e.g. explosive) powder combinations.

[00040] In some embodiments, the control system is configured to comply with U.S. Department of Homeland Security chemical facility anti -terrorism act requirements on metal powder storage.

[00041] In some embodiments, the apparatus further comprises one or more sampling points configured to dispense a representative sample of the powder blend.

[00042] In some embodiments, the apparatus further comprises a sample dispensing point to dispense a representative sample of the mixed powder.

[00043] In some embodiments, the apparatus further comprises further comprises an in-situ sampler to analyze a representative sample of the mixed powder.

[00044] In some embodiments, the output container is configured to interface with an apparatus suitable for performing an additive manufacturing process, a hot isostatic pressing process, a metal injection molding process, or powder conform process. [00045] In some embodiments of the disclosure, a method for dispensing a powder mixture is provided, comprising: dispensing a predetermined amount of a plurality of additive manufacturing source powders from a plurality of input containers, wherein the predetermined amount of the additive manufacturing source powders is dispensed into a mixing container; mixing the predetermined amount of the additive manufacturing source powder to form a powder blend; collecting a sample of the powder blend; analyzing the sample to determine powder characteristics; comparing the powder characteristics of the powder blend to the target additive manufacturing powder blend; and dispensing the powder blend to an output container if the powder characteristics of the powder blend match the target additive manufacturing powder blend.

[00046] In some embodiments, the method comprises selecting the powder blend composition and the amount (e.g. mass, volume) of powder blend to dispense to the output container.

[00047] In some embodiments, the method comprises maintaining an inventory of the source powder levels.

[00048] In some embodiments, the method comprises triggering an alert to order more source powder based on powder usage rate.

[00049] In some embodiments, the method comprises selecting one or more pre-set powder blends.

[00050] In some embodiments, the method comprises selecting a recommended amount of powder blend to be dispensed based on the additive manufacturing process used and the object to be additively manufactured.

[00051] In some embodiments, the method comprises printing labels having barcodes that allow for powder lot tracking and inventory control. [00052] In some embodiments of the disclosure, an apparatus comprises: a plurality of input containers, each input container configured to retain a different source powder, wherein the source powder is an additive manufacturing feedstock component or an additive manufacturing feedstock powder (e.g. as used herein different source powder means: different characteristics of the same powder composition, or different powder compositions, or a combination thereof); a feed system fluidly coupling the plurality of input containers and configured to receive the source powder, the source powder having at least one powder from an input container (e.g. a plurality of powders from at least two input containers) and wherein the feed system directs the source powder into a mixing container; wherein the mixing container is configured to receive the source powder from the feed system and mix the source powder into a powder blend; an output container fluidly coupled to the mixing container, wherein the output container is configured to receive the powder blend from the mixing container, and wherein the output container is configured to detach from the apparatus; and a control system configured to tailor powder composition and powder blend to produce a target additive manufacturing feedstock, wherein the plurality of input containers, the feed system, the mixing container, and the output container are configured to retain one of an inert atmosphere or a vacuum.

[00053] In some embodiments of the disclosure, a method comprises: selecting a target additive manufacturing powder feedstock composition (e.g. on a control system); comparing the target additive manufacturing powder feedstock composition to an inventory list, the inventory list including: a plurality of pre blended additive manufacturing powder feedstock compositions and a plurality of component additive manufacturing powder feedstocks; one of: dispensing the pre-blended additive manufacturing powder feedstock to an output container if the target corresponds to a pre-blended additive manufacturing powder feedstock, or if the target does not correspond to a pre-blended AM powder feedstock, then dispensing a predetermined amount of component additive manufacturing powder feedstocks from a plurality of input containers, wherein the predetermined amount of the component additive manufacturing powder feedstocks is dispensed into a mixing container; mixing the predetermined amount of the component additive manufacturing powder feedstocks to form a product additive manufacturing powder feedstock composition; and dispensing the product additive manufacturing powder feedstock composition to an output container.

