WO2022018447A1

WO2022018447A1 - Additive manufacturing

Info

Publication number: WO2022018447A1
Application number: PCT/GB2021/051896
Authority: WO
Inventors: Andre GAIO; Christian FOLGAR; Luis FOLGAR; Jay Jones; Rory CHARLESWORTH; Viktor Pap-Kovacs
Original assignee: Additive Manufacturing Technologies Ltd
Current assignee: Additive Manufacturing Technologies Ltd
Priority date: 2020-07-24
Filing date: 2021-07-22
Publication date: 2022-01-27
Anticipated expiration: 2023-01-24
Also published as: GB202011515D0

Abstract

The present invention relates to methods and systems for removing powder from one or more additively manufactured (AM) parts or a powder cake containing one or more AM parts. The method comprises the steps of: locating one or more AM parts (14) and/or a powder cake (16) containing one or more AM parts in a chamber (12); directing a first flow of fluid in a first direction into the chamber (12) in order to impact the one or more AM parts (14) and/or powder cake (16); and directing a second flow of fluid in a second direction into the chamber (12) in order to impact the one or more AM parts (14) and/or powder cake (16), wherein the second direction is different to the first direction. The method/system has been found to effectively remove powder from an AM part or powder cake.

Description

Additive Manufacturing

FIELD OF THE INVENTION

The present invention relates to methods of removing powder from parts manufactured using a powder-based additive manufacturing (AM) process, and systems and apparatus for achieving the same.

BACKGROUND OF THE INVENTION

Powder-based additive manufacturing (AM) techniques, such as selective laser sintering (SLS), use lasers or other power sources to sinter powdered material (typically nylon/polyamide). This is achieved by aiming the laser/other power source automatically at points in space defined by a 3D model to bind the material together and create a solid structure. The laser selectively fuses powdered material by scanning cross-sections generated from a 3-D digital description of the part (for example from a CAD file or scan data) on the surface of a powder bed. After each cross-section is +scanned, the powder bed is lowered by one-layer thickness, a new layer of material is applied on top, and the process is repeated until the part is completed. In contrast with some other additive manufacturing processes, such as stereolithography (SLA) and fused deposition modelling (FDM), which most often require special support structures to fabricate overhanging designs, powder-based AM techniques such as SLS do not need a separate feeder for support material because the part being constructed is surrounded by un-sintered powder at all times. Furthermore, since the build chamber is always filled with powder material, multiple parts can be fabricated within the boundaries of the powder bed allowing for high volume productivity.

However, after a part has been made using a powder-based AM process, it is encapsulated by an amount of un-sintered powder known as a powder 'cake' which is left to cool before being manually removed from the build chamber. The un-sintered power surrounding the sintered part is then removed manually with a brush, vacuum, compressed air gun, tumbler, blasting, or the like. This cooling and manual removal of un-sintered powder, particularly from AM parts having relatively complex geometries, is labour intensive, time consuming and costly. Furthermore, such manual methods are often inefficient and it is often particularly difficult to remove all un-sintered powder from an AM part. Additionally, much of the un-sintered powder is currently disposed of and not recycled which is costly and environmentally unfriendly. The present invention seeks to overcome, or at least mitigate, one or more problems of the prior art.

SUMMARY OF THE INVENTION

According to a first aspect of the invention, a method of removing powder from one or more additively manufactured (AM) parts or a powder cake containing one or more AM parts is provided, the method comprising the steps of: locating one or more AM parts and/or a powder cake containing one or more AM parts in a chamber; directing a first flow of fluid in a first direction into the chamber in order to impact the one or more AM parts and/or powder cake; and directing a second flow of fluid in a second direction into the chamber in order to impact the one or more AM parts and/or powder cake, wherein the second direction is different to the first direction.

Having first and second fluid flows in different directions has been found to more effectively remove powder from an AM part or powder cake. This contrasts with a system with fluid flowing in only a first direction, in which features of the part/powder cake downstream in this first direction may be shielded from the fluid flow by the body of the part/powder cake.

In exemplary embodiments, the first flow of fluid is a flow of gas (e.g. air) and/or the second flow of fluid is a flow of gas (e.g. air).

It has been found that gases are particularly suitable for removing powder from AM parts, since removed powder particles can become entrained in flows of gas, which allows simple transfer of removed powder out of the chamber. Powder particles are also easy to separate from gas flow via sifting, filtering or gravity alone (e.g. for disposal or recycling of powder).

In addition, if air is used there is no need to provide a separate reservoir of fluid, since this can be pumped and/or compressed from the environment in which the chamber is located.

In exemplary embodiments, said first and second flows of fluid are directed simultaneously into said chamber. Simultaneous flows of fluid from different directions have been found to be particularly effective for removing powder from AM parts or powder cakes.

In exemplary embodiments, the second direction is opposite the first direction.

Having first and second fluid flows in opposite directions has been found to be more effective for removing powder from AM parts/powder cakes, since more faces if the AM parts/powder cakes are exposed to fluid flows than would be the case if only a first fluid flow was used.

In exemplary embodiments, the method further comprises moving the one or more AM parts and/or powder cake within the chamber with the first fluid flow and/or second fluid flow.

Moving the one or more AM parts and/or powder cake within the chamber has been found to increase removal of powder, since different faces of the AM parts and/powder cake are exposed to the first and second fluid flows. Furthermore, moving the one or more AM parts and/or powder cake with the first fluid flow and/or second fluid flow removes the need for an additional actuator (e.g. a robotic arm) for moving the parts/powder cakes.

In exemplary embodiments, the method further comprises altering the first direction and/or second direction (e.g. for removal of powder from the one or more AM parts and/or powder cake, and/or for moving one or more AM parts and/or the powder cake within the chamber).

Altering the first and/or second direction (e.g. in a rotary motion) allows the first and/or second fluid flow to be directed to different regions of the chamber (e.g. to impact AM parts or portions of AM parts located in different regions of the chamber).

In exemplary embodiments, the method further comprises identifying one or more locations of one or more AM parts within the chamber and directing the first fluid flow and/or second flow of fluid towards the one or more locations (e.g. for removal of powder from the one or more AM parts and/or powder cake, and/or for moving one or more AM parts and/or the powder cake within the chamber).

Identifying one or more locations of one or more AM parts within the chamber and directing the first and/or second flow of fluid towards the one or more locations has been found to increase the rate of de-powdering or agitation/movement of parts, since fluid is directed towards AM parts, rather than vacant spaces in the chamber.

In exemplary embodiments, the first fluid flow comprises a relatively high volumetric flow rate compared with the second fluid flow, and wherein the second fluid flow comprises a relatively high velocity compared with the first fluid flow; optionally, wherein the first and/or second fluid flow comprises intermittent bursts of compressed gas (e.g. a pulsed flow).

Having a first fluid flow with a high volumetric flow rate has been found to facilitate a high removal rate of powder. However, on its own, this first flow of fluid may be ineffective for removing powder from downstream faces of the AM part(s) or powder cake. Having a high velocity second flow has been found to facilitate moving the AM part(s) or powder cake, so that different faces are exposed to the first fluid flow. Furthermore, the high velocity second fluid flow may be suitable for breaking apart a powder cake into smaller pieces, which increases the surface area exposed to the first fluid flow and thus increases the rate of powder removal. The high velocity second fluid flow may also be suitable for agitating and/or removing powder in cracks or other shielded areas of AM parts.

In exemplary embodiments, the first direction is upwards, and the second direction is downwards.

In such a configuration, the AM part(s) or powder cakes will rest at the bottom of the chamber due to gravity. Therefore, the upwards high volumetric flow rate first fluid flow (i.e. from the bottom of the chamber) will be close to the AM part(s), which facilitates agitation/removal of powder from cracks or other shielded areas of AM parts.

In exemplary embodiments, the method further comprises transferring powder removed from the one or more AM parts and/or powder cake by the first and/or second fluid flows from the chamber; optionally, further comprising transferring said powder from the chamber to a collection chamber.

Transferring said powder ensures that the one or more AM parts and/or powder cake are not covered by accumulations of removed powder, and ensures that said powder does not become re-attached to parts. This has been found to increase the effectiveness of the de- powdering process. Transferring said powder to a collection chamber allows removed powder to be gathered for disposal or re-cycling.

In exemplary embodiments, the first direction is opposite the second direction, wherein the first fluid flow comprises a relatively high volumetric flow rate compared with the second fluid flow, wherein the second fluid flow comprises a relatively high velocity compared with the first fluid flow, and wherein the chamber comprises a first end configured for directing the first fluid flow into the chamber and for transferring removed powder from the chamber; optionally, wherein the first end comprises an interface device comprising an array of apertures, wherein the array of apertures comprises a first set of apertures for directing the first fluid flow into the chamber and a second set of apertures for transferring removed powder from the chamber.

Such a configuration has been found to facilitate an effective transfer of powder from the chamber. Furthermore, any parts or powder cake located within the chamber will be directed towards the first end (either via the high velocity of the second fluid flow, or via gravity if the first direction is upwards). Therefore, the first end also being configured for directing the first fluid flow into the chamber allows the high volumetric flow rate of first fluid to be directed close to the parts or powder cake, which has been found to facilitate effective agitation/removal of powder and/or moving of the part(s) or powder cake.

Having a first set of apertures for directing the first fluid flow into the chamber facilitates input of first fluid flow over a wide surface area (e.g. as opposed to a single aperture), which ensures more effective agitation/removal of powder and/or moving of parts or powder cakes.

Having a second set of apertures for transferring removed powder from the chamber facilitates transfer of powder over a wide surface area (e.g. as opposed to a single aperture), which ensures more effective transfer of powder from the chamber.

In exemplary embodiments, the method further comprises controlling the first flow of fluid through the first set of apertures; optionally, wherein controlling the first flow of fluid through the first set of apertures comprises selectively actuating (i.e. opening) or de activating (i.e. closing) a subset of the first set of apertures.

Selectively activating or deactivating a subset of the first set of apertures has been found to improve de-powdering performance (e.g. by activating apertures which are close to one or more parts or powder cakes within the de-powdering chamber in use and deactivating apertures which are not close to one or more parts or powder cakes within the de- powdering chamber in use.

In exemplary embodiments, the method further comprises connecting the second set of apertures to a vacuum source for urging removed powder in the de-powdering chamber through said second set of apertures.

Connecting the second set of apertures to a vacuum source has been found to increase the rate at which removed powder is transferred from the de-powdering chamber.

In exemplary embodiments, the chamber is at least partly defined by a moveable pod or container, the method further comprising: locating one or more AM parts and/or a powder cake containing one or more AM parts in the moveable pod or container at a first location; transporting the moveable pod or container to a second location; and performing a de-powdering operation at the second location in order to remove powder from the one or more AM parts and/or powder cake located within the moveable pod or container; optionally, wherein the moveable pod or container is configured for coupling to a de-powdering unit, and wherein the de-powdering unit is configured to direct the first and second flows of fluid through the moveable pod or container for agitating and removing powder from the one or more AM parts and/or powder cake.

