Skillful three-dimensional printing

• US 10,183,330 B2
• Filed: 12/09/2016
• Issued: 01/22/2019
• Est. Priority Date: 12/10/2015
• Status: Active Grant

• Current Assignee: Velo3D, Inc.
• Original Assignee: Velo3D, Inc.
• Inventors: Buller, Benyamin, Milshtein, Erel, Brezoczky, Thomas Blasius, Murphree, Zachary Ryan, Christiansen, Daniel, Lappen, Alan Rick
• Primary Examiner(s): Tentoni, Leo B
• Application Number:
  US15/374,535
• Publication Number:
  US 20170165753A1
• Time in Patent Office: 774 Days
• Field of Search: 264 3729, 264460, 264461, 264462, 264463, 264497, 21912117, 21912125, 21912138, 21912159, 21912166, 21912173, 21912185
• CPC Class Codes: B22F 10/28 Powder bed fusion, e.g. selective laser melting [SLM] or electron beam melting [EBM]
• CPC Class Codes: B22F 10/36 of energy beam parameters
• CPC Class Codes: B22F 10/47 characterised by structural features
• CPC Class Codes: B22F 10/68 Cleaning or washing
• CPC Class Codes: B22F 10/73 of powder
• CPC Class Codes: B22F 12/70 Gas flow means
• CPC Class Codes: B22F 2998/10 Processes characterised by the sequence of their steps
• CPC Class Codes: B23K 26/04 Automatically aligning, aiming or focusing the laser beam, e.g. using the back-scattered light
• CPC Class Codes: B23K 26/0869 Devices involving movement of the laser head in at least one axial direction
• CPC Class Codes: B23K 26/142 for the removal of by-products
• CPC Class Codes: B23K 26/144 the fluid stream containing particles, e.g. powder
• CPC Class Codes: B23K 26/1462 Nozzles; Features related to nozzles
• CPC Class Codes: B23K 26/342 Build-up welding
• CPC Class Codes: B23K 26/702 Auxiliary equipment
• CPC Class Codes: B23K 37/06 for positioning the molten material, e.g. confining it to a desired area
• CPC Class Codes: B28B 1/001 Rapid manufacturing of 3D objects by additive depositing, agglomerating or laminating of material selective deposition modelling of metallic powder B22F10/00; rapid manufacturing of 3D objects in general and in particular of plastics B29C64/00
• CPC Class Codes: B29B 17/0005 Direct recuperation and re-use of scrap material during moulding operation, i.e. feed-back of used material
• CPC Class Codes: B29C 64/153 using layers of powder being selectively joined, e.g. by selective laser sintering or melting
• CPC Class Codes: B29C 64/171 specially adapted for manufacturing multiple 3D objects
• CPC Class Codes: B29C 64/188 involving additional operations performed on the added layers, e.g. smoothing, grinding or thickness control surface shaping B29C59/00; after-treatment of articles without altering their shape B29C71/00
• CPC Class Codes: B29C 64/214 : Doctor blades
• CPC Class Codes: B29C 64/307 : Handling of material to be used in additive manufacturing
• CPC Class Codes: B29C 64/35 : Cleaning
• CPC Class Codes: B29C 64/357 : Recycling
• CPC Class Codes: B29C 64/386 : Data acquisition or data processing for additive manufacturing
• CPC Class Codes: B29C 64/393 : for controlling or regulating additive manufacturing processes
• CPC Class Codes: B29C 64/40 : Structures for supporting 3D objects during manufacture and intended to be sacrificed after completion thereof
• CPC Class Codes: B29K 2105/251 : Particles, powder or granules expandable particles B29K2105/046
• CPC Class Codes: B33Y 10/00 : Processes of additive manufacturing
• CPC Class Codes: B33Y 30/00 : Apparatus for additive manufacturing; Details thereof or accessories therefor
• CPC Class Codes: B33Y 40/00 : Auxiliary operations or equipment, e.g. for material handling
• CPC Class Codes: B33Y 40/20 : Post-treatment, e.g. curing, coating or polishing
• CPC Class Codes: B33Y 50/02 : for controlling or regulating additive manufacturing processes
• CPC Class Codes: B33Y 70/00 : Materials specially adapted for additive manufacturing
• CPC Class Codes: B33Y 80/00 : Products made by additive manufacturing
• CPC Class Codes: G05B 19/4099 : Surface or curve machining, making 3D objects, e.g. desktop manufacturing
• CPC Class Codes: G05B 2219/35134 : 3-D cad-cam
• CPC Class Codes: G05B 2219/49007 : Making, forming 3-D object, model, surface
• CPC Class Codes: Y02P 10/25 : Process efficiency
• CPC Class Codes: Y02P 90/02 : Total factory control, e.g. smart factories, flexible manufacturing systems [FMS] or integrated manufacturing systems [IMS]

Abstract

The present disclosure various apparatuses, and systems for 3D printing. The present disclosure provides three-dimensional (3D) printing methods, apparatuses, software and systems for a step and repeat energy irradiation process; controlling material characteristics and/or deformation of the 3D object; reducing deformation in a printed 3D object; and planarizing a material bed.