[00054] In some embodiments, if the target does not correspond to a pre-blended AM powder feedstock, then a sample of the product additive manufacturing powder feedstock composition is collected; the sample is analyzing to determine if the product powder characteristics corresponds to the target powder characteristics; and the product powder is dispensed to the output container, provided the product powder characteristics correspond to the target.

BRIEF DESCRIPTION OF THE DRAWINGS

[00055] Embodiments of the present invention, briefly summarized above and discussed in greater detail below, can be understood by reference to the illustrative embodiments of the invention depicted in the appended drawings. It is to be noted, however, that the appended drawings illustrate only typical embodiments of this invention and are therefore not to be considered limiting of its scope, for the invention may admit to other equally effective embodiments.

[00056] Figure 1 is a schematic view of an automated powder handling and management system in accordance with some embodiments of the present disclosure. [00057] Figure 2 is a schematic view of an automated powder handling and management system in accordance with some embodiments of the present disclosure.

[00058] Figure 3A-3D is a schematic cross-sectional view of a powder container used with an additive manufacturing machine in accordance with some embodiments of the present disclosure.

[00059] Figure 4 is a flow diagram of a method for powder mixing, handling, and dispensing in accordance with some embodiments of the present invention.

[00060] To facilitate understanding, identical reference numerals have been used, where possible, to designate identical elements that are common to the figures. The figures are not drawn to scale and may be simplified for clarity. It is contemplated that elements and features of one embodiment may be beneficially incorporated in other embodiments without further recitation.

DETAILED DESCRIPTION OF THE INVENTION

[00061] Figure 1 and Figure 2 depict exemplary embodiments of an apparatus 100 for dispensing a powder mixture in accordance with some embodiments of the present disclosure. In some embodiments, non-limiting examples of processes for which the apparatus 100 can be adapted to dispense powder blends include: additive manufacturing, hot isostatic pressing, metal injection molding, and powder conform.

[00062] In some embodiments, the apparatus 100 comprises a plurality of input containers 102. In some embodiments, the input containers 102 are replaceable cartridges that can be coupled and decoupled from the apparatus 100. In some embodiments, each input container 102 has a hollow volume to retain a different source powder. [00063] In some embodiments, the source powder is an additive manufacturing feedstock component. In some embodiments, different source powder means different characteristics of the same powder composition, or different powder compositions, or a combination thereof. In some embodiments, the source powder can include but is not limited to: metals, polymers, thermoplastics, and color pigments. In some embodiments, suitable thermoplastics can include but are not limited to polylactic acrylic, acrylonitrile butadiene styrene (ABS), poly ether ether ketone (PEEK), polyetherketoneketone (PEKK), or a combination thereof. In some embodiments, the source powder is suitable for use in an additive manufacturing process (i.e. a process of joining materials to make objects from 3D model data, usually layer upon layer, as opposed to subtractive manufacturing methodologies). In some embodiments, non-limiting examples of source powder suitable for an additive manufacturing process includes aluminum, silicon, magnesium, or a combination thereof.

[00064] In some embodiments, the hollow volume of the input container 102 retains the source powder and an inert gas. In some embodiments, the inert gas is chosen based on the source powder in the input container. In some embodiments, the inert gas is a gas that does not chemically react with the source powder. In some embodiments, the inert gas is a noble gas such as argon, xenon, krypton, or the like. In some embodiments, the inert gas is nitrogen (N₂).

