Method and system for software defined metallurgy

• US 10,191,456 B2
• Filed: 02/21/2018
• Issued: 01/29/2019
• Est. Priority Date: 05/01/2017
• Status: Active Grant

• Current Assignee: Desktop Metal, Inc.
• Original Assignee: Desktop Metal, Inc.
• Inventors: Tuncer, Nihan, Kernan, Brian, Bose, Animesh, Sowerbutts, Mark
• Primary Examiner(s): Sultana, Nahida
• Application Number:
  US15/901,265
• Publication Number:
  US 20180314216A1
• Time in Patent Office: 342 Days
• CPC Class Codes: B22F 10/14 by jetting of binder onto a bed of metal powder
• CPC Class Codes: B22F 2203/11 temperature, temperature profile
• CPC Class Codes: B22F 3/003 Apparatus, e.g. furnaces in general F27B
• CPC Class Codes: B22F 3/1007 Atmosphere B22F3/1021 takes precedence
• CPC Class Codes: B22F 3/1017 Multiple heating or additional steps B22F3/101 takes precedence
• CPC Class Codes: B22F 3/1021 Removal of binder or filler removal of binder from ceramics C04B35/638
• CPC Class Codes: B22F 3/24 After-treatment of workpieces or articles B22F3/1146 takes precedence
• 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: F27D 19/00 Arrangements of controlling devices
• CPC Class Codes: F27D 2019/0003 Monitoring the temperature or a characteristic of the charge and using it as a controlling value
• CPC Class Codes: F27D 2019/0096 involving simulation means, e.g. of the treating or charging step
• CPC Class Codes: F27D 21/00 Arrangements of monitoring devices; Arrangements of safety devices
• CPC Class Codes: G05B 13/042 in which a parameter or coefficient is automatically adjusted to optimise the performance
• CPC Class Codes: G05B 15/02 electric
• CPC Class Codes: G06F 3/0482 Interaction with lists of selectable items, e.g. menus
• CPC Class Codes: G06F 3/04847 Interaction techniques to control parameter settings, e.g. interaction with sliders or dials
• CPC Class Codes: Y02P 10/25 : Process efficiency

Abstract

A system for generating a user-adjustable furnace profile, comprises a user interface configured to receive one or more materials properties from a user, a processor, and a memory with computer code instructions stored thereon. The memory is operatively coupled to the processor such that, when executed by the processor, the computer code instructions cause the system to implement communicating with a furnace to ascertain one or more thermal processes associated with the furnace, identifying one or more object characteristics associated with an object to be processed by furnace, and determining a thermal processing parameter profile of at least one thermal processing parameter corresponding to each of the thermal processes, based on (i) the one or more part characteristics and (ii) the one or more materials properties, the thermal processing parameter profile characterizing a cycle of the one or more thermal processes.

Claims

1. A system for generating a user-adjustable thermal processing parameter profile for use by a furnace, comprising:

a user interface configured to receive one or more materials properties provided by a user;

a processor;

a memory with computer code instructions stored thereon, the memory operatively coupled to the processor such that, when executed by the processor, the computer code instructions cause the system to implement;

communicating with the furnace to ascertain one or more thermal processes associated with the furnace;

identifying one or more part characteristics associated with a part to be processed by the furnace; and

determining a thermal processing parameter profile of at least one thermal processing parameter corresponding to each of the one or more thermal processes, based on (i) the one or more part characteristics and (ii) the one or more materials properties, the thermal processing parameter profile characterizing a cycle of the each of the one or more thermal processes;

a binder trap configured to store binder hydrocarbon products; and

a valve that controls a path from the binder trap to the furnace, such that through the valve, the binder hydrocarbon products are selectively introduced to the furnace to control a carbon potential of the furnace environment.

2. The system of claim 1, wherein the materials properties comprise at least one of (i) hardness, (ii) ductility, (iii) microstructure, (iv) material content, (v) surface property, and (vi) transverse rupture strength.

3. The system of claim 1, wherein the thermal processing parameter profile is a function of time.

4. The system of claim 1, wherein the thermal processing parameter profile is a function of temperature.

5. The system of claim 1, wherein the at least one thermal processing parameter comprises at least one of (i) temperature, (ii) furnace internal atmosphere composition, (iii) chamber pressure, (iv) gas species, (v) gas flow rate, and (vi) furnace load.

6. The system of claim 1, wherein the materials properties from the user comprise characteristics of a completed part, and the system determines the profile suitable to produce the characteristics of the completed part.

7. The system of claim 1, wherein the user interface is a graphical user interface configured to one or more of (i) receive the one or more materials properties from the user, (ii) present guidance and options concerning subsequent input from the user, and (iii) present feedback to the user concerning each of the one or more thermal processes.

8. The system of claim 1, wherein the computer code instructions further cause the system to communicate with the user through a graphical user interface, and, based on the communicating, one or both of (i) guide the user to an outcome of a cycle of each of the one or more thermal process and the materials properties of the part and (ii) direct the user to the outcome of a cycle of each of the one or more thermal process and the materials properties of the part.

9. The system of claim 1, wherein the computer code instructions further cause the system to receive and implement user direction regarding surface modifications to be applied to the part in conjunction with the one or more thermal processes being applied to the part.

10. The system of claim 9, wherein a first user direction associated with a first part characterizes the one or more thermal processes for the cycle of the one or more thermal processes.

11. The system of claim 10, wherein the computer code instructions further cause the system to one or both of (i) notify the user of subsequent user direction that would conflict with the one or more thermal processes corresponding to the first user direction and (ii) prevent the system from implementing changes associated with the subsequent user direction that would conflict with the one or more thermal processes corresponding to the first user direction.

12. The system of claim 1, wherein the computer code instructions further cause the system to receive user input configured to tailor the one or more process parameter profiles according to specific result requirements.

13. The system of claim 1, further including a binder trap configured to store binder hydrocarbon products, and a valve that controls a path from the binder trap to the sintering furnace, such that through the valve, the binder hydrocarbon products are selectively introduced to the sintering furnace to control a carbon potential of the sintering furnace environment.

14. A non-transitory computer-readable medium with computer code instruction stored thereon, the computer code instructions, when executed by a processor, cause an apparatus to:

receive, through a user interface, one or more materials properties provided by a user;

communicate with a furnace to ascertain one or more thermal processes associated with the furnace;

identify one or more object characteristics associated with an object to be processed by furnace; and

determine a thermal processing parameter profile of at least one thermal processing parameter corresponding to each of the thermal processes, based on (i) the one or more object characteristics and (ii) the one or more materials properties, the thermal processing parameter profile characterizing a cycle of the one or more thermal processes.

15. The non-transitory computer-readable medium of claim 14, wherein the computer code instructions, when executed by an a processor, further cause the apparatus to communicate with the user through a graphical user interface, and, based on the communicating, one or both of (i) guide the user to an outcome of a cycle of the thermal process and the materials properties of the part and (ii) direct the user to the outcome of a cycle of the thermal process and the materials properties of the part.

16. The non-transitory computer-readable medium of claim 14, wherein the computer code instructions, when executed by an a processor, further cause the apparatus to receive and implement user direction regarding surface modifications to be applied to the part in conjunction with the one or more thermal processes being applied to the part.