Claims

1. A method for printing a three-dimensional object, comprising:

(a) providing a material bed comprising a pre-transformed material;

(b) planarizing an exposed surface of the material bed by displacing, with a first force, the pre-transformed material from the exposed surface into an internal compartment of a material remover, which planarizing comprises translating the internal compartment;

(c) removing the pre-transformed material from the internal compartment with a second force; and

(d) using an energy beam to irradiate at least a portion of the exposed surface to transform the pre-transformed material at the at least the portion of the exposed surface into a transformed material, wherein the transformed material is at least a portion of the three-dimensional object.

2. The method of claim 1, wherein the first force is different from the second force in one or more members selected from the group consisting of force type, force direction, and force amount.

5. The method of claim 2, wherein a direction of the first force is substantially perpendicular to a direction of the second force.

6. The method of claim 1, wherein while removing the pre-transformed material, the pre-transformed material accumulates in the internal compartment of the material remover.

7. The method of claim 1, further comprising, subsequent to (b) or contemporaneous with (b), recycling the pre-transformed material for use in the material bed.

21. The method of claim 1, wherein displacing the pre-transformed material comprises attracting the pre-transformed material.

22. The method of claim 1, wherein removing the pre-transformed material comprises pushing or attracting the pre-transformed material.

23. The method of claim 2, wherein a direction of the first force is substantially perpendicular to a direction of the second force.

24. The method of claim 1, wherein while removing the pre-transformed material, the pre-transformed material accumulates in the internal compartment of the material remover.

25. The method of claim 7, wherein the pre-transformed material is recycled during printing.

26. The method of claim 1, wherein the material remover is disconnected from the exposed surface while planarizing the exposed surface.

27. The method of claim 1, wherein the internal compartment is translated along the exposed surface of the material bed.

29. The method of claim 6, wherein the pre-transformed material accumulates at least in part by separating the pre-transformed material from a gas flow that is formed while displacing the pre-transformed material from the exposed surface.

31. The method of claim 29, wherein the pre-transformed material is cyclonically separated from the gas flow.

3. A method for printing a three-dimensional object, comprising:

(a) providing a material bed comprising a pre-transformed material;

(b) planarizing an exposed surface of the material bed by displacing, with a first force, the pre-transformed material from the exposed surface into an internal compartment of a material remover, wherein displacing the pre-transformed material comprises attracting the pre-transformed material;

(c) removing the pre-transformed material from the internal compartment with a second force; and

(d) using an energy beam to irradiate at least a portion of the exposed surface to transform the pre-transformed material at the at least the portion of the exposed surface into a transformed material, wherein the transformed material is at least a portion of the three-dimensional object.

33. The method of claim 3, wherein displacement of the pre-transformed material is along an upwards direction oriented vertically away from the exposed surface.

34. The method of claim 3, wherein the material remover is disconnected from the exposed surface while planarizing the exposed surface.

35. The method of claim 3, wherein the first force is generated by gas flow, a magnetic field, or an electric field.

36. The method of claim 35, wherein the first force is generated under vacuum.

37. The method of claim 3, wherein the first force is generated under vacuum.

4. A method for printing a three-dimensional object, comprising:

(a) providing a material bed comprising a pre-transformed material;

(b) planarizing an exposed surface of the material bed by displacing, with a first force, the pre-transformed material from the exposed surface into an internal compartment of a material remover;

(c) removing the pre-transformed material from the internal compartment with a second force, wherein removing the pre-transformed material comprises pushing or attracting the pre-transformed material; and

(d) using an energy beam to irradiate at least a portion of the exposed surface to transform the pre-transformed material at the at least the portion of the exposed surface into a transformed material, wherein the transformed material is at least a portion of the three-dimensional object.

38. The method of claim 4, wherein the first force is different from the second force in one or more members selected from the group consisting of force type, force direction, and force amount.

39. The method of claim 38, wherein a direction of the first force is substantially perpendicular to a direction of the second force.

40. The method of claim 4, wherein the material remover is disconnected from the exposed surface while planarizing the exposed surface.

41. The method of claim 4, wherein removing the pre-transformed material comprises pushing the pre-transformed material.

42. The method of claim 4, wherein removing the pre-transformed material comprises attracting the pre-transformed material.

43. The method of claim 4, wherein removing the pre-transformed material comprises pushing and attracting the pre-transformed material.