[00065] In some embodiments, the input container 102 has a body 112 having a hollow volume to retain the source powder. In some embodiments, the input container 102 is any suitable shape to hold the source powder, such as cylindrical, circular, or square. In some embodiments, the input container has an outlet 114. In some embodiments, the walls of the outlet 114 may be at a suitable angle to provide a suitable amount of powder flow from the input containers 102. In some embodiments, the walls of outlet 114 may have a curvature and slope to gravity feed powder into the feed system described below. In some embodiments, the walls of the outlet 114 are vertical. In some embodiments, the walls of the outlet 114 form a funnel shape. In some embodiments, the curvature and slope of the walls of the outlet can be varied based on the flow properties of the powder. In some embodiments, flow properties include but are not limited to: shear properties of the powder, wall friction properties (e.g. a measurement of the sliding resistance between the powder and the surface of the process equipment), powder density, powder compressibility, and powder permeability (e.g. a measure of the powder's resistance to air flow). In some embodiments, the curvature and slope of the walls of the outlet is determined using a powder rheometer, for example a FT4 Powder Rheometer® from Freeman Technology, a part of Micromeritic Instrument Corporation. In some embodiments, the body 112 is integrally formed with the outlet 114 (e.g. the body and the outlet are formed from a single piece of material). In some embodiments, the body 112 is coupled to the outlet 114 with mechanical fasteners, such as bolts, screws or other appropriate mechanical fastening devices. In some embodiments, the coupled components 112, 114 may have appropriate seals at the coupling points to prevent exposure to the atmosphere. In some embodiments, the input container 102 is sealed to prevent access to the powder inside except via connection to the feed system 106 described below.

[00066] In some embodiments, the input containers 102 are disposed within a hollow volume of a body of the apparatus 100. In some embodiments, the input containers 102 are disposed outside the body of the apparatus 100 or are disposed partially within the body of the apparatus 100. In some embodiments, the body of the apparatus 100 is a suitable storage container to comply with any applicable flammable metal powder regulations. [00067] In some embodiments, each input container 102 has a metering valve to control the flow of powder from each input container 102. Providing a metering valve at each input container reduces or prevents undesired powder cross-contamination. In some embodiments, the metering valve can be a rotary metering valve.

[00068] The apparatus 100 further comprises a feed system 106 fluidly coupling the plurality of input containers 102. In some embodiments, the feed system 106 is configured to receive source powder from the plurality of input containers 102 and direct the source powder to the mixing container 104. In some embodiments, the source powder has at least one powder from an input container (e.g. a plurality of powders from at least two input containers). In some embodiments, the feed system 106 comprises a first end coupled to the input container 102. In some embodiments, the first end of the feed system 106 is coupled to an opening of the outlet 1 14. In some embodiments, the feed system 106 comprises a second end. In some embodiments, the second end of the feed system 106 is coupled to the inlet of the mixing container 104. In some embodiments, the feed system comprises a metering valve, for example a rotary metering valve, configured to deliver a predetermined amount of powder from the input container 102 to the mixing container. In some embodiments, the feed system 106 is a flexible pipe. In some embodiments, the feed system 106 is a rigid pipe. In some embodiments, the feed system 106 is detachable from the input container 102. In some embodiments, the feed system 106 is detachable from the mixing container 104. In some embodiments, the feed system is mechanically coupled to the input container 102 and the mixing container 106 via suitable fasteners (e.g. screws, nuts and bolts) or mating threaded portions.

[00069] In some embodiments, the apparatus 100 comprises a rotating carousel configured to accept the input containers 102. In some embodiments, the rotating carousel positions a selected input container 102 to couple to the feed system 106. In some embodiments, the input containers 102 are detachable from the rotating carousel.

[00070] In some embodiments, the apparatus 100 comprises an intermediate powder holder 116 configured to receive source powder from the plurality of input containers 102 via the feed system 106 and transfer the source powder to the mixing container 104. In some embodiments, the intermediate powder holder 116 weights the source powder from the plurality of input containers 102 to determine that a correct amount of source powder is fed to the mixing container 104. In some embodiments, the intermediate powder holder 116 rests on a scale to weight the source powder. In some embodiments, the intermediate powder holder 116 has a hollow volume to hold source powder. In some embodiments, individual amounts of source powder can be transferred to the intermediate powder holder 116, weighed and transferred to the mixing container 104. In some embodiments, all the source powder to be mixed in the mixing container 104 can be transferred to the mixing container 104, weighed, and then transferred to the mixing container 104.

