Apparatuses, systems and methods for three-dimensional printing

• US 10,195,693 B2
• Filed: 01/05/2017
• Issued: 02/05/2019
• Est. Priority Date: 06/20/2014
• Status: Active Grant

• Current Assignee: Velo3D, Inc.
• Original Assignee: Velo3D, Inc.
• Inventors: Buller, Benyamin, Milshtein, Erel, Seelinger, Sherman
• Primary Examiner(s): Grun, Robert J
• Assistant Examiner(s): Moreno Hernandez, Jerzi H
• Application Number:
  US15/399,186
• Publication Number:
  US 20170144254A1
• Time in Patent Office: 761 Days
• CPC Class Codes: B22F 10/12 by photopolymerisation, e.g. stereolithography [SLA] or digital light processing [DLP]
• CPC Class Codes: B22F 10/18 by mixing binder with metal in filament form, e.g. fused filament fabrication [FFF]
• CPC Class Codes: B22F 10/20 Direct sintering or melting
• CPC Class Codes: B22F 10/25 Direct deposition of metal particles, e.g. direct metal deposition [DMD] or laser engineered net shaping [LENS]
• CPC Class Codes: B22F 10/28 Powder bed fusion, e.g. selective laser melting [SLM] or electron beam melting [EBM]
• CPC Class Codes: B22F 10/30 Process control
• CPC Class Codes: B22F 10/32 of the atmosphere, e.g. composition or pressure in a building chamber
• CPC Class Codes: B22F 10/47 characterised by structural features
• CPC Class Codes: B22F 10/50 Treatment of workpieces or articles during build-up, e.g. treatments applied to fused layers during build-up
• CPC Class Codes: B22F 10/73 of powder
• CPC Class Codes: B22F 12/52 Hoppers
• CPC Class Codes: B22F 12/57 Metering means
• CPC Class Codes: B22F 12/60 Planarisation devices; Compression devices
• CPC Class Codes: B22F 12/90 Means for process control, e.g. cameras or sensors
• CPC Class Codes: B22F 2003/1054 by microwave
• CPC Class Codes: B22F 2003/248 Thermal after-treatment
• CPC Class Codes: B22F 2201/20 Use of vacuum
• CPC Class Codes: B22F 2202/01 Use of vibrations
• CPC Class Codes: B22F 2202/05 Use of magnetic field
• CPC Class Codes: B22F 2998/10 Processes characterised by the sequence of their steps
• CPC Class Codes: B22F 2999/00 : Aspects linked to processes or compositions used in powder metallurgy
• CPC Class Codes: B22F 3/003 : Apparatus, e.g. furnaces in general F27B
• CPC Class Codes: B22F 3/004 : Filling molds with powder feeding material to presses in general B30B15/302
• CPC Class Codes: B22F 3/105 : by using electric current other than for infrared radiant energy, laser radiation or plasma B22F3/11 takes precedence; by ultrasonic bonding B22F3/115 takes precedence
• CPC Class Codes: B22F 3/24 : After-treatment of workpieces or articles B22F3/1146 takes precedence
• CPC Class Codes: B22F 7/00 : Manufacture of composite layers, workpieces, or articles, comprising metallic powder, by sintering the powder, with or without compacting wherein at least one part is obtained by sintering or compression application of coating layers by use of metal powders, see C23C
• CPC Class Codes: B23K 10/006 : Control circuits therefor circuits for plasma torches H05H1/36
• CPC Class Codes: B23K 10/027 : Welding for purposes other than joining, e.g. build-up welding
• CPC Class Codes: B23K 15/002 : Devices involving relative movement between electronbeam and workpiece
• CPC Class Codes: B23K 15/0026 : Auxiliary equipment
• CPC Class Codes: B23K 15/0086 : welding for purposes other than joining, e.g. built-up welding
• CPC Class Codes: B23K 15/0093 : characterised by the properties of the materials to be welded
• CPC Class Codes: B23K 15/02 : Control circuits therefor
• CPC Class Codes: B23K 2103/50 : Inorganic material, e.g. metals, not provided for in B23K2103/02 – B23K2103/26
• CPC Class Codes: B23K 2103/52 : Ceramics
• CPC Class Codes: B23K 26/0853 : Devices involving movement of the workpiece in at least in two axial directions, e.g. in a plane
• CPC Class Codes: B23K 26/1224 : in vacuum
• CPC Class Codes: B23K 26/123 : in an atmosphere of particular gases
• CPC Class Codes: B23K 26/144 : the fluid stream containing particles, e.g. powder
• CPC Class Codes: B23K 26/16 : Removal of by-products, e.g. particles or vapours produced during treatment of a workpiece by a fluid stream B23K26/142
• CPC Class Codes: B23K 26/22 : Spot welding
• CPC Class Codes: B23K 26/32 : taking account of the properties of the material involved
• CPC Class Codes: B23K 26/342 : Build-up welding
• CPC Class Codes: B23K 26/346 : in combination with welding or cutting covered by groups B23K5/00 - B23K25/00, e.g. in combination with resistance welding
• CPC Class Codes: B23K 26/70 : Auxiliary operations or equipment
• CPC Class Codes: B23K 26/702 : Auxiliary equipment
• 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: B28B 17/0072 : Product control or inspection
• CPC Class Codes: B28B 17/0081 : Process control
• 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 64/165 : using a combination of solid and fluid materials, e.g. a powder selectively bound by a liquid binder, catalyst, inhibitor or energy absorber
• 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 64/194 : during lay-up
• CPC Class Codes: B29C 64/214 : Doctor blades
• CPC Class Codes: B29C 64/245 : Platforms or substrates support structures intended to be sacrificed after manufacture B29C64/40
• CPC Class Codes: B29C 64/255 : Enclosures for the building material, e.g. powder containers
• CPC Class Codes: B29C 64/264 : Arrangements for irradiation
• CPC Class Codes: B29C 64/268 : using laser beams; using electron beams [EB]
• CPC Class Codes: B29C 64/35 : Cleaning
• 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: C04B 2235/6026 : Computer aided shaping, e.g. rapid prototyping
• CPC Class Codes: C04B 35/522 : Graphite C04B35/536 takes precedence
• CPC Class Codes: C04B 35/5626 : based on tungsten carbides
• CPC Class Codes: C04B 35/565 : based on silicon carbide
• CPC Class Codes: C04B 35/64 : Burning or sintering processes C04B33/32 takes precedence ; powder metallurgy B22F
• CPC Class Codes: C22C 38/00 : Ferrous alloys, e.g. steel alloys cast-iron alloys C22C37/00
• CPC Class Codes: C22C 38/02 : containing silicon
• CPC Class Codes: C22C 38/44 : with molybdenum or tungsten
• CPC Class Codes: C22C 38/58 : with more than 1.5% by weight of manganese
• CPC Class Codes: H05B 6/68 : for monitoring or control
• CPC Class Codes: H05B 6/80 : Apparatus for specific applications stoves or ranges F24C7/02
• CPC Class Codes: Y02P 10/20 : Recycling
• CPC Class Codes: Y02P 10/25 : Process efficiency