Such a method has been found to facilitate easy transfer of parts or powder cakes from an additive manufacturing build unit at a first location, to a second location (e.g. a de- powdering unit) for removing powder. In addition, such a moveable pod may protect the parts and/or powder cake during transit from the first to the second location, and prevent any loose powder from falling on the floor, where it would be difficult to recycle or reuse.

According to a second aspect of the invention, a method of removing powder from one or more additively manufactured (AM) parts and/or a powder cake containing one or more AM parts is provided, the method comprising the steps of: providing a chamber at least partly defined by a moveable pod or container; locating one or more AM parts and/or a powder cake containing one or more AM parts in the moveable pod or container at a first location; transporting the moveable pod or container to a second location; and performing a de-powdering operation at the second location in order to remove powder from the one or more AM parts and/or powder cake located within the moveable pod or container.

Such a method has been found to facilitate easy transfer of parts or powder cakes from an additive manufacturing build unit at a first location, to a second location (e.g. a de- powdering unit) for removing powder. In addition, such a moveable pod or container may protect the parts and/or powder cake during transit from the first to the second location, and prevent any loose powder from falling on the floor, where it would be difficult to recycle or reuse.

In exemplary embodiments, the moveable pod or container comprises an open end, and wherein the step of locating one or more AM parts and/or a powder cake in the moveable pod or container at a first location comprises: placing the open end of the moveable pod or container over the one or more AM parts and/or powder cake; and sealing the open end of the moveable pod or container with a sealing member; optionally, wherein the step of sealing the open end of the moveable pod or container with a sealing member comprises inserting the sealing member under the one or more AM parts and/or powder cake.

By sealing the open end, the moveable pod or container can be transported robustly (e.g. flipped upside down etc.) without loss of powder, parts or powder cakes from the moveable pod.

By inserting the sealing member under the one or more AM parts and/or powder cake, the parts or powder cake do not need to be picked up, which reduces the likelihood of powder falling off at the first location (where it may not be possible to recycle loose powder easily).

In exemplary embodiments, the sealing member comprises a cutting part, and wherein the step of sealing the open end of the moveable pod or container with a sealing member comprises cutting a powder cake from an additive manufacturing build unit using the cutting part.

By having a cutting part, the sealing member performs the two functions of separating a powder cake from a build unit, and sealing the moveable pod or container. This removes the need for an additional cutting tool. In exemplary embodiments, the step of performing a de-powdering operation at the second location comprises coupling the moveable pod or container to a de-powdering unit at the second location.

By coupling the moveable pod or container to a de-powdering unit, the moveable pod can at least partly define the chamber without needing to remove parts or powder cakes from the movable pod or container.

In exemplary embodiments, the moveable pod or container comprises an open end, wherein the de-powdering unit comprises an interface device configured for transfer of fluid and/or powder therethrough, and wherein the step of coupling the moveable pod or container to the de-powdering unit at the second location comprises placing the open end of the moveable pod or container adjacent the interface device; optionally, wherein the step of coupling the moveable pod or container to the de-powdering unit at the second location further comprises removing the or a sealing member from the open end of the moveable pod or container.

Such a method allows the interface device to form an end of the chamber in use. This allows input of fluid to the chamber (e.g. for agitation of parts/powder cakes and/or removal of powder from parts/powder cakes located therein) and/or transfer of removed powder from the chamber.

Removing the or a sealing member from the open end of the moveable pod or container facilitates a fluid communication between the interior of the moveable pod or container, which contains the parts/powder cake, and the interface device.

In exemplary embodiments, the method(s) further comprise: decoupling the moveable pod or container from the de-powdering unit; and transporting one or more de-powdered AM parts within the moveable pod or container to a third location (e.g. a storage unit, or an inspection area); optionally, wherein the step of decoupling the moveable pod or container from the de-powdering unit comprises sealing the or an open end of the moveable pod or container with the or a sealing member.

By de-coupling the moveable pod or container from the de-powdering unit and transporting de-powdered parts within the parts to a further location, the parts are protected from damage or being lost etc. This may be particularly useful for smaller parts. Furthermore, this may help with part inventories, since labels, barcodes or the like can easily be attached to the moveable pod or container.

Sealing the open end of the moveable pod or container ensures the parts stay within the moveable pod, which reduces the likelihood of parts becoming damaged or lost during transport.

In exemplary embodiments, transporting the moveable pod or container to a second location and/or third location comprises autonomously transporting the moveable pod or container (e.g. via robotic assistance and or autonomously guided vehicles).

Autonomously transporting the moveable pod or container (e.g. via robotic assistance and or autonomously guided vehicles) reduces the need for human input in moving the pod or container.

In exemplary embodiments, the method(s) further comprise transferring powder removed from the one or more AM parts and/or powder cake by the de-powdering operation from the chamber; optionally, further comprising transferring said powder from the chamber through the or an interface device; optionally, further comprising transferring said powder from the chamber to a collection chamber; optionally, further comprising transferring said powder from the chamber through the or an interface device to a collection chamber; optionally, further comprising transferring said powder from the collection chamber using a vacuum.

Transferring removed powder ensures that the one or more AM parts and/or powder cake are not covered by accumulations of removed powder, and ensures that removed powder does not become re-attached to parts. This has been found to increase the effectiveness of the de-powdering process.

Transferring removed powder to a collection chamber allows removed powder to be gathered for disposal or re-cycling.

Transferring removed powder from the collection chamber using a vacuum allows the removed powder to be reused (e.g. via connecting the vacuum to a powder tank of an additive manufacturing build unit) or disposed of (e.g. via connecting the vacuum to a bin).

In exemplary embodiments, the method(s) further comprise transferring powder removed from the one or more AM parts and/or powder cake from the chamber to a collection chamber coupled to the or a de-powdering unit, wherein the moveable pod or container is a first moveable pod or container and the collection chamber is at least partly defined by a second moveable pod or container, and wherein the method(s) further comprises: de-coupling the second moveable pod or container from the de-powdering unit; and transporting powder removed from the one or more AM parts and/or powder cake by the de-powdering operation within the second moveable pod or container to a different location (e.g. an additive manufacturing build unit, or a waste/recycling location); optionally, wherein the second moveable pod or container is of the same shape and configuration as the first moveable pod or container; optionally, wherein the step of de-coupling the second moveable pod or container from the de-powdering unit comprises sealing an open end of the second moveable pod or container with a sealing member; optionally, wherein the method further comprises transferring said powder from the second moveable pod or container; optionally, further comprising transferring said powder from the second moveable pod or container using a vacuum at the different location.

The collection chamber being at least partly defined by a second moveable pod or container allows removed powder to be transported within the collection chamber to a different location. This facilitates recycling and/or tidy disposal of powder.

The first and second moveable pods or containers being of the same shape and configuration allows them to be used interchangeably.

Sealing an open end of the second moveable pod or container allows removed powder to be transported robustly, without loss of powder from the second moveable pod.

Transferring removed powder from the collection chamber using a vacuum allows the removed powder to be reused (e.g. via connecting the vacuum to a powder tank of an additive manufacturing build unit) or disposed of (e.g. via connecting the vacuum to a bin). In exemplary embodiments, the method(s) further comprise shaking and/or vibrating the one or more AM parts and/or powder cake within the chamber, to agitate and remove powder from the one or more AM parts and/or powder cake.

Shaking and/or vibrating the parts or powder cake has been found to be effective for agitating and removing powder on its own, or in combination with one or more fluid flows through the chamber. This may also help to move parts or powder cakes so that different faces are exposed to fluid flows for removal of powder.

In exemplary embodiments, the method(s) further comprise rotating and/or tilting the de- powdering chamber, to agitate and remove powder from the one or more AM parts and/or powder cake.

Rotating and/or tilting the de-powdering chamber has been found to increase de- powdering performance.

In exemplary embodiments, the method(s) further comprise cooling the one or more AM parts and/or powder cake prior to agitating and removing powder; optionally, further comprising introducing a flow of cooling fluid (e.g. air, nitrogen, argon, carbon dioxide, other gas or gaseous mixture) to the chamber; optionally, further comprising controlling the flow of cooling fluid so that it does not affect the structural integrity of a powder cake (e.g. the flow of cooling fluid has a volumetric flow rate and/or velocity low enough to inhibit breaking apart a powder cake); optionally, further comprising controlling the temperature of the flow of cooling fluid and/or the velocity of the flow of cooling fluid to control the rate of cooling of the one or more AM parts and/or powder cake; and/or optionally, wherein the cooling fluid is an inert gas.

Cooling the parts and/or powder cake prior to agitating and removing powder has been found to reduce the likelihood of damage to AM parts (e.g. shrinkage or warping of the AM parts).

A flow of cooling fluid has been found to be an effective method of cooling parts and/or powder cakes.

Controlling the flow of cooling fluid so that it does not affect the structural integrity of a powder cake allows cooling fluid to pass through material voidage (fluid spaces between powder particles) whilst avoiding high temperature gradients which would be associated with a sudden breaking of the powder cake. This has been found to avoid shrinkage and/or warping of the one or more AM parts during crystallisation.

Controlling the temperature of the flow of cooling fluid and/or the flow rate of the flow of cooling fluid to control the rate of cooling of the one or more AM parts and/or powder cake containing one or more AM part, ensures high temperature gradients are avoided. This has been found to avoid shrinkage and/or warping of the one or more AM parts during crystallisation.

The cooling fluid being an inert gas minimises the introduction of impurities which could result in discolouration or other damage to parts. This has been found to result in better physical characteristics of the cooled and de-powdered parts.

In exemplary embodiments, the method(s) comprise moving the de-powdering unit (e.g. moving the de-powdering unit proximal an additive manufacturing build unit).

Moving the de-powdering unit (e.g. moving proximal an additive manufacturing build unit) reduces the distance required to move AM parts/powder cakes, which reduces time, effort and risk of losing powder.

In exemplary embodiments, the method(s) further comprise preventing generation of static electricity in the de-powdering chamber and/or cancelling static electricity generated within the de-powdering chamber.

Preventing generation of static electricity and/or cancelling static energy reduces the likelihood of damage to the de-powdering system and/or AM parts. Preventing generation of static electricity and/or cancelling static energy also prevents AM parts from being charged in ways which would be detrimental to further processing operations, such as coating operations.

According to a third aspect of the invention, a moveable pod for use in a system for de- powdering one or more additively manufactured (AM) parts and/or a powder cake containing one or more AM parts is provided, the moveable pod comprising a housing defining a chamber for receiving one or more AM parts and/or a powder cake, wherein the chamber comprises: a first end comprising a first opening for input of fluid to the chamber and/or removal of fluid and/or powder from the chamber; and a second end comprising one or more second openings for input of fluid and/or powder to the chamber and/or removal of fluid and/or powder from the chamber.

Such a moveable pod chamber is suitable for receiving parts or powder cakes, and also allows input of fluid for removing powder from said parts or powder cakes. This makes it suitable for use as a de-powdering chamber in a de-powdering system. Such a moveable pod is also suitable for receiving removed powder, which makes it suitable for use as a collection chamber in a de-powdering system.