[00071] In some embodiments, the apparatus 100 further comprises a mixing container 104. In some embodiments, the mixing container 104 is configured to receive source powder from the feed system 106. In some embodiments, the mixing container 104 is configured to mix the source powder into a powder blend. In some embodiments, the mixing container 104 is fluidly coupled to the plurality of input containers 102 such that the source powder flows from the plurality of input containers 102 to the mixing container 104. In some embodiments, the mixing container 104 is any suitable container that can homogenize one or more source powders (i.e. a powder blend). In some embodiments, the powder blend can be a mixture of different powders or can be a mixture of the same powder from different sources. Some exemplary embodiments of the mixing container include but are not limited to a ribbon mixer, a blade mixer, and a v-mill mixer. In some embodiments, the mixing container 104 comprises a body. The body of the mixing container 104 comprises a hollow volume to retain the powder blend, an inlet to receive source powder from the plurality of input containers 102 and an outlet to discharge the powder blend. In some embodiments, the hollow volume of the mixing container 104 retains the powder blend and an inert gas, as described above with respect to the input container.

[00072] The apparatus 100 further comprises an output container 108. In some embodiments, the output container 108 is configured to receive the powder blend from the mixing container 104. In some embodiments, the output container 108 is fluidly coupled to the mixing container 104 such that the powder blend flows from the mixing container 104 to the output container 108. In some embodiments, the output container 108 receives the powder blend from the mixing container 104 via a flexible pipe. In some embodiments, the output container 108 receives the powder blend from the mixing container 104 via a rigid pipe. In some embodiments, the output container 108 is any suitable shape to hold the powder blend, such as cylindrical, circular, or square. In some embodiments, the output container 108 comprises a body. The body of the output container 108 comprises a hollow volume to retain the powder blend, an inlet to receive the powder blend from the plurality of input containers 102 and an outlet to discharge the powder blend. In some embodiments, the hollow volume of the mixing container 104 retains the powder blend and an inert gas, as described above with respect to the input container. In some embodiments, the output container 108 is detachable from the apparatus 100.

[00073] In some embodiments, the apparatus 100 further comprises a gas transport system. In some embodiments, the gas transport system is configured to provide an inert gas to the one or more of the components of the systems described above, such as the mixing container 104 and the output container 108. In some embodiments, the gas transport system is configured to remove atmosphere the one or more of components of the systems described above to maintain a vacuum within the one or more of components of the systems. In some embodiments, the gas transport system comprises an inert gas source, an inert gas flow path, such as tubes or pipes, to transfer inert gas to one or more components of the apparatus 100, one or more valves to control the flow of inert gas, a vent flow path, such as tubes or pipes, to remove any atmosphere within the one or more components that is replaced by the inert gas.

[00074] In some embodiments, the apparatus 100 further comprises a control system 110. In some embodiments, the control system 110 is a computer/control system (processor and/or memory), which includes any such computing device capable of sending and receiving information/messages (e.g. over a network, to and from other computing devices (e.g. servers, etc.). In some embodiments, computing devices include laptops, personal computers, multiprocessor systems, microprocessor-based systems; network PCs, and/or programmable consumer electronics (e.g. cameras). In some embodiments, the computer/control system can be configured wirelessly or with wires to enable communication between components and/or other computing devices. In some embodiments, the control system 110 is configured to tailor the powder composition and powder blend to produce a target additive manufacturing feedstock. In some embodiments, the target additive manufacturing feedstock is user selected via the control system 110. In some embodiments, the control system 110 is configured to maintain an inventory of the source powder levels. In some embodiments, the control system 110 is configured to alert a user of the apparatus to order more source powder based on powder usage rate. In some embodiments, the control system 110 is configured to allow the user to select a desired powder blend. In some embodiments, the control system 110 is configured to allow a user to save one or more specific desired powder blends within the control system. In some embodiments, the control system 110 is configured to provide a user with one or more pre-set powder blends. In some embodiments, the control system 110 is configured to recommend an amount of powder blend to be dispensed based on the additive manufacturing process used and the object to be additively manufactured. In some embodiments, the control system 110 is configured to print labels having barcodes that allow for powder lot tracking and inventory control. In some embodiments, the control system 110 is configured to prevent users from mixing potentially dangerous powder combinations (e.g. powder combinations that are explosive). In some embodiments, the control system 110 is configured to comply with U.S. Department of Homeland Security chemical facility anti -terrorism act requirements on metal powder storage, including but not limited to: a lock and key system, a finger print recognition system, and a security key fob system (e.g. a wireless transmitter and receiver system) which restricts access to the source powder. In some embodiments, the control system 110 is configured to control the inert gas feed system.