Abstract

The present disclosure provides three-dimensional (3D) objects, 3D printing processes, as well as methods, apparatuses and systems for the production of a 3D object. Methods, apparatuses and systems of the present disclosure may reduce or eliminate the need for auxiliary supports. The present disclosure provides three dimensional (3D) objects printed utilizing the printing processes, methods, apparatuses and systems described herein.

Claims

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

a powder dispenser configured to dispense a powder material to form a powder bed comprising an exposed surface;

a powder remover configured to remove the powder material from the powder bed;

an energy source that is configured to provide an energy beam directed to the powder bed, which energy beam transforms at least a portion of the powder material to form a hardened material; and

at least one controller that is operatively coupled to the powder dispenser, powder remover, and the energy beam, wherein the at least one controller is configured to facilitate printing of the three-dimensional object at least in part by;

(i) individually directing (1) the powder dispenser to dispense the powder material to form the powder bed having an initial exposed surface and (2) the powder remover to planarize the initial exposed surface to form a first planar exposed surface,

(ii) directing the energy beam to transform the at least the portion of the powder material to form the hardened material that is at least a portion of the three-dimensional object and protrudes from the first planar exposed surface of the powder bed, and

(iii) individually directing (a) the powder dispenser to dispense the powder material on the first planar exposed surface of the powder bed to yield a subsequent exposed surface, and (b) the powder remover to planarize the subsequent exposed surface to form a second planar exposed surface,

wherein the powder remover is configured to form the second planar exposed surface such that the hardened material protrudes from the first planar exposed surface and the second planar exposed surface, and wherein the powder remover is configured to planarize the subsequent exposed surface of the powder bed without contacting the subsequent exposed surface of the powder bed when the hardened material protrudes from the first planar exposed surface and/or from the second planar exposed surface in a manner such that the hardened material is displaced horizontally by at most 300 micrometers or not displaced.

2. The system of claim 1, wherein the at least the portion of the three-dimensional object comprises warping, buckling, bulging, or balling.

3. The system of claim 1, wherein the powder remover is configured to remove an excess of the powder material from the powder bed without contacting the powder bed, to form the first planar exposed surface and/or the second planar exposed surface.

4. The system of claim 3, wherein the powder remover is configured to remove the excess of the powder material from the powder bed at least in part using a magnetic force, an electrostatic force, a gas flow, or any combination thereof.

5. The system of claim 4, further comprising a vacuum source that is configured to provide the gas flow.

6. The system of claim 1, wherein the at least one controller is configured to facilitate printing of the three-dimensional object when the hardened material is horizontally movable by being suspended anchorlessly in the powder bed.

7. The system of claim 1, wherein the powder remover is configured to remove an excess of the powder material from the powder bed at least in part using a nozzle and a chamber having a narrowing shape, which chamber (I) is different from a nozzle chamber and (II) is flowably connected to the nozzle such that the powder material is permitted to flow from the nozzle to the chamber.