Such first and second openings allow first and second fluid flows in different directions to be introduced to the moveable pod, for agitating and removing powder from one or more AM parts and/or powder cake located therein. This allows powder to be effectively removed since it increases the faces of the AM part or powder cake which are exposed to the first and second fluid flows.

Furthermore, the moveable pod allows parts or powder cakes to be loaded into the pod at a first location (e.g. an additive manufacturing build unit) and robustly transported to a second location (e.g. a de-powdering unit).

In exemplary embodiments, the second end is opposite the first end.

The first and second ends being opposite each other means the first and second openings allow first and second fluid flows in opposite directions to be introduced to the moveable pod, for agitating and removing powder from one or more AM parts and/or powder cake located therein. This allows powder to be effectively removed since opposing faces of the AM part or powder cake are exposed to the first and second fluid flows.

In exemplary embodiments, the second end is an open end defining said second opening.

Having an open end allows the moveable pod to be connected to an interface device of a de-powdering unit (e.g. for input of fluid and/or powder through the interface device to the moveable pod, and/or transfer of fluid and or powder from the moveable pod through the interface device).

In exemplary embodiments, the moveable pod further comprises a sealing member for covering the one or more second openings to seal the second end of the chamber. Such a sealing member allows parts and/or powder cakes and/or powder to be transported robustly in the moveable pod, without loss of parts and/or powder cakes and/or powder or damage to the same.

In exemplary embodiments, the moveable pod comprises wheels; optionally, wherein the wheels are controlled autonomously.

Having wheels allows heavy parts to be transported without lifting. Furthermore, the wheels being controlled autonomously (e.g. via a control system including position sensors and motors for driving the wheels) reduces the need for human input in moving the pod.

According to a fourth aspect of the invention, a moveable pod for use in a system for de- powdering additively manufactured (AM) parts and or powder cakes containing one or more AM parts is provided, the moveable pod comprising: a housing comprising an open end for placing over one or more AM parts and/or a powder cake containing one or more AM parts; and a sealing member for closing the open end of the housing in order to seal the one or more AM parts and/or powder cake within the housing.

Such a moveable pod is suitable for receiving parts or powder cakes, and for transporting them robustly without a risk of losing parts or powder.

In exemplary embodiments, the sealing member comprises a cutting part for cutting a powder cake to remove it from an additive manufacturing build unit.

By having a cutting part, the sealing member performs the two functions of separating a powder cake from a build unit, and sealing the moveable pod. This removes the need for an additional cutting tool.

According to a fifth aspect of the invention, a system for de-powdering one or more additively manufactured (AM) parts and/or a powder cake containing one or more AM parts is provided, the system comprising a de-powdering chamber configured to receive one or more AM parts and/or a powder cake containing one or more AM parts therein, wherein the system is configured for removing powder from one or more AM parts and/or a powder cake received within the de-powdering chamber.

In exemplary embodiments, the de-powdering chamber is at least partly defined by a moveable pod according to the third or fourth aspects of the invention.

Such a system with a de-powdering chamber at least partly defined by a moveable pod allows parts and/or powder cakes and/or powder to be robustly transported between an additive manufacturing build unit and a de-powdering location. This system also allows powder to be removed from the parts and/or powder cake at the de-powdering location, then the de-powdered parts to be robustly transported to a further location (e.g. a storage or inspection site).

In exemplary embodiments, the system further comprises: a collection chamber configured for receiving removed powder from the de- powdering chamber; and an interface device configured to define a fluid communication between the de- powdering chamber and the collection chamber.

Such a system allows powder to be removed from one or more AM parts and/or a powder cake and transferred via the interface device to the collection chamber for re-use or disposal.

In exemplary embodiments, the collection chamber is at least partly defined by a moveable pod according to the third or fourth aspects of the invention.

Providing the collection chamber in the form of a moveable pod allows removed powder to be transported robustly (i.e. without loss of powder) from a de-powdering location to a further location for re-use, recycling or disposal.

In exemplary embodiments, the de-powdering chamber comprises an inlet configured to introduce a flow of fluid into the de-powdering chamber; optionally, wherein the inlet comprises a moveable nozzle for directing a flow of fluid to different areas of the de- powdering chamber; optionally, wherein the system is configured to detect the location of one or more AM parts within the de-powdering chamber, and to actuate the moveable nozzle to direct a flow of fluid towards said location. Having an inlet in the de-powdering chamber configured to introduce a flow of fluid into the de-powdering chamber has been found to facilitate effective removal of powder from parts or powder cakes (i.e. such a fluid flow will agitate and remove powder from parts or powder cakes). Such an inlet has also been found to be suitable for introducing a cooling flow of fluid at a pressure and volumetric flow rate low enough to not affect the structural integrity of a powder cake, prior to de-powdering. This has been found to allow cooling fluid to pass through material voidage (fluid spaces between powder particles) whilst avoiding high temperature gradients which would be associated with a sudden breaking of the powder cake. This avoids shrinkage and/or warping of the one or more AM parts during crystallisation.

The inlet having a moveable nozzle for directing a flow of fluid to different areas of the de- powdering chamber allows fluid to be directed from the inlet to the AM parts (e.g. via moving the nozzle in a rotating motion around the de-powdering chamber to impact parts in different portions of the de-powdering chamber with the fluid flow).

The system being configured to detect the location of one or more AM parts within the de- powdering chamber, and to actuate the moveable nozzle to direct a flow of fluid towards said increases the rate of de-powdering or agitation/movement of parts, since fluid is directed towards AM parts, rather than vacant spaces in the de-powdering chamber.

In exemplary embodiments, the system further comprises an outlet for expelling a flow of fluid from the de-powdering chamber and/or the or a collection chamber; optionally, wherein the system further comprises a filter coupled to the outlet.

Such an outlet ensures that the de-powdering chamber and/or collection chamber do not become pressurised as fluid flows into the de-powdering chamber via the inlet.

Providing a filter coupled to the outlet allows any powder or other small particles to be removed from a flow of fluid leaving the outlet. This may be particularly useful when the fluid is air which is released back into the atmosphere surrounding the system, since it prevents small powder particles from being inhaled by people positioned close to the system.

In exemplary embodiments, the system comprises an interface device configured to define a fluid communication between the de-powdering chamber and the or a collection chamber, wherein the interface device defines an end of the de-powdering chamber, and wherein the interface device comprises one or more apertures configured to introduce a flow of fluid into the de-powdering chamber; optionally, wherein the interface device defines an end of the de-powdering chamber opposite the or an inlet in the de-powdering chamber; optionally, wherein the one or more apertures comprise an array of apertures; optionally wherein the array of apertures is arranged in a grid formation.

Having one or more apertures in the interface device configured to introduce a flow of fluid into the de-powdering chamber has been found to facilitate effective removal of powder from parts or powder cakes (i.e. such a fluid flow will agitate and remove powder from parts or powder cakes). Such fluid flow can also be used for agitating or moving the parts and/or powder cakes for exposing different faces of the parts/powder cake to an alternative fluid flow(s) (e.g. a flow of fluid through an inlet at an opposite end of the de- powdering chamber), for removal of powder via the alternative fluid flow(s).

The interface device defining an end of the de-powdering chamber opposite the inlet in the de-powdering chamber allows first and second fluid flows to be introduced to the de- powdering chamber in opposite directions. This has been found to facilitate effective removal of powder from an AM part or powder cake. This contrasts with a system with fluid flowing in only a first direction, in which features of the part/powder cake downstream in this first direction may be shielded from the fluid flow by the body of the part/powder cake.

Having an array of apertures facilitates input of second fluid flow to the de-powdering chamber over a wide surface area (e.g. as opposed to a single aperture), which has been found to result in more effective powder removal and/or agitation and/or moving of parts or powder cakes in the de-powdering chamber.

In exemplary embodiments, the system is configured to control a flow of fluid through the array of apertures; optionally, the system is configured to selectively activate (i.e. open) or de-activate (i.e. close) a subset of the array of apertures.

Selectively activating or deactivating a subset of the array of apertures has been found to improve de-powdering performance (e.g. by activating apertures which are close to one or more parts or powder cakes within the de-powdering chamber in use and deactivating apertures which are not close to one or more parts or powder cakes within the de- powdering chamber in use). In exemplary embodiments, the inlet and/or one or more apertures of the interface device comprises a nozzle for introducing fluid having high flow velocity to the de-powdering chamber.

Having one or more nozzles for introducing fluid having high flow velocity to the de- powdering chamber has been found to improve de-powdering performance.

In exemplary embodiments, one or more of the nozzles for introducing fluid having high flow velocity to the de-powdering chamber comprises an adjustable orifice for increasing fluid volumetric flow rate and/or velocity, and/or for directing fluid towards the one or more AM parts and/or powder cake.

Having an adjustable orifice for increasing fluid volumetric flow rate and/or velocity, and/or for directing fluid towards the one or more AM parts and/or powder cake has been found to increase de-powdering performance (e.g. over a system without such orifices).

In exemplary embodiments, the inlet and/or one or more apertures of the interface device comprises an air flow amplifier.

Having an air flow amplifier increases the volumetric flow rate and/or flow velocity through said inlet and/or one or more apertures of the interface device, which has been found to increase de-powdering performance.

In exemplary embodiments, the system comprises an interface device configured to define a fluid communication between the de-powdering chamber and the or a collection chamber, and wherein the interface device comprises: a first plate and a second plate defining a cavity therebetween; and an interface device inlet configured to introduce a flow of fluid into the cavity; wherein the first plate comprises one or more apertures configured to provide a fluid communication between the de-powdering chamber and the cavity for introduction of fluid from the interface device inlet to the de-powdering chamber; and wherein the interface device is configured to isolate the interface device inlet from the collection chamber; optionally, wherein the one or more apertures of the first plate comprise an array of apertures; optionally, wherein the array of apertures is arranged in a grid formation.

Such an interface device allows fluid to be introduced from the interface device inlet to the de-powdering chamber (e.g. for removal of powder from parts and/or powder cakes, or for agitating or moving the parts and/or powder cakes for exposing different faces of the parts/powder cake to an alternative fluid flow(s) for removal of powder via the alternative fluid flow(s)) whilst isolating the interface device inlet from the collection chamber (where a flow of fluid is not required).

Having an array of apertures facilitates input of second fluid flow to the de-powdering chamber over a wide surface area (e.g. as opposed to a single aperture), which has been found to facilitate effective powder removal and/or agitation and/or moving of parts or powder cakes in the de-powdering chamber.

In exemplary embodiments, the interface device further comprises one or more conduits between the first plate and the second plate, wherein the one or more conduits are configured to provide a fluid communication between the de-powdering chamber and the collection chamber, and wherein an interior of the or each conduit is fluidly isolated from the cavity; optionally, wherein the one or more conduits comprise an array of conduits; optionally, wherein the array of conduits is arranged in a grid formation.