[00075] In some embodiments, the apparatus 100 further comprises a sampling point 118 configured to dispense a representative sample 120 of the powder blend. In some embodiments, the sampling point 118 includes a valve and a nozzle to discharge the representative sample 120. In some embodiments, the sampling point is fluidly coupled to the mixing container 104 via a flow path, such as tubes or pipes. In some embodiments, the representative sample 120 is dispensed in a detachable container. In some embodiments, the control system 110 can print labels for the sample container providing information such as powder blend composition. In some embodiments, the apparatus comprises a plurality of sampling points 118. In some embodiments, the apparatus 100 further comprises an in-situ sampler 122 to analyze a representative sample 120 of the mixed powder. In some embodiments, the in-situ sampler can perform, for example, a moisture analysis, powder particle size distribution analysis, thermogravimetric analysis, and bulk density analysis.

[00076] In some embodiments, the output container 108 is configured to interface with an apparatus suitable for performing processes including but not limited to additive manufacturing process, a hot isostatic pressing process, a metal injection molding process, and powder conform process. In some embodiments, the output container 108 is configured to interface with and provide a powder blend to an additive manufacturing apparatus. Figure 3A-3E shows a portion of an exemplary additive manufacturing apparatus 300, wherein the output container 108 is configured to interface with the additive manufacturing apparatus 300.

[00077] Figure 3A depicts a portion of an exemplary additive manufacturing apparatus 300 comprising a powder dispenser elevator 302, a build platform elevator 304, a collector elevator 305, and a re-coater mechanism 306. The re-coater mechanism 306 is configured to traverse laterally over the powder dispenser elevator 302, build platform elevator 304, and collector elevator 305. The re-coater mechanism 306 is configured to transfer a layer of powder from the powder dispenser elevator 302 to the build platform elevator 304.

[00078] Figure 3B depicts the output container 108 interfacing with the additive manufacturing apparatus 300. The output container 108 is positioned over and interfaces with the powder dispenser elevator 302.

[00079] Figure 3C depicts a cross-sectional view of the output container 108 interfacing with the additive manufacturing apparatus 300. In some embodiments, a bottom 308 of the output container 108 is a moveable slide gate. In some embodiments, the moveable slide gate is detachably coupled to the re-coater mechanism 306 at a first end 310. The re-coater mechanism 306 is positioned proximate the output container 108. In some embodiments, prior to moving the slide gate as depicted in Figure 3C, an additive manufacturing chamber (not shown) in which the additive manufacturing apparatus 300 is disposed, can be sealed and purged of atmosphere to avoid exposing the powder in the output container 108 to atmosphere, which can negatively impact the quality of the additively manufactured part made from the powder.

[00080] As depicted in Figure 3D, the re-coater mechanism 306 traverses horizontally in a direction opposite the output container 108. The moveable slide gate detachably coupled to the re-coater mechanism 306 is pulled along with the re-coater mechanism 306 until a second end 312, opposite the first end 310 is removed from the output container 108.

