Material processing methods and related apparatus

Abstract

The application describes a machine tool adapted and arranged to carry out removal and addition of material on a work piece located in a work station, the machine having a first head arranged to remove material from the work piece and at least a second head arranged to process the work piece, each of the first and second heads being arranged to be moveable in at least two axes and preferably in 3, 4 or 5 axes and wherein the machine is arranged to control an environment of the work station. The work station is at least partially sealable. The machine has a clean side and a dirty side. Novel processing heads particularly adapted for use in the new machine tool are disclosed. These may also be retrofitted to CNC machines. The novel heads include heads adapted to carry out two processes simultaneously. Heads adapted to carry out heat and pressure treatment are also disclosed. Use of the processing beads to carry out analysis in manufacturing steps is disclosed as is the provision and use of heads that can carry out analysis as well as processing.

1 . A machine tool adapted and arranged to carry out removal and addition of material on a work piece located in a work station, the machine having a first head arranged to remove material from the work piece and at least a second head arranged to process the work piece, each of the first and second heads being arranged to be moveable in at least two axes and preferably in 3, 4 or 5 axes and wherein the machine is arranged to control an environment of the work station. 
     
     
         2 . The machine tool of  claim 1 , wherein the machine comprises a clean side and a dirty side. 
     
     
         3 . The machine tool of  claim 1 , wherein the first head is selectable from a plurality of first interchangeable processing heads and the second head is selectable from a plurality of second interchangeable processing heads and wherein the first interchangeable processing heads are storable in a first tool changer and the second interchangeable processing heads are storable in a second tool changer. 
     
     
         4 . The machine tool of  claim 3 , wherein the first and the second tool changers are remote from the work station. 
     
     
         5 . The machine of  claim 1 , wherein the work station comprises a chamber that is, at least in part, sealable. 
     
     
         6 . The machine tool of  claim 5 , wherein the chamber is partially open and is provided with a local shielding locatable around the work-piece during processing. 
     
     
         7 . The machine tool of  claim 5 , wherein an environment in the chamber is controllable and may be provided with at least one of:
 at least a partial inert gas atmosphere   a low oxygen atmosphere;   a coolant;   a pressure above ambient pressure;   a pressure below ambient pressure;   a vacuum.   
     
     
         8 . The machine tool of  claim 1 , further comprising a waste extractor. 
     
     
         9 . The machine tool of  claim 1 , wherein the machine further comprises an integral docking system, preferably having a supply manifold located on one or each carriage and arranged to connect with a receiving manifold on the processing head. 
     
     
         10 . The machine tool of  claim 9 , wherein the docking system is arranged to provide a clean connection between a supply docking manifold on the machine and a receiving manifold on the processing head. 
     
     
         11 . The machine tool of  claim 9 , wherein the docking system is arranged to be able to supply material and energy to the or each processing head in use. 
     
     
         12 . The machine tool of  claim 11 , wherein the media is supplied to a reservoir in the processing head or is continuously supplied to the processing head. 
     
     
         13 . The machine tool of  claim 9 , wherein energy is supplied to the processing head by a laser beam or by a fibre optic cable and wherein the energy source is preferably integral to the machine. 
     
     
         14 . The machine tool of  claim 1 , wherein the machine comprises one or more heads arranged to monitor and/or analyse at least one of the work-piece and a processing head. 
     
     
         15 . A method of creating an article using a machine tool having a work station and at least one tool changer remote from the work station, the method comprising
 using a first processing head, having a first deposition characteristic, to lay down material having a first set of properties on a work piece in the work station;   changing the first processing head for a second processing head selected from the tool changer, the second processing head having a second deposition characteristic different from the first;   laying further material down having a second set of properties.   in which the machine tool holding the processing head automatically changes the processing head from the first head to the second head and the second deposition characteristic is arranged to improve the fidelity of the article being created to the desired article   
     
     
         16 . The method of  claim 15 , wherein the second deposition characteristic varies one or more of the following parameters when compared to the first deposition characteristic:
 angle of deposition (relative to the build surface); type of material; mixture of materials being deposited; deposition rate; bead size; cross-sectional shape of deposition; energy input; nano/micro characteristic of material; colour and transparency of material; texture of the surface finish   
     
     
         17 . The method of  claim 15 , wherein the article is created in stages such that at least one of the first and second processing heads are used a plurality of times. 
     
     
         18 . The method of  claim 15 , wherein a third processing head is used and arranged to remove material from the article. 
     
     
         19 . The method of  claim 15 , wherein the machine tool further comprises a controller and the controller is arranged to control the first processing head to deposit material and is then arranged to select a second processing head dependent on the material deposited and the work piece to be created. 
     
     
         20 . The method of  claim 19 , wherein the controller uses data from the first or the second processing head to select a further processing head to be utilised. 
     
     
         21 - 72 . (canceled)