8. A method for printing a three-dimensional object, comprising:

(a) providing a material bed comprising a pre-transformed material;

(b) planarizing an exposed surface of the material bed by displacing, with a first force, the pre-transformed material from the exposed surface into an internal compartment of a material remover;

(c) removing the pre-transformed material from the internal compartment with a second force;

(d) using an energy beam to irradiate at least a portion of the exposed surface to transform the pre-transformed material at the at least the portion of the exposed surface into a transformed material, wherein the transformed material is at least a portion of the three-dimensional object; and

(e) subsequent to (b) or contemporaneous with (b), recycling the pre-transformed material for use in the material bed, wherein the pre-transformed material is recycled during printing.

44. The method of claim 8, wherein the material remover is disconnected from the exposed surface while planarizing the exposed surface.

45. The method of claim 8, wherein the first force is different from the second force in one or more members selected from the group consisting of force type, force direction, and force amount.

46. The method of claim 8, further comprising separating the pre-transformed material from a gas flow.

47. The method of claim 8, further comprising cyclonically separating the pre-transformed material from a gas flow.

9. A method for printing a three-dimensional object, comprising:

(a) providing a material bed comprising a pre-transformed material;

(b) planarizing an exposed surface of the material bed by displacing the pre-transformed material from the exposed surface into an internal compartment of a material remover, which pre-transformed material accumulates within the internal compartment while planarizing the exposed surface, which planarizing comprises translating the internal compartment; and

(c) using an energy beam to irradiate at least a portion of the exposed surface to transform the pre-transformed material at the at least the portion of the exposed surface into a transformed material, wherein the transformed material is at least a portion of the three-dimensional object.

10. The method of claim 9, wherein the pre-transformed material accumulates at least in part by separating the pre-transformed material from a gas flow that is formed while displacing the pre-transformed material from the exposed surface.

11. The method of claim 10, wherein the pre-transformed material separates from the gas flow in the internal compartment and accumulates within the internal compartment.

12. The method of claim 11, wherein the pre-transformed material is cyclonically separated from the gas flow.

14. The method of claim 9, wherein the material remover is disconnected from the exposed surface while planarizing the exposed surface.

28. The method of claim 9, wherein the internal compartment is translated along the exposed surface of the material bed.

30. The method of claim 10, wherein the pre-transformed material separates from the gas flow in the internal compartment as it accumulates within the internal compartment.

32. The method of claim 9, wherein displacing the pre-transformed material comprises attracting the pre-transformed material.

13. A method for printing a three-dimensional object, comprising:

(a) providing a material bed comprising a pre-transformed material;

(b) planarizing an exposed surface of the material bed by displacing the pre-transformed material from the exposed surface into an internal compartment of a material remover, which pre-transformed material accumulates within the internal compartment while planarizing the exposed surface, wherein displacing the pre-transformed material comprises attracting the pre-transformed material; and

(c) using an energy beam to irradiate at least a portion of the exposed surface to transform the pre-transformed material at the at least the portion of the exposed surface into a transformed material, wherein the transformed material is at least a portion of the three-dimensional object.

48. The method of claim 13, wherein the pre-transformed material accumulates at least in part by separating the pre-transformed material from a gas flow that is formed while displacing the pre-transformed material from the exposed surface.

49. The method of claim 13, wherein the material remover is disconnected from the exposed surface while planarizing the exposed surface.

50. The method of claim 13, wherein in (b), the pre-transformed material is displaced along an upwards direction oriented vertically away from the exposed surface.

51. The method of claim 13, wherein displacing comprises using a gas flow, a magnetic force, or an electrostatic force.

52. The method of claim 13, wherein displacing comprises using a vacuum to direct the pre-transformed material from the exposed surface into the internal compartment.

15. A method for printing a three-dimensional object, comprising:

(a) providing a material bed comprising a pre-transformed material;

(b) planarizing an exposed surface of the material bed by displacing the pre-transformed material from the exposed surface into an internal compartment of a material remover, which internal compartment has a narrowing horizontal cross-section; and

(c) using an energy beam to irradiate at least a portion of the exposed surface to transform the pre-transformed material at the at least the portion of the exposed surface into a transformed material, wherein the transformed material is at least a portion of the three-dimensional object.

16. The method of claim 15, wherein the narrowing horizontal cross-section has a long axis that is perpendicular to a direction of movement of the material remover.

17. The method of claim 15, wherein the material bed is disposed above a platform, and wherein the narrowing horizontal cross-section is substantially parallel to the platform.

18. The method of claim 15, wherein the material remover comprises an opening that is directed towards the exposed surface.

19. The method of claim 15, wherein the pre-transformed material is displaced using a force that is distributed homogenously along the narrowing horizontal cross-section.

20. The method of claim 15, wherein the planarizing in (b) comprises forming a substantially planar exposed surface of the material bed within a height error range of at most about 200 micrometers.