Such conduits provide a path for transferring powder and/or powder entrained fluid through the interface device from the de-powdering chamber to the collection chamber, whilst preventing a flow of fluid from the interface device inlet (e.g. a clean fluid with no entrained powder) from entering the collection chamber.

Having an array of conduits facilitates transfer of powder to the collection chamber over a wide surface area (e.g. as opposed to a single conduit), which has been found to facilitate effective transfer of powder from the de-powdering chamber.

In exemplary embodiments, the one or more conduits are in fluid communication with a vacuum source in use.

Connecting the one or more conduits to a vacuum source has been found to increase the rate at which removed powder is transferred from the de-powdering chamber.

In exemplary embodiments, the system further comprises a mechanism for shaking or vibrating one or more AM parts and/or a powder cake received within the de-powdering chamber in use; optionally, wherein the system comprises a vibration motor coupled to the de-powdering chamber and/or the or an interface device. Shaking and/or vibrating the parts or powder cake has been found to be effective for agitating and removing powder on its own, or in combination with one or more fluid flows through the de-powdering chamber. This may also help to move parts or powder cakes so that different faces are exposed to fluid flows for removal of powder.

A vibration motor coupled to the de-powdering chamber and/or interface device provides a simple mechanism for shaking/vibrating the parts or powder cake.

In exemplary embodiments, the system further comprises an interface device configured to define a fluid communication between the de-powdering chamber and the collection chamber, wherein the de-powdering chamber is arranged above the interface device; optionally, wherein the interface device is configured to support one or more AM parts and/or a powder cake received within the de-powdering chamber; and/or optionally, wherein the or a collection chamber is arranged below the interface device.

Arranging the de-powdering chamber above the interface device allows powder to be directed via gravity to the interface device (i.e. for transfer to the collection chamber).

Arranging the collection chamber below the interface device allows powder to be directed via gravity to through the interface device to the collection chamber (i.e. for transfer to the collection chamber).

In exemplary embodiments, the system further comprises a separating arrangement for separating non-recoverable (i.e. large) removed powder particles from reusable (i.e. small) removed powder particles.

In exemplary embodiments, the separating arrangement comprises a screen located within the collection chamber or between the collection chamber and the interface device, wherein the screen is configured to isolate non-recoverable (i.e. large) removed powder particles from reusable (i.e. small) removed powder particles.

In exemplary embodiments, the system further comprises a sensor configured to detect a de-powdering state of the one or more AM parts have been fully de-powdered (e.g. a load cell to detect a weight of the one or more AM parts and/or powder cake and/or powder within the de-powdering chamber).

Having a sensor configured to detect a de-powdering state of the one or more AM parts have been fully de-powdered allows the system to be automated, which reduces the need for manual input to the de-powdering process (e.g. determining an appropriate cycle time, checking whether parts are de-powdered and re-running a de-powdering operation if checked parts are not fully de-powdered).

In exemplary embodiments, the system comprises a frame for supporting the de- powdering chamber, wherein the frame comprises wheels or the like.

Having a frame with wheels (or tracks/rollers or other movement mechanism) allows the system to be moved close to an additive manufacturing build unit. This reduces the distance required to move AM parts/powder cakes, which reduces time, effort and risk of losing powder.

In exemplary embodiments, the de-powdering chamber is rotatable and/or tiltable for agitation of parts and/or powder cakes located within the de-powdering chamber in use.

The de-powdering chamber being rotatable or tiltable for agitation of parts and/or powder cakes located within the de-powdering chamber in use has been found to increase de- powdering performance.

In exemplary embodiments, the system is configured to prevent generation of static electricity in the de-powdering chamber and/or cancel static electricity generated within the de-powdering chamber; optionally, wherein the system comprises one or more de ionising devices.

According to a sixth aspect of the invention, a flow distributor apparatus is provided, the flow distributor apparatus comprising: a first plate configured to at least partly define wall of a first chamber in use and a second plate, wherein the first plate is spaced apart from the second plate to define a cavity therebetween; and an inlet for introducing fluid to said cavity; wherein the first plate comprises one or more apertures configured to provide a fluid communication between said cavity and said first chamber in use; and wherein the flow distributor apparatus further comprises one or more conduits between the first and second plates, wherein the or each conduit is configured to provide a fluid communication between said first chamber and a side of the second plate opposite the cavity (e.g. a second chamber), and wherein an interior of the or each conduit is fluidly isolated from said cavity.

Such a flow distributor apparatus facilitates a fluid flow path from an inlet to a chamber and then from the chamber to an outlet (e.g. a second chamber). This is useful for applications where a fluid flow is used in a manufacturing process in the chamber (e.g. a de-powdering operation) and subsequently needs to be removed from the chamber (e.g. to prevent build-up of pressure in the chamber). Furthermore, such a flow distributor apparatus allows a flow to be both introduced and removed from the same end of a chamber, which has been found to be beneficial in systems/methods such as de-powdering systems.

BRIEF DESCRIPTION OF THE DRAWINGS

Figure 1 is a cross section of a de-powdering chamber and interface device of a de- powdering system according to an embodiment, when the de-powdering system is in a de-powdering mode;

Figure 2 is a cross section of the de-powdering system of Figure 1 after a de-powdering operation has been performed;

Figures 3a and 3b are perspective views of a de-powdering unit of the de-powdering system of Figures 1 and 2;

Figure 4 is a cross section of the de-powdering chamber and interface device of Figures 1 to 3b, when the de-powdering system is in a cooling mode;

Figure 5a is a perspective view of a moveable pod for use in the de-powdering system of Figures 1 to 4 with a sealing member separated from the moveable pod;

Figure 5b is a perspective view of the moveable pod of figure 5a with the sealing member coupled to the moveable pod;

Figure 5c is a cross section through the moveable pod of Figures 5a and 5b, showing a powder cake located within the moveable pod; Figures 6a to 6c show a method of transporting AM parts or powder cake from an additive manufacturing build unit to a de-powdering unit, using the moveable pod of Figures 5a to 5c; and

Figures 7a and 7b are perspective and cross section views of a flow distributor apparatus for use as the interface device in the system of Figures 1 to 4.

DETAILED DESCRIPTION

Referring firstly to Figures 1 to 4, a system for de-powdering one or more additively manufactured (AM) parts is indicated at 10. The system 10 includes a de-powdering chamber 12 configured to receive one or more AM parts 14 and/or a powder cake 16 containing one or more AM parts. As will be described in detail below, the system 10 is configured for removing powder from one or more AM parts 14 and/or a powder cake 16 received within the de-powdering chamber 12, as will be described in more detail below.

In the illustrated embodiment, the system 10 also includes a collection chamber 18 configured for receiving removed powder 20 from the de-powdering chamber 12, and an interface device 22 configured to define a fluid communication between the de-powdering chamber 12 and the collection chamber 18 (e.g. as illustrated in Figure 7). It will be understood that the interface device 22 effectively functions as a flow distributor apparatus insofar as it allows a flow of fluid and/or powder or other material to be input and removed from the de-powdering chamber 12.

Such a system 10 allows powder 20 to be removed from one or more AM parts 14 and/or a powder cake 16 and transferred via the interface device 22 to the collection chamber 18 for re-use or disposal. In alternative embodiments, the collection chamber 18 and interface device 22 may be omitted, such that removed powder 20 remains within the de-powdering chamber 12 for removal at a later stage (e.g. for removal via vacuum after a de-powdering operation).

The de-powdering chamber 12 includes an inlet 24 configured to introduce a flow of fluid into the de-powdering chamber 12. In alternative embodiments, the de-powdering chamber 12 may include two or more such inlets 24. As will be described in more detail below, flow of fluid through the inlet 24 can be used to agitate/ remove powder 20, and also to move AM parts 14 or to cool a powder cake 16 and AM parts 14 within the de- powdering chamber 12. In the illustrated embodiment, the interface device is provided at a first end 34 of the de-powdering chamber 12 and the inlet 24 is provided at a second end 36 of the de-powdering chamber 12 (e.g. the first and second ends 34, 36 are opposite lower and upper ends of the de-powdering chamber 12).

In exemplary embodiments, the inlet 24 includes a moveable nozzle (not shown) for directing a flow of fluid to different areas of the de-powdering chamber 12. In exemplary embodiments, the system is configured to detect the location of one or more AM parts 14 within the de-powdering chamber 12 (e.g. via a camera, ultrasound, laser or other mechanism/device), and to actuate the moveable nozzle to direct a flow of fluid towards the identified location. This makes it possible to increase the rate of de-powdering or agitation/movement of parts 14, since fluid can be directed towards AM parts 14, rather than vacant spaces in the de-powdering chamber 12.

The system 10 includes an outlet 26 for expelling a flow of fluid from the de-powdering chamber 12 and the collection chamber 18. Such an outlet 26 ensures that the de- powdering chamber 12 and collection chamber 18 do not become pressurised as fluid flows into the de-powdering chamber 12 via the inlet 24.

In the embodiment of Figure 1, fluid flows from the inlet 24 to the de-powdering chamber 12. Fluid then flows from the de-powdering chamber 12 via the interface device 22 to the collection chamber 18, and from the collection chamber 18 to the outlet 26. In the illustrated embodiment, the outlet 26 includes a hose 28 and a gap 30 around an end of the interface device 22 defining a fluid communication between the collection chamber 18 and the hose 28. In alternative embodiments where the collection chamber 18 and/or interface device 22 are omitted, the outlet 26 may be connected directly to the de- powdering chamber 12.

In the illustrated embodiment, the system 10 also includes a filter 32 coupled to the outlet 26. Specifically, the filter 32 is connected directly to the hose 28. In alternative embodiments with different outlet arrangements, the filter 32 may be coupled to the outlet 26 via any suitable mechanism, arrangement or device. Providing a filter 32 coupled to the outlet 26 allows any powder 20 or other small particles to be removed from a flow of fluid leaving the outlet 26. This may be particularly useful when the fluid is air which is released back into the atmosphere surrounding the system 10, since it prevents small powder particles from being inhaled by people positioned close to the system. In alternative embodiments, the filter 32 may be omitted (e.g. a filter may not be necessary in embodiments where the system defines a closed circuit between the outlet 26 and inlet 24).

In the illustrated embodiment, the interface device 22 defines the first end 34 of the de- powdering chamber 12. In alternative embodiments, the interface device 22 may define only a portion of the first end 34 of the de-powdering chamber. The interface device 22 includes an array of apertures 38 configured to introduce a flow of fluid into the de- powdering chamber 12.

A flow of fluid through the apertures 38 and/or the inlet 24 can be used to agitate/ remove powder 20 from AM parts 14 or powder cakes 16 within the de-powdering chamber 12 and/or to move AM parts 14 (e.g. via the force of the fluid flow) and/or to break apart a powder cake 16 (e.g. via the force of the fluid flow).

In exemplary embodiments, the system 10 is configured to control a flow of fluid through the apertures 38. In particular, the system 10 is configured to selectively activate (i.e. open) or de-activate (i.e. close) a subset of the apertures 38. Selectively activating or deactivating a subset of the apertures 38 has been found to improve de-powdering performance (e.g. by activating apertures 38 which are close to one or more parts 14 within the de-powdering chamber 12 in use and deactivating apertures 38 which are not close to one or more parts 14 within the de-powdering chamber 12 in use.