[00081] As depicted in Figure 3E, the powder dispenser elevator 302 is lowered until all the powder in the output container 108 is transferred to the powder dispenser elevator 302. Once all the powder is transferred, the re-coater mechanism 306 traverses horizontally in a direction toward the output container 108. The moveable slide gate detachably coupled to the re-coater mechanism 306 is pushed by the re-coater mechanism 306 until the moveable slide gate is returned to its original position shown in Figure 3C. The output container 108 is removed from the additive manufacturing chamber (not shown) and the additive manufacturing process can proceed.

[00082] Figure 4 is a flow diagram 400 of a method for dispensing a powder mixture in accordance with some embodiments of the present invention. In some embodiments, the method 400 is performed by the apparatus 100 described above. In some embodiments, the method 400 begins at 401 by selecting a target additive manufacturing powder feedstock composition (e.g. on a control system 1 10). Next, at 402 a predetermined amount of a plurality of additive manufacturing source powders is dispensed from a plurality of input containers, wherein the predetermined amount of the source powders is dispensed into a mixing container. Next at 404, the predetermined amount of the additive manufacturing source powder is mixed to form a predetermined powder blend. Next, at 406, a sample of the powder blend is collected. Next, at 408 the sample is analyzed to determine powder characteristics. Next, at 409, the powder characteristics of the powder blend is compared to the target additive manufacturing powder blend (e.g. by the control system 1 10). Next at 410, the powder blend is dispensed to an output container if the powder characteristics of the powder blend match the target additive manufacturing powder blend.

[00083] In some embodiments, the method 400 further comprises, cleaning the components of the apparatus 100 used to perform the method 400 to prevent contamination of a subsequent powder blend with a prior powder blend. In some embodiments, the cleaning comprises a solvent wash for the components of the apparatus 100, wherein a flow of solvent is circulated through any components of the apparatus that come in contact with the powder. In some embodiments, the solvent can be an alcohol wash. In some embodiments, the cleaning comprises blowing a gas, such as air or an inert gas, through the interior of the components of the apparatus 100 to dislodge and remove powder particles that adhere to the components of the apparatus 100. In some embodiments, a cleaning fluid transport system is configured to provide a solvent to the one or more of the components of the systems described above, such as the mixing container 104 and the output container 108. In some embodiments, the cleaning fluid transport system comprises a cleaning fluid source, a cleaning fluid flow path, such as tubes or pipes, to transfer cleaning fluid to one or more components of the apparatus 100, one or more valves to control the flow of cleaning fluid, a vent flow path, such as tubes or pipes, to remove any used cleaning fluid within the one or more components. [00084] In some embodiments of the disclosure, a method comprises: selecting a target additive manufacturing powder feedstock composition (e.g. on a control system); comparing the target additive manufacturing powder feedstock composition to an inventory list, the inventory list including: a plurality of pre blended additive manufacturing powder feedstock compositions and a plurality of component additive manufacturing powder feedstocks; one of: dispensing the pre-blended additive manufacturing powder feedstock to an output container if the target corresponds to a pre-blended additive manufacturing powder feedstock, or if the target does not correspond to a pre-blended AM powder feedstock, then dispensing a predetermined amount of component additive manufacturing powder feedstocks from a plurality of input containers, wherein the predetermined amount of the component additive manufacturing powder feedstocks is dispensed into a mixing container; mixing the predetermined amount of the component additive manufacturing powder feedstocks to form a product additive manufacturing powder feedstock composition; and dispensing the product additive manufacturing powder feedstock composition to an output container.

[00085] In some embodiments, if the target does not correspond to a pre-blended AM powder feedstock, then a sample of the product additive manufacturing powder feedstock composition is collected; the sample is analyzing to determine if the product powder characteristics corresponds to the target powder characteristics; and the product powder is dispensed to the output container, provided the product powder characteristics correspond to the target.