8. The system of claim 1, wherein the powder dispenser is configured to dispense the powder material from an exit opening that is separated by a gaseous gap from the second planar exposed surface.

9. The system of claim 8, wherein the exit opening is not parallel to (1) the first planar exposed surface, (2) the second planar exposed surface, or (3) the first planar exposed surface and the second planar exposed surface.

10. The system of claim 9, wherein the exit opening does not face (I) the first planar exposed surface, (II) the second planar exposed surface, or (III) the first planar exposed surface and the second planar exposed surface.

11. The system of claim 8, wherein the at least one controller is configured to direct the powder dispenser to regulate an amount of the powder material that is dispensed to form the powder bed.

12. The system of claim 8, wherein the at least one controller is configured to direct the powder dispenser to vibrate the powder material (1) within the powder dispenser, or (2) substantially at the exit opening, which exit opening is part of the powder dispenser.

13. The system of claim 12, wherein the at least one controller is configured to direct the powder dispenser to regulate an amount of the powder material that is dispensed to form the powder bed at least in part by regulating vibration of the powder material.

14. The system of claim 1, wherein the at least one controller is configured to direct planarization of the initial exposed surface and/or subsequent exposed surface, at least in part by directing removal of an excess of the powder material without contacting the powder bed.

15. The system of claim 1, wherein the at least one controller is configured to direct the powder remover to planarize the initial exposed surface and/or the subsequent exposed surface at least in part by removing an excess of the powder material from the initial exposed surface and/or the subsequent exposed surface without laterally displacing the excess of the powder material to another position of the powder bed.

16. The system of claim 1, wherein the at least one controller is configured to facilitate printing of the three-dimensional object when the hardened material is horizontally movable by being devoid of auxiliary support having a scaffold that is (I) suspended anchorlessly in the powder bed and (II) encloses the three-dimensional object.

17. The system of claim 1, wherein the system is configured such that during printing of the three-dimensional object, the hardened material is suspended anchorlessly in the powder bed.

18. The system of claim 17, wherein the system is configured such that during printing of the three-dimensional object, the hardened material comprises auxiliary support that is suspended anchorlessly in the powder bed.

19. The system of claim 1, wherein the system is configured such that during printing of the three-dimensional object, the hardened material comprises an auxiliary support that is suspended anchorlessly in the powder bed.

20. The system of claim 1, wherein the system is configured such that during printing of the three-dimensional object, the hardened material is devoid of auxiliary support.

21. The system of claim 1, wherein the system is configured such that during printing of the three-dimensional object, the hardened material is disconnected from a platform that supports the powder bed while the energy beam transforms the at least the portion of the powder material to form the hardened material.

22. The system of claim 1, wherein the at least one controller is configured to direct the powder remover to generate the second planar exposed surface, in a manner such that (I) the hardened material is displaced horizontally by at most 300 micrometers or not displaced, and (II) a shape of the hardened material is preserved during generation of a layer of the powder material having the second planar exposed surface.

23. The system of claim 1, wherein the at least one controller is configured to facilitate printing of the three-dimensional object at least in part by directing the energy beam to transform the at least the portion of the powder material to form the hardened material that is at least a fraction of the three-dimensional object and is horizontally movable within the powder bed.

24. The system of claim 23, wherein the powder remover is configured such that as the second planar exposed surface is formed, (i) the hardened material disposed in the powder bed is displaced horizontally by at most 300 micrometers or not displaced, and/or (ii) a shape of the hardened material during formation of the second planar exposed surface is preserved.

25. The system of claim 24, wherein the powder remover is configured such that as the second planar exposed surface is formed, the hardened material is suspended anchorlessly in the powder bed.

26. The system of claim 1, wherein the powder remover is configured to be separated from (i) the first planar exposed surface and/or (ii) the second planar exposed surface by a gap.

27. The system of claim 1, wherein the powder remover comprises an opening and at least one internal chamber having a lateral cross section that is greater than a lateral cross section of the opening.

28. The system of claim 1, wherein the powder remover comprises a nozzle having a length to diameter aspect ratio of at least 2:

1 or higher.

29. The system of claim 1, wherein the powder dispenser and the powder remover are configured to operate separately.

30. The system of claim 1, wherein the at least one controller is configured to direct the powder remover to planarize the subsequent exposed surface to form the second planar exposed surface such that a planar uniformity across the second planar exposed surface deviates vertically by at most about 20 percent (20%).

31. The system of claim 1, wherein the at least one controller is configured to direct the powder dispenser to regulate an amount of the powder material to form a layer of the powder material as part of the powder bed.

32. The system of claim 1, wherein the at least one controller is configured to noncontemporaneously direct (1) the powder dispenser to dispense the powder material to form the powder bed having the initial exposed surface and (2) the powder remover to planarize the initial exposed surface to form the first planar exposed surface.