In exemplary embodiments, the inlet 24 and/or one or more of the apertures 38 include a nozzle for introducing fluid having high flow velocity to the de-powdering chamber. Such nozzles may include an adjustable orifice for increasing fluid volumetric flow rate and/or velocity, and/or for directing fluid towards the one or more AM parts 14 and/or powder cake 16. Such nozzles/orifices have been found to improve de-powdering performance.

In exemplary embodiments, the inlet 24 and/or one or more of the apertures include an air flow amplifier. Having an air flow amplifier increases the volumetric flow rate and/or flow velocity through said inlet 24 and/or apertures 38, which has been found to increase de-powdering performance.

In the illustrated embodiment, the first end 34 of the de-powdering chamber 12 defined by the interface device 22 is opposite the inlet 24. This allows first and second fluid flows to be introduced to the de-powdering chamber 12 in opposite directions, which increases the faces of an AM part 14 or powder cake 16 which are exposed to fluid flow. This contrasts with a system with fluid flowing in only a first direction, in which faces of parts 14 or powder cakes 16 which are arranged downstream in this first direction may be shielded from the fluid flow by the body of the part 14 or powder cake 16.

In the illustrated embodiment, the array of apertures 38 define a grid formation extending across substantially all of the first end of the de-powdering chamber 12. As a result, fluid can be introduced to the de-powdering chamber 12 via the apertures 38 over a relatively large surface area (e.g. the apertures are spread out across the majority of the surface area of the interface device 22). In alternative embodiments, the array of apertures 38 is irregularly distributed, or only a single aperture 38 is provided). In the illustrated embodiment, the apertures 38 define approximately 2% of the cross-sectional area of the de-powdering chamber 12, although they could define a larger area (e.g. by including more apertures 38, or by widening the apertures 38) or smaller area (e.g. by including less apertures 38, or by narrowing the apertures 38). The aperture 38 arrangement described above ensures effective removal of powder 20 across the de-powdering chamber 12 (e.g. over a system with a single aperture 38 or group of apertures 38 in a small area of the first end 34 of the de-powdering chamber 12). For a given volumetric flow rate, the relatively large surface area of the apertures 38 results in a relatively low velocity (e.g. over an inlet 24 or set of apertures defining a smaller surface area).

In the illustrated embodiment, the inlet 24 has a relatively small surface area (e.g. in the region of 0.05% of the cross-sectional area of the de-powdering chamber 12). For a given volumetric flow rate, the small surface area of the inlet 24 results in a relatively high velocity (e.g. over a plurality of apertures 38 defining a larger surface area). Such a high velocity fluid flow may be suitable for moving AM parts 14, for breaking apart a powder cake 16, and/or for removing powder from AM parts 14 or powder cakes 16.

In the illustrated embodiment, the interface device 22 includes a first plate 40 and a second plate 42 defining a cavity 44 therebetween. The interface device 22 also includes an interface device inlet 46 configured to introduce a flow of fluid into the cavity 44. The array of apertures 38 are provided in the first plate 40 to provide a fluid communication between the de-powdering chamber 12 and the cavity 44 for introduction of fluid from the interface device inlet 46 to the de-powdering chamber 12. The interface device 22 is also configured to isolate the interface device inlet 46 from the collection chamber 18, as will be described in more detail below. Such an interface device 22 allows fluid to be introduced from the interface device inlet 46 to the de-powdering chamber 12 (e.g. for removal of powder 20 from parts 14 and/or powder cakes 16, or for agitating or moving the parts 14 and/or powder cakes 16 for exposing different faces of the parts 14 or powder cakes 16 to an alternative fluid flow(s) (e.g. from the inlet 24) for removal of powder via the alternative fluid flow(s)) whilst isolating the interface device inlet 46 from the collection chamber 18 (where a flow of fluid is not required).

In the illustrated embodiment, the interface device 22 includes an array of conduits 48 between the first plate 40 and the second plate 42. The conduits 48 are configured to provide a fluid communication between the de-powdering chamber 12 and the collection chamber 18. Furthermore, an interior of each conduit 48 is fluidly isolated from the cavity 44 (e.g. via the walls of the cavity). Such conduits 48 provide a path for transferring powder 20 and/or powder entrained fluid through the interface device 22 from the de- powdering chamber 12 to the collection chamber 18, whilst preventing a flow of fluid from the interface device inlet 46 (e.g. a clean fluid with no entrained powder) from entering the collection chamber 18 (where it is not needed).

In the illustrated embodiment, the array of conduits 48 is arranged in a grid formation. Having an array of conduits 48 arranged in a grid formation facilitates transfer of powder 20 to the collection chamber 18 over a wide surface area, which ensures more effective transfer of powder 20 from the de-powdering chamber 12. In alternative embodiments, the conduits 48 may be alternatively arranged (e.g. in an irregular pattern) or only a single conduit 48 (e.g. a conduit in the centre of the interface device 22) may be provided.

In exemplary embodiments, the conduits 48 are in fluid communication with a vacuum source in use. For example, the collection chamber 18 may be connected to a vacuum. Connecting the conduits 48 to a vacuum source has been found to increase the rate at which removed powder 20 is transferred from the de-powdering chamber 12.

In the illustrated embodiment, the system 10 also includes a mechanism for shaking or vibrating one or more AM parts 14 and/or a powder cake 16 received within the de- powdering chamber 12, as will be described in more detail below. Shaking and/or vibrating the parts 14 or powder cakes 16 has been found to be effective for agitating and removing powder 20 on its own, or in combination with one or more fluid flows through the de- powdering chamber 12. This may also help to move parts 14 or powder cakes 16 so that different faces are exposed to fluid flows for removal of powder 20.

In the illustrated embodiment, the system 10 includes a vibration motor 50 coupled to the de-powdering chamber 12 and interface device 22. In particular, the vibration motor 50 is attached to a frame 52 supporting the de-powdering chamber 12 and interface device 22. The frame 52 includes an upper portion coupled to a lower portion via springs 54. The vibration motor 50 is attached to the upper portion of the frame 52, which causes the upper portion of the frame 52 to vibrate/shake. The springs 54 facilitate movement (i.e. vibration/shaking) of the upper portion of the frame 52. The interface device 22, de- powdering chamber 12 and collection chamber 18 are coupled to the upper portion of the frame 52. Thus, vibration/shaking of the upper portion of the frame 52 via the vibration motor 50, leads to vibration/shaking of any parts 14 or powder cakes 16 located within the de-powdering chamber 12. This vibrating/shaking may also encourage a flow of removed powder 20 through the conduits 48 of the interface device 22 (i.e. it may prevent powder from building up at the first end 34 of the de-powdering chamber 12.

Such an arrangement provides a simple mechanism for shaking/vibrating parts 14 or powder cakes 16 within the de-powdering chamber 12. However, in alternative embodiments, a different type of shaking or vibration mechanism may be used.

In exemplary embodiments, the frame 52 includes wheels, tracks, rollers or the like, which allows the system 10 to be moved close to an additive manufacturing build unit 70. This reduces the distance required to move AM parts/powder cakes 14, 16, which reduces time, effort and risk of losing powder 20.

In the illustrated embodiment, the de-powdering chamber 12 is arranged above the interface device 22 (e.g. the interface device 22 is configured to support one or more AM parts 14 and/or a powder cake 16 received within the de-powdering chamber 12). This allows powder 20 to be directed via gravity to the interface device 22 (i.e. for transfer to the collection chamber 18). The collection chamber 18 is arranged below the interface device 22. This allows powder to be directed via gravity to through the interface device 22 to the collection chamber 18. In alternative embodiments, the de-powdering chamber 12, interface device 22 and/or collection chamber 18 may be located side-by-side (e.g. rotated approximately 90 degrees from the arrangement of the illustrated embodiment), may be flipped vertically (e.g. rotated approximately 180 degrees from the arrangement of the illustrated embodiment), or may be arranged at an angle (e.g. rotated between 0 and 180 degrees from the arrangement of the illustrated embodiment). In such embodiments, the flow of fluid through the de-powdering chamber 12 may be sufficient to transfer powder 20 through the interface device 22 to the collection chamber 18, without the assistance of gravity.

In exemplary embodiments, the system 10 also includes a separating arrangement for separating non-recoverable (i.e. large) removed powder particles from reusable (i.e. small) removed powder particles. For example, the separating arrangement may be a screen (not shown) located within the collection chamber 18 or between the collection chamber 18 and the interface device 22. Such a screen would be configured to isolate non- recoverable (i.e. large) removed powder particles from reusable (i.e. small) removed powder particles.

In exemplary embodiments, the system 10 includes a sensor configured to detect a de- powdering state of the AM parts 14 (e.g. a load cell to detect weight of the AM parts 14 and/or powder cake 16 and/or powder 20 within the de-powdering chamber 12). Such a sensor allows the system 10 to be automated, which reduces the need for manual input to the de-powdering process (e.g. determining an appropriate cycle time, checking whether parts are de-powdered and re-running a de-powdering operation if checked parts are not fully de-powdered).

The illustrated system 10 is configured for removing powder from typical sized AM parts 14 or powder cakes 16. For example, the width of the de-powdering chamber 12 may be in the range of 0.1 m to 0.8 m, the depth of the de-powdering chamber 12 may be in the range of 0.1 m to 0.8 m, and the height of the de-powdering chamber may be in the range of 0.1 m to 0.8 m. However, the skilled person would understand that the same principles would work on larger or smaller scales.

In exemplary embodiments, the de-powdering chamber 12 is rotatable and/or tiltable for agitation of parts 14 and/or powder cakes 16 located within the de-powdering chamber 12 in use.

In exemplary embodiments, the system 10 is configured to prevent generation of static electricity in the de-powdering chamber 12 and/or cancel static electricity generated within the de-powdering chamber 12. In such embodiments, the system 10 may include one or more de-ionising devices. Preventing generation of static electricity and/or cancelling static energy reduces the likelihood of damage to the de-powdering system 10 and/or AM parts 14. Preventing generation of static electricity and/or cancelling static energy also prevents AM parts 14 from being charged in ways which would be detrimental to further processing operations, such as coating operations.

In the illustrated embodiment, the de-powdering chamber 12 is partly defined by a moveable pod or container 56 and the collection chamber 18 is partly defined by a moveable pod or container 56 (as will be described in more detail below). In alternative embodiments, the de-powdering chamber 12 and/or collection chamber may be permanently fixed to the system 10 (e.g. welded to the interface device 22). Referring now to Figures 5a to 5c, the illustrated moveable pod 56 has a housing 58 defining a chamber 60 for receiving one or more AM parts 14 and/or a powder cake 16 and/or powder 20. The chamber 60 has a first end 62 including a first opening 64 (e.g. inlet 24 of the de-powdering chamber described above) for input of fluid and/or powder 20 to the chamber 60 and/or removal of fluid and/or powder 20 from the chamber 60. The chamber 60 also has a second end 66 including a second opening 68 for input of fluid and/or powder 20 to the chamber 60 and/or removal of fluid and/or powder 20 from the chamber 60. In alternative embodiments, the first end 62 may include a plurality of first openings 64 and/or the second end 66 may include a plurality of second openings 68.