[00086] While specific embodiments of the invention have been described in detail, it will be appreciated by those skilled in the art that various modifications and alternatives to those details could be developed in light of the overall teachings of the disclosure. Accordingly, the particular arrangements disclosed are meant to be illustrative only and not limiting as to the scope of the invention which is to be given the full breadth of the appended claims and any and all equivalents thereof.

[00087] Reference Numbers:

[00088] 102 plurality of input containers

[00089] 104 mixing container

[00090] 106 feed system

[00091] 108 output container

[00092] 110 control system

[00093] 112 body of 102

[00094] 114 outlet of 102

[00095] 116 intermediate powder holder

[00096] 118 sampling point

[00097] 120 sample

[00098] 122 in-situ sampler

[00099] 300 AM machine

[000100] 302 powder dispenser elevator

[000101] 304 build platform elevator

[000102] 305 collector elevator

[000103] 306 re-coater mechanism

[000104] 308 bottom of the output container [000105] 310 I^s end of the bottom of the output container

[000106] 312 2^nd end of the bottom of the output container

Claims

CLAIMS We claim:

1. An apparatus, comprising:

a plurality of input containers, each input container configured to retain a different source powder, wherein the source powder is an additive manufacturing feedstock component or an additive manufacturing feedstock powder;

a feed system fluidly coupling the plurality of input containers and configured to receive the source powder, the source powder having at least one powder from an input container and wherein the feed system directs the source powder into a mixing container;

wherein the mixing container is configured to receive the source powder from the feed system and mix the source powder into a powder blend;

an output container fluidly coupled to the mixing container, wherein the output container is configured to receive the powder blend from the mixing container, and wherein the output container is configured to detach from the apparatus; and

a control system configured to tailor powder composition and powder blend to produce a target additive manufacturing feedstock, wherein the plurality of input containers, the feed system, the mixing container, and the output container are configured to retain one of an inert atmosphere or a vacuum.

2. The apparatus of claim 1, wherein each of the plurality of input containers comprises: a body having a hollow volume to retain the source powder; and

an outlet in the body.

3. The apparatus of claim 2, wherein the body and the outlet are integrally formed.

4. The apparatus of claim 2, wherein the body is coupled to the outlet via mechanical fasteners.

5. The apparatus of claim 2, wherein the outlet comprises a sidewall having a slope configured to gravity feed source powder into the feed system.

6. The apparatus of claim 1, wherein each of the input containers comprises a metering valve, wherein the metering value is configured to control the flow of powder from each input container.

7. The apparatus of claim 1, wherein the mixing container comprises:

a body;

an inlet in the body configured to receive source powder from the plurality of input containers; and

an outlet in the body to discharge the powder blend,

wherein the mixing container is fluidly coupled to the plurality of input containers, and wherein the mixing container is configured to homogenize one or more source powders into a powder blend.

8. The apparatus of claim 1, wherein the feed system comprises:

a first end coupled to the input container,

wherein the first end of the feed system is coupled to an opening of the outlet; and a second end.

9. The apparatus of claim 8, wherein the second end of the feed system is coupled to the inlet of the mixing container.

10. The apparatus of claim 8, wherein the second end of the feed system is coupled to an intermediate powder holder, wherein the intermediate powder holder is configured to receive source powder from the plurality of input containers and transfer the source powder to the mixing container.

11. The apparatus of claim 10, wherein the intermediate powder holder is configured to weight source powder from the plurality of input containers.

12. The apparatus of claim 10, further comprising a rotating carousel configured to retain the plurality of input containers.

13. The apparatus of claim 12, wherein the rotating carousel is configured to position a selected input container to couple to the feed system.

14. The apparatus of claim 1, wherein the output container comprises a body having a hollow volume to retain the powder blend, an inlet to receive the powder blend from the plurality of input containers, and an outlet to discharge the powder blend.

15. The apparatus of claim 1, wherein the control system is configured to allow a user to select the powder blend composition and the amount of powder blend to dispense to the output container.

16. The apparatus of claim 1, wherein the control system is configured to maintain an inventory of the source powder levels.

17. The apparatus of claim 1, wherein the control system is configured to alert a user to order more source powder based on powder usage rate.

18. The apparatus of claim 1, wherein the control system is configured to allow the user to save one or more specific predetermined powder blends within the control system.

19. The apparatus of claim 1, wherein the control system is configured to provide a user with one or more pre-set powder blends.

20. The apparatus of claim 1, wherein the control system is configured to recommend an amount of powder blend to be dispensed based on the additive manufacturing process used and the object to be additively manufactured.

21. The apparatus of claim 1, wherein the control system is configured to print labels having barcodes that allow for powder lot tracking and inventory control.

22. The apparatus of claim 1, wherein the control system is configured to prevent users from mixing potentially dangerous powder combinations.

23. The apparatus of claim 1, wherein the control system is configured to comply with U.S. Department of Homeland Security chemical facility anti -terrorism act requirements on metal powder storage.

24. The apparatus of claim 1, further comprising a sampling point configured to dispense a representative sample of the powder blend.

25. The apparatus of claim 1, wherein the apparatus further comprises an in-situ sampler to analyze a representative sample of the mixed powder.

26. The apparatus of claim 1, wherein the output container is configured to interface with an apparatus suitable for performing an additive manufacturing process, a hot isostatic pressing process, a metal injection molding process, or powder conform process.

27. A method, comprising:

selecting a target additive manufacturing powder blend;

dispensing a predetermined amount of a plurality of additive manufacturing source powders from a plurality of input containers, wherein the predetermined amount of the additive manufacturing source powders is dispensed into a mixing container; mixing the predetermined amount of the additive manufacturing source powder to form a powder blend;

collecting a sample of the powder blend;

analyzing the sample to determine powder characteristics;

comparing the powder characteristics of the powder blend to the target additive manufacturing powder blend; and

dispensing the powder blend to an output container when the powder characteristics of the powder blend match the target additive manufacturing powder blend.

28. The method of claim 27, further comprising: selecting the powder blend composition and an amount of powder blend to dispense to the output container.

29. The method of claim 27, further comprising: maintaining an inventory of the source powder levels.

30. The method of claim 27, further comprising: triggering an alert to order more source powder based on powder usage rate.

31. The method of claim 27, further comprising: selecting one or more pre-set powder blends.

32. The method of claim 27, further comprising: selecting a recommended amount of powder blend to be dispensed based on the additive manufacturing process used and the object to be additively manufactured.

33. The method of claim 27, further comprising: printing labels having barcodes that allow for powder lot tracking and inventory control.

34. A method, comprising:

selecting a target additive manufacturing powder feedstock composition; comparing the target additive manufacturing powder feedstock composition to an inventory list, the inventory list including: a plurality of pre-blended additive manufacturing powder feedstock compositions and a plurality of component additive manufacturing powder feedstocks;

one of:

dispensing the pre-blended additive manufacturing powder feedstock to an output container if the target corresponds to a pre-blended additive manufacturing powder feedstock, or if the target does not correspond to a pre-blended AM powder feedstock, then

dispensing a predetermined amount of component additive manufacturing powder feedstocks from a plurality of input containers, wherein the predetermined amount of the component additive manufacturing powder feedstocks is dispensed into a mixing container;

mixing the predetermined amount of the component additive manufacturing powder feedstocks to form a product additive manufacturing powder feedstock composition;

dispensing the product additive manufacturing powder feedstock composition to an output container.

35. The method of claim 34, further comprising: collecting a sample of the product additive manufacturing powder feedstock composition, if the target does not correspond to a pre-blended AM powder feedstock;

analyzing the sample to determine if the product powder characteristics correspond to the target powder characteristics; and dispensing the product powder to the output container, provided the product powder characteristics correspond to the target.