It will be understood that such a moveable pod 56 forms part of the de-powdering chamber 12 of the de-powdering system 10 in use (the other part of the de-powdering chamber 12 being defined by the interface member 22). In alternative embodiments, the moveable pod 56 may form the entire de-powdering chamber 12 (e.g. in embodiments where the interface member 22 and collection chamber 18 are omitted).

It will also be understood that such a moveable pod 56 forms part of the collection chamber 18 of the de-powdering system 10 in use (the other part of the collection chamber 18 being defined by the interface member 22). In alternative embodiments, the moveable pod 56 may form the entire collection chamber 18 (e.g. in embodiments where the first opening 64 of the moveable pod 56 is connected to an outlet in the de-powdering chamber 12 via a hose).

Such a moveable pod chamber 60 is suitable for receiving parts 14 or powder cakes 16, and also allows input of fluid for removing powder 20 from said parts 14 or powder cakes 16. The first and second openings 64, 68 allow first and second fluid flows in different directions to be introduced to the moveable pod chamber 60, for agitating and removing powder 20 from one or more AM parts 14 and/or powder cake 16 located therein. Furthermore, the moveable pod 56 allows parts 14 or powder cakes 16 to be loaded into the pod 56 at a first location (e.g. an additive manufacturing build unit 70) and robustly transported to a second location (e.g. a de-powdering unit 72), as will be described in more detail in relation to Figures 6a to 6c.

In the illustrated embodiment, the second end 66 is opposite the first end 62 of the moveable pod chamber 60 (i.e. the first end second ends 62, 66 are opposing lower and upper ends). The first and second ends 62, 66 being opposite each other means the first and second openings 64, 68 allow first and second fluid flows in opposite directions to be introduced to the moveable pod chamber 60, for agitating and removing powder 20 from one or more AM parts 14 and/or powder cakes 16 located therein. This allows powder 20 to be effectively removed, since opposing faces of the AM part 14 or powder cake 16 are exposed to the first and second fluid flows.

In the illustrated embodiment, the second end 66 is an open end defining the second opening 68. Having an open end allows the moveable pod 56 to be connected to the interface device 22 of the de-powdering system 10 (e.g. for transfer of fluid and/or powder 20 through the interface device 22 to the moveable pod 56 in the case of a collection chamber 18, and/or transfer of fluid and/or powder 20 from the moveable pod 56 through the interface device 22 in the case of a de-powdering chamber 12).

In the illustrated embodiment, the moveable pod 56 also includes a sealing member 74 for covering the second opening 68 to seal the second end 66 of the chamber 60. This allows parts 14 and/or powder cakes 16 and/or powder 20 to be transported robustly in the moveable pod, without loss of parts 14 and/or powder cakes 16 and/or powder 20 or damage to the same. In the illustrated embodiment, the sealing member 74 includes a cutting part 76 (e.g. a sharpened and/or serrated blade) for cutting a powder cake 16 to remove it from an additive manufacturing build unit 70. In other words, the sealing member 74 performs the two functions of separating a powder cake 16 from a build unit 70, and sealing the moveable pod 56, which removes the need for an additional cutting tool. However, in alternative embodiments, the cutting part 76 may be a separate component (e.g. a blade, wire or other cutting tool).

The moveable pod 56 includes clips 80 for securing the sealing member 74 in position over the open end of the moveable pod 56. In addition, the sealing member 74 includes a handle for easy movement of the sealing member 74.

The open end of the moveable pod is also configured for placing over one or more AM parts 14 and/or a powder cake 16. This removes the need to pick up the parts 14 or powder cake 16, which reduces the likelihood of loose powder 20 being removed where it cannot be recovered. For example, the open end can be placed over parts 14 or a powder cake 16, then the sealing member 74 can be slid underneath the parts 14 or powder cake 16 to seal the parts 14 or powder cake 16 within the pod 56.

In the illustrated embodiment, the moveable pod 56 also includes handles 78 for manual transport of the moveable pod 56. In alternative embodiments, the moveable pod may be configured for automatics transport (e.g. via a robotic arm, conveyor, or other automated mechanism).

In exemplary embodiments, the moveable pod 56 also includes a removable plug configured for inserting in the first opening 64 (e.g. inlet 24) to seal the first opening 64 during transit. This prevents loss of powder 20 or small parts 14 through the first opening 64. In exemplary embodiments, where the main powder removal mechanism is shaking/vibrating rather than fluid flow(s), the removable plug may remain inserted in the first opening 64 (e.g. inlet 24) throughout a de-powdering operation. In other embodiments, where de-powdering or cooling fluid flows are used, the removable plug may be removed, and the first opening 64 (e.g. inlet 24) may be connected to a hose or other fluid source. In exemplary embodiments, the first opening 64 at the first end 62 of the moveable pod 56 (e.g. inlet 24) may be omitted. For example, in systems where the main powder removal mechanism is shaking/vibration rather than fluid flow, this first opening 64 may not be needed.

In the illustrated embodiment, moveable pod 56 partly defining the collection chamber 18 is of the same configuration as the moveable pod 56 partly defining the de-powdering chamber 12, as described above. In alternative embodiments, the collection chamber 18 may be at least partly defined by a moveable pod of different configuration (e.g. the first opening 64 may be removed). The collection chamber 18 being partly defined by a second moveable pod 56 allows removed powder 20 to be transported within the second moveable pod 56 to a different location. This facilitates recycling and/or tidy disposal of powder 20. Furthermore, the two moveable pods 56 being of the same configuration allows them to be used interchangeably.

In the illustrated embodiment, the second opening 68 of the collection chamber 18 facilitates input of removed powder 20 from the de-powdering chamber 12, via the interface device 22 to the collection chamber 18. The first opening 64 of the collection chamber 18 may be used to remove powder 20 from the collection chamber 18 (e.g. via a vacuum). Alternatively, the first opening 64 of the collection chamber 18 may have the removable plug inserted at all times, or may be omitted entirely.

The moveable pods 56 partly defining the de-powdering chamber 12 and collection chamber 18 are each configured for coupling to a de-powdering unit 72 (e.g. as shown in Figure 6c). For example, the moveable pods 56 include a flange 82 around the open end for sliding into a receiving groove of the de-powdering unit 72 (e.g. a receiving groove adjacent the interface device 22). This is particularly useful for the collection chamber 18, since the flange allows it to be supported from the top when in position in the de-powdering unit (as shown in Figures 6b and 6c).

The de-powdering unit 72 includes a hinged fastening member 84 for securing the moveable pods 56 in the de-powdering unit after the flanges 82 have been engaged with the corresponding receiving grooves.

In alternative embodiments, the moveable pods 56 may be coupled to the de-powdering unit 72 via any other suitable mechanism, arrangement or device.

The illustrated moveable pods 56 are configured for receiving typical sized AM parts 14 or powder cakes 16. For example, the width of the moveable pod chamber 60 may be in the range of 0.1 m to 0.8 m, the depth of the moveable pod chamber 60 may be in the range of 0.1 m to 0.8 m, and the height of moveable pod chamber 60 may be in the range of 0.1 m to 0.8 m. However, the skilled person would understand that the same principles would work on larger or smaller scales.

In exemplary embodiments, the moveable pods 56 include wheels, which allow heavy parts to be transported without lifting. In such embodiments, the wheels may be controlled autonomously (e.g. via a control system including position sensors and motors for driving the wheels), which reduces the need for human input in moving the pods 56.

Referring again to Figures 1 to 4, a method of removing powder from one or more AM parts 14 using the system 10 described above includes the following steps: locating one or more AM parts 14 or a powder cake 16 in the de-powdering chamber 12; directing a first flow of fluid in a first direction into the de-powdering chamber 12 in order to impact the one or more AM parts 14 and/or powder cake 16 (e.g. via the apertures 38 of the interface device 22); and simultaneously directing a second flow of fluid in a second direction into the de-powdering chamber 12 in order to impact the one or more AM parts 14 and/or powder cake 16, the second direction being opposite to the first direction (e.g. via the inlet 24). Having first and second fluid flows in different first and second directions allows powder to be more effectively removed from an AM part 14 or powder cake 16, since it increases the faces of the AM part 14 or powder cake 16 which are exposed to the fluid flows. This contrasts with a system with fluid flowing in only a first direction, in which part/powder cake faces which are arranged downstream in this first direction may be shielded from the fluid flow by the body of the part 14 or powder cake 16. In exemplary embodiments, the first and second fluid flows are a flow of gas (e.g. air, nitrogen, argon, carbon dioxide, other gas or gaseous mixture). Gases are particularly suitable for removing powder from AM parts 14, since removed powder particles 20 can become entrained in flows of gas, which allows simple transfer of removed powder 20 out of the de-powdering chamber 12. Powder particles are also easy to separate from gas flow via sifting, filtering or gravity alone (e.g. for disposal or recycling of powder 20). If air is used there is no need to provide a separate reservoir of fluid, since this can be pumped and/or compressed from the environment in which the de-powdering chamber 12 is located. If an inert gas is used, this minimises the introduction of impurities which could result in discolouration or other damage to parts 14, which result in better physical characteristics of the de-powdered parts 14.

The first fluid flow through apertures 38 of the interface device 22 may have a relatively high volumetric flow rate compared with the second fluid flow through inlet 24. The second fluid flow through inlet 24 may have a relatively high velocity compared with the first fluid flow through apertures 38. Note that the apertures 38 defining a larger surface area than the inlet 24 may result in the first fluid flow having a lower velocity than the second fluid flow, despite having a higher volumetric flow rate.

Having a first fluid flow with a high volumetric flow rate facilitates a high removal rate of powder 20. However, on its own, this first flow of fluid may be ineffective for removing powder from downstream faces of AM parts 14 or powder cakes 16. Having a high velocity second flow facilitates moving AM parts 14 or powder cakes 16, so that different faces are exposed to the first fluid flow. Furthermore, the high velocity second fluid flow may be suitable for breaking apart a powder cake 16 into smaller pieces, which increases the surface area exposed to the first fluid flow and thus increases the rate of powder removal. The high velocity second fluid flow may also be suitable for agitating and/or removing powder 20 in cracks or other shielded areas of AM parts 14.

In exemplary embodiments, the volumetric flow rate of the first fluid flow is in the range of 0.01 mV¹ to 0.5 mV¹. In exemplary embodiments, the volumetric flow rate of the second fluid flow is in the range of 0.001 mV¹ to 0.01 mV¹. In exemplary embodiments, the velocity of the first fluid flow is in the range of 1 ms ¹ to 30 ms ¹. In exemplary embodiments, the velocity of the second fluid flow is in the range of 30 ms ¹ to 120 ms ¹.

In exemplary embodiments, the method includes altering the second direction (e.g. via a moveable nozzle in the inlet 24). This allows the second fluid flow to be directed to different regions of the de-powdering chamber (e.g. to impact AM parts/powder cakes 14, 16 or portions of AM parts/powder cakes 14, 16 located in different regions of the de-powdering chamber 12 for removal of powder 20 or moving the AM parts/powder cakes 14, 16).

In exemplary embodiments, the method includes identifying one or more locations of one or more AM parts 14 within the de-powdering chamber 12 (e.g. via a camera, ultrasound, laser or other mechanism/device) and directing the second flow of fluid towards the one or more locations. This increases the rate of de-powdering or agitation/movement of parts 14, since fluid is directed towards AM parts 14, rather than vacant spaces in the de- powdering chamber 12.

In exemplary embodiments, the first and/or second fluid flows comprise intermittent bursts of compressed gas (e.g. a pulsed flow).

Referring now to Figures 6a to 6c, a second method of removing powder from one or more AM parts 14 using the system 10 described above includes the following steps: providing a de-powdering chamber 12 at least partly defined by a moveable pod or container 56; locating one or more AM parts 14 and/or a powder cake 16 in the moveable pod 56 at a first location (e.g. an additive manufacturing build unit 70); transporting the moveable pod 56 to a second location (e.g. a de-powdering unit 72); and performing a de-powdering operation at the second location (e.g. de-powdering unit 72) in order to remove powder 20 from the parts 14 and/or powder cake 16 located within the moveable pod 56. Such a method allows parts 14 or powder cakes 16 to be transferred easily from an additive manufacturing build unit 70 at a first location, to a second location (e.g. a de-powdering unit 72) for removing powder 20. In addition, such a moveable pod 56 may protect the parts 14 and/or powder cake 16 during transit from the first to the second location, and prevent any loose powder 20 from falling on the floor, where it would be difficult to recycle or reuse.

Note that in the illustrated embodiment, the step of performing a de-powdering operation at the second includes implementing the first method described above (i.e. using two fluid flows in opposite directions). In alternative embodiments, this step may be performed via a different mechanism (e.g. using shaking/vibration, passing ultrasonic energy through liquid, or using other suitable de-powdering mechanisms/devices).

The second method optionally includes the following steps: placing the open end of the moveable pod 56 over the one or more AM parts 14 and/or powder cake 16; and sealing the open end of the moveable pod 56 with the sealing member 74 (e.g. via inserting the sealing member 74 under the one or more AM parts 14 and/or powder cake 16). In embodiments where the sealing member 74 includes a cutting part 76 or a separate cutting tool is provided, the method may also include the step of cutting a powder cake 16 from an additive manufacturing build unit 70 (e.g. via inserting the cutting part 76 under the powder cake 16).

The second method optionally includes the step of coupling the moveable pod 56 to a de- powdering unit 72 at the second location (e.g. via the pod flange 82 and hinged fastening member 84 described above). This step also includes placing the open end of the movable pod 56 adjacent the interface device 22 (e.g. via removing the sealing member 74 from the open end of the moveable pod 56).

Once the parts have been de-powdered, the second method optionally includes the steps of: decoupling the moveable pod 56 from the de-powdering unit 72 (e.g. via sealing the open end of the moveable pod 56 with the sealing member 74 and then sliding the flange 82 out of its corresponding receiving groove); and transporting one or more de-powdered AM parts 14 within the moveable pod 56 to a third location (e.g. a storage unit, or an inspection area, not shown). This ensures that the parts 14 are protected from damage or being lost etc. as they are transported to the third location. This may be particularly useful for smaller parts 14. Furthermore, this may help with part inventories, since labels, barcodes or the like can easily be attached to the moveable pod 56. Furthermore, sealing the open end of the moveable pod 56 ensures the parts stay within the moveable pod 56, which reduces the likelihood of parts becoming damaged or lost during transport.

The second method optionally includes the steps of transferring powder 20 removed from the AM parts/powder cake 14, 16 from the moveable pod 56 defining the de-powdering chamber 12 through the interface device 22 to the moveable pod 56 defining the collection chamber 18. This ensures that the one or more AM parts 14 and/or powder cake 16 are not covered by accumulations of removed powder 20, and ensures that removed powder 20 does not become re-attached to parts 14. This increases the effectiveness of the de- powdering process. Transferring removed powder 20 to the collection chamber 18 also allows removed powder to be gathered for disposal or re-cycling.

The second method optionally includes the further steps of: de-coupling the moveable pod 56 defining the collection chamber 18 from the de-powdering unit 72 (e.g. via sealing the open end of the moveable pod 56 with the sealing member 74 and then sliding the flange 82 out of its corresponding receiving groove); and transporting removed powder 20 within the moveable pod 56 defining the collection chamber to a different location (e.g. an additive manufacturing build unit 70, or a waste/recycling location).

The second method optionally includes transferring removed powder from the collection chamber 18 using a vacuum (e.g. a vacuum connected to the first opening 64 of the moveable pod 56 defining the collection chamber 18). This allows the removed powder 20 to be reused (e.g. via connecting the vacuum to a powder tank of an additive manufacturing build unit 70) or disposed of (e.g. via connecting the vacuum to a bin). This step can be performed directly at the de-powdering unit 72 or at a different location.

In exemplary embodiments, transporting the moveable pod 56 to a second location and/or third location involves autonomously transporting the moveable pod 56 (e.g. via robotic assistance and or autonomously guided vehicles). Autonomously transporting the moveable pod 56 (e.g. via robotic assistance and or autonomously guided vehicles) reduces the need for human input in moving the pod 56.

The methods described above optionally also include shaking and/or vibrating the one or more AM parts 14 and/or powder cake 16 within the de-powdering chamber 12, to agitate and remove powder from the one or more AM parts 14 and/or powder cake 16 (e.g. via the vibration motor 50, as described above). Shaking and/or vibrating the parts 14 or powder cakes 16 has been found to be effective for agitating and removing powder 20 on its own, or in combination with one or more fluid flows through the de-powdering chamber 12. This may also help to move parts 14 or powder cakes 16 so that different faces are exposed to fluid flows for removal of powder 20.

The methods described above optionally also include cooling the one or more AM parts 14 and/or powder cake 16 prior to agitating and removing powder 20. Cooling the parts 14 and/or powder cake 16 prior to agitating and removing powder 20 allows them to reach a temperature suitable for de-powdering.

As shown in Figure 4, this cooling step may include introducing a flow of cooling fluid (e.g. air, nitrogen, argon, carbon dioxide, other gas or gaseous mixture) to the de-powdering chamber 12 (e.g. via the inlet 24). This is an effective approach to cooling parts 14 and/or powder cakes 16. The flow of cooling fluid may be controlled so that it does not affect the structural integrity of a powder cake 16 (e.g. the flow of cooling fluid may have a volumetric flow rate and/or pressure and/or velocity low enough to inhibit breaking apart a powder cake 16). This allows cooling fluid to pass through material voidage in the powder cake 16 (fluid spaces between powder particles) whilst avoiding high temperature gradients which would be associated with a sudden breaking of the powder cake 16. This avoids shrinkage and/or warping of the one or more AM parts 14 during crystallisation.

The cooling step may also include controlling the temperature of the flow of cooling fluid and/or the flow rate of the flow of cooling fluid to control the rate of cooling of the one or more AM parts 14 and/or powder cake 16. This ensures high temperature gradients are avoided, which avoids shrinkage and/or warping of the one or more AM parts 14 during crystallisation.

In exemplary embodiments, the cooling fluid is an inert gas, which minimises the introduction of impurities which could result in discolouration or other damage to parts 14. This result in better physical characteristics of the cooled and de-powdered parts 14.

In exemplary embodiments, one or more of the fluid flows may be omitted (e.g. the shaking/vibrating the parts 14 or powder cake 16 may be the primary mechanism for removing powder 20 from the parts 14). In such embodiments, the interface device 22 may be alternatively configured (e.g. it may be a single perforated plate separating the de-powdering chamber 12 from the collection chamber).

Although the invention has been described in relation to one or more embodiments, it will be appreciated that various changes or modifications can be made without departing from the scope of the invention as defined in the appended claims. For example: the de-powdering chamber 12 and/or collection chamber 18 may be permanently attached to the de-powdering unit (e.g. via welding to the de-powdering interface device 22); in embodiments with a permanently fixed de-powdering chamber, the de- powdering chamber 12 may include a door or other closable opening for input/removal of parts 14 or powder cakes 16; the interface device 22 as described above (and depicted in Figure 7) may be used as a flow distributor apparatus in any other type of system where a flow needs to be directed from an inlet, to a first chamber and then to a second chamber (i.e. not necessarily in a de-powdering system); the interface device 22 and collection chamber 18 may be omitted, and removed powder 20 may remain within the de-powdering chamber 12; the de-powdering chamber 12 may have two or more inlets 24, and these may be provided at the first or second ends 34, 36, on one or more sides of the de-powdering chamber (i.e. between the first and second ends 34, 36), or on a combination of ends/sides; the moveable pods 56 may have two or more first openings 64; the outlet 26 may be connected directly to the de-powdering chamber 12 (e.g. in embodiments where the interface device 22 and collection chamber 18 are omitted); a different type of shaking/vibrating mechanism may be used to the vibration motor; the de-powdering chamber 12, interface device 22 and/or collection chamber 18 may be located side-by-side (e.g. rotated approximately 90 degrees from the arrangement of the illustrated embodiment); the cutting part 76 may be a separate component to the sealing member 74 (e.g. a blade, wire or other cutting tool); the moveable pods 56 may be configured for automated transport (e.g. via a robotic arm, conveyor, or other automation mechanism); the collection chamber 18 may be of different shape and/or configuration to the de-powdering chamber 12; the moveable pods 56 may be coupled to the de-powdering unit 72 via any other suitable mechanism, arrangement or device; and/or the dimensions, volumetric flow rates and flow velocities may differ from the ranges indicated in the description.

Claims

1. A method of removing powder from one or more additively manufactured (AM) parts or a powder cake containing one or more AM parts, the method comprising the steps of: locating one or more AM parts and/or a powder cake containing one or more AM parts in a chamber; directing a first flow of fluid in a first direction into the chamber in order to impact the one or more AM parts and/or powder cake; and directing a second flow of fluid in a second direction into the chamber in order to impact the one or more AM parts and/or powder cake, wherein the second direction is different to the first direction.

2. A method according to claim 1, wherein said first and second flows of fluid are directed simultaneously into said chamber.

3. A method according to claim 2, wherein the second direction is opposite the first direction; optionally, wherein the first direction is upwards, and wherein the second direction is downwards.

4. A method according to any preceding claim, wherein the first fluid flow comprises a relatively high volumetric flow rate compared with the second fluid flow, and wherein the second fluid flow comprises a relatively high velocity compared with the first fluid flow; optionally, wherein the first and/or second fluid flow comprises intermittent bursts of compressed gas (e.g. a pulsed flow).

5. A method according to any preceding claim, further comprising moving the one or more AM parts and/or powder cake within the chamber with the first fluid flow and/or second fluid flow; optionally, further comprising altering the first direction and/or second direction for moving parts within the chamber; optionally, further comprising identifying one or more locations of one or more AM parts within the chamber and directing the first fluid flow and/or second flow of fluid towards the one or more locations for moving parts within the chamber.

6. A method according to any preceding claim, further comprising transferring powder removed from the one or more AM parts and/or powder cake by the first and/or second fluid flows from the chamber; optionally, further comprising transferring said powder from the chamber to a collection chamber.

7. A method according to claim 6, wherein the first direction is opposite the second direction, wherein the first fluid flow comprises a relatively high volumetric flow rate compared with the second fluid flow, wherein the second fluid flow comprises a relatively high velocity compared with the first fluid flow, and wherein the chamber comprises a first end configured for directing the first fluid flow into the chamber and for transferring removed powder from the chamber; optionally, wherein the first end comprises an interface device comprising an array of apertures, wherein the array of apertures comprises a first set of apertures for directing the first fluid flow into the chamber and a second set of apertures for transferring removed powder from the chamber.

8. A method according to any preceding claim, wherein the chamber is at least partly defined by a moveable pod or container, the method further comprising: locating one or more AM parts and/or a powder cake containing one or more AM parts in the moveable pod or container at a first location; transporting the moveable pod or container to a second location; and performing a de-powdering operation at the second location in order to remove powder from the one or more AM parts and/or powder cake located within the moveable pod or container; optionally, wherein the moveable pod or container is configured for coupling to a de-powdering unit, and wherein the de-powdering unit is configured to direct the first and second flows of fluid through the moveable pod or container for agitating and removing powder from the one or more AM parts and/or powder cake; and/or optionally, wherein the moveable pod or container comprises an open end, and wherein the step of locating one or more AM parts and/or a powder cake in the moveable pod or container at a first location comprises: placing the open end of the moveable pod or container over the one or more AM parts and/or powder cake; and sealing the open end of the moveable pod or container with a sealing member, optionally, wherein the step of sealing the open end of the moveable pod or container with a sealing member comprises inserting the sealing member under the one or more AM parts and/or powder cake, and/or wherein the sealing member comprises a cutting part, and wherein the step of sealing the open end of the moveable pod or container with a sealing member comprises cutting a powder cake from an additive manufacturing build unit using the cutting part.

9. A method of removing powder from one or more additively manufactured (AM) parts and/or a powder cake containing one or more AM parts, the method comprising the steps of: providing a chamber at least partly defined by a moveable pod or container; locating one or more AM parts and/or a powder cake containing one or more AM parts in the moveable pod or container at a first location; transporting the moveable pod or container to a second location; and performing a de-powdering operation at the second location in order to remove powder from the one or more AM parts and/or powder cake located within the moveable pod or container; optionally, wherein the moveable pod or container comprises an open end, and wherein the step of locating one or more AM parts and/or a powder cake in the moveable pod or container at a first location comprises: placing the open end of the moveable pod or container over the one or more AM parts and/or powder cake; and sealing the open end of the moveable pod or container with a sealing member, optionally, wherein the step of sealing the open end of the moveable pod or container with a sealing member comprises inserting the sealing member under the one or more AM parts and/or powder cake, and/or wherein the sealing member comprises a cutting part, and wherein the step of sealing the open end of the moveable pod or container with a sealing member comprises cutting a powder cake from an additive manufacturing build unit using the cutting part.

10. A method according to claim 8 or 9, wherein the step of performing a de-powdering operation at the second location comprises coupling the moveable pod or container to a de-powdering unit at the second location, wherein the moveable pod or container comprises an open end, wherein the de-powdering unit comprises an interface device configured for transfer of fluid and/or powder therethrough, and wherein the step of coupling the moveable pod or container to the de-powdering unit at the second location comprises placing the open end of the moveable pod or container adjacent the interface device; optionally, wherein the step of coupling the moveable pod or container to the de- powdering unit at the second location further comprises removing the or a sealing member from the open end of the moveable pod or container; and/or optionally, wherein the method further comprises: decoupling the moveable pod or container from the de-powdering unit, optionally, wherein the step of decoupling the moveable pod or container from the de-powdering unit comprises sealing the or an open end of the moveable pod or container with the or a sealing member; and transporting one or more de-powdered AM parts within the moveable pod or container to a third location (e.g. a storage unit, or an inspection area).

11. A method according to any of claims 8 to 10, further comprising transferring powder removed from the one or more AM parts and/or powder cake by the de-powdering operation from the chamber through the or an interface device to a collection chamber; optionally, further comprising transferring said powder from the collection chamber using a vacuum; and/or optionally, wherein the moveable pod or container is a first moveable pod or container and the collection chamber is at least partly defined by a second moveable pod or container, and wherein the method further comprises: de-coupling the second moveable pod or container from the de-powdering unit; and transporting powder removed from the one or more AM parts and/or powder cake by the de-powdering operation within the second moveable pod or container to a different location (e.g. an additive manufacturing build unit, or a waste/recycling location); optionally, wherein the second moveable pod or container is of the same shape and configuration as the first moveable pod or container; optionally, wherein the step of de-coupling the second moveable pod or container from the de-powdering unit comprises sealing an open end of the second moveable pod or container with a sealing member; optionally, wherein the method further comprises transferring said powder from the second moveable pod or container; optionally, further comprising transferring said powder from the second moveable pod or container using a vacuum at the different location.

12. A method according to any preceding claim, further comprising cooling the or a powder cake prior to removing powder by introducing a flow of cooling fluid (e.g. air, nitrogen, argon, carbon dioxide, other gas or gaseous mixture) to the chamber; optionally, further comprising controlling the flow of cooling fluid so that it does not affect the structural integrity of the powder cake (e.g. the flow of cooling fluid has a volumetric flow rate and/or velocity low enough to inhibit breaking apart the powder cake); optionally, further comprising controlling the temperature of the flow of cooling fluid and/or the velocity of the flow of cooling fluid to control the rate of cooling of the one or more AM parts and/or powder cake; and/or optionally, wherein the cooling fluid is an inert gas.

13. A moveable pod for use in a system for de-powdering one or more additively manufactured (AM) parts and/or a powder cake containing one or more AM parts, the moveable pod comprising a housing defining a chamber for receiving one or more AM parts and/or a powder cake, wherein the chamber comprises: a first end comprising a first opening for input of fluid to the chamber and/or removal of fluid and/or powder from the chamber; and a second end comprising one or more second openings for input of fluid and/or powder to the chamber and/or removal of fluid and/or powder from the chamber; optionally, wherein the second end is opposite the first end, and/or wherein the second end is an open end defining said second opening, and/or wherein the moveable pod further comprises a sealing member for covering the one or more second openings to seal the second end of the chamber, optionally, wherein the sealing member comprises a cutting part for cutting a powder cake to remove it from an additive manufacturing build unit .

14. A system for de-powdering one or more additively manufactured (AM) parts and/or a powder cake containing one or more AM parts, the system comprising a de-powdering chamber configured to receive one or more AM parts and/or a powder cake containing one or more AM parts therein; wherein the system is configured for removing powder from one or more AM parts and/or a powder cake received within the de-powdering chamber; and wherein the de-powdering chamber is at least partly defined by a moveable pod according to claim 13; optionally, wherein the collection chamber is at least partly defined by a moveable pod according to claim 13.

15. A system for de-powdering one or more additively manufactured (AM) parts and/or a powder cake containing one or more AM parts, the system comprising a de-powdering chamber configured to receive one or more AM parts and/or a powder cake containing one or more AM parts therein; wherein the system is configured for removing powder from one or more AM parts and/or a powder cake received within the de-powdering chamber; and further comprising a collection chamber configured for receiving removed powder from the de-powdering chamber, and an interface device configured to define a fluid communication between the de-powdering chamber and the collection chamber; optionally, wherein the collection chamber is at least partly defined by a moveable pod according to claim 13.

16. A system according to claim 14 or 15, wherein the de-powdering chamber comprises an inlet configured to introduce a flow of fluid into the de-powdering chamber; optionally, wherein the inlet comprises a moveable nozzle for directing a flow of fluid to different areas of the de-powdering chamber; optionally, wherein the system is configured to detect the location of one or more AM parts within the de-powdering chamber, and to actuate the moveable nozzle to direct a flow of fluid towards said location; optionally, wherein the system further comprises an outlet for expelling a flow of fluid from the de- powdering chamber and/or the or a collection chamber; optionally, wherein the system further comprises a filter coupled to the outlet.

17. A system according to any of claims 14 to 16, wherein the system comprises an interface device configured to define a fluid communication between the de-powdering chamber and the or a collection chamber, wherein the interface device defines an end of the de-powdering chamber, and wherein the interface device comprises one or more apertures configured to introduce a flow of fluid into the de-powdering chamber; optionally, wherein the interface device defines an end of the de-powdering chamber opposite the or an inlet in the de-powdering chamber; and/or optionally, wherein the one or more apertures comprise an array of apertures; and/or optionally wherein the array of apertures is arranged in a grid formation; and/or optionally, wherein the de-powdering chamber is arranged above the interface device, optionally, wherein the interface device is configured to support one or more AM parts and/or a powder cake received within the de-powdering chamber and/or wherein the or a collection chamber is arranged below the interface device.

18. A system according to claim 17, wherein the interface device comprises: a first plate and a second plate defining a cavity therebetween; and an interface device inlet configured to introduce a flow of fluid into the cavity; wherein the first plate comprises one or more apertures configured to provide a fluid communication between the de-powdering chamber and the cavity for introduction of fluid from the interface device inlet to the de-powdering chamber; and wherein the interface device is configured to isolate the interface device inlet from the collection chamber; optionally, wherein the interface device further comprises one or more conduits between the first plate and the second plate, wherein the one or more conduits are configured to provide a fluid communication between the de-powdering chamber and the collection chamber, and wherein an interior of the or each conduit is fluidly isolated from the cavity; optionally, wherein the one or more conduits comprise an array of conduits; optionally, wherein the array of conduits is arranged in a grid formation.

19. A system according to any of claims 14 to 18, further comprising a mechanism for shaking or vibrating one or more AM parts and/or a powder cake received within the de- powdering chamber in use; optionally, wherein the system comprises a vibration motor coupled to the de-powdering chamber and/or the or an interface device.

20. An apparatus for processing an additively manufactured part, the apparatus having a flow distributor device comprising: a first plate configured to at least partly define wall of a first chamber in use and a second plate, wherein the first plate is spaced apart from the second plate to define a cavity therebetween; and an inlet for introducing fluid to said cavity; wherein the first plate comprises one or more apertures configured to provide a fluid communication between said cavity and said first chamber in use; and wherein the flow distributor apparatus further comprises one or more conduits between the first and second plates, wherein the or each conduit is configured to provide a fluid communication between said first chamber and a side of the second plate opposite the cavity (e.g. a second chamber), and wherein an interior of the or each conduit is fluidly isolated from said cavity.