Additive manufacturing apparatus and method

• US 10,252,333 B2
• Filed: 06/11/2014
• Issued: 04/09/2019
• Est. Priority Date: 06/11/2013
• Status: Active Grant

• Current Assignee: Renishaw PLC
• Original Assignee: Renishaw PLC
• Inventors: McMurtry, David Roberts, Dimter, Marc, Mayer, Ralph
• Primary Examiner(s): Koslow, C Melissa
• Application Number:
  US14/897,731
• Publication Number:
  US 20160136731A1
• Time in Patent Office: 1,763 Days
• CPC Class Codes: B08B 15/04 from a small area, e.g. a tool removing chips B23Q11/0042
• CPC Class Codes: B22F 10/28 Powder bed fusion, e.g. selective laser melting [SLM] or electron beam melting [EBM]
• CPC Class Codes: B22F 10/322 of the gas flow, e.g. rate or direction
• CPC Class Codes: B22F 10/366 Scanning parameters, e.g. hatch distance or scanning strategy
• CPC Class Codes: B22F 10/77 of gas
• CPC Class Codes: B22F 12/67 Blades
• CPC Class Codes: B22F 12/70 Gas flow means
• CPC Class Codes: B22F 12/90 Means for process control, e.g. cameras or sensors
• CPC Class Codes: B22F 2201/00 Treatment under specific atmosphere
• CPC Class Codes: B22F 2203/00 Controlling
• CPC Class Codes: B22F 2999/00 Aspects linked to processes or compositions used in powder metallurgy
• 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 64/371 using an environment other than air, e.g. inert gas
• 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 50/02 for controlling or regulating additive manufacturing processes
• CPC Class Codes: Y02P 10/25 Process efficiency

Abstract

An additive manufacturing apparatus for building objects by layerwise consolidation of material. The apparatus includes a build chamber containing a working area, a high energy beam for consolidating material deposited in the working area in layers and a flow device for generating a gas flow across at least a part of the working area from a gas inlet to a gas outlet. The gas inlet and gas outlet are arranged to be movable within the build chamber.

Claims

1. Additive manufacturing apparatus for building objects by layerwise consolidation of material, the apparatus comprising:

a build chamber containing a working area,

a high energy beam configured to consolidate material deposited in the working area in layers, and

a flow device configured to generate a gas flow across at least a part of the working area from a gas inlet to a gas outlet, the gas inlet and gas outlet arranged to be movable within the build chamber, wherein

the gas inlet and gas outlet are movable such that a position of the gas inlet relative to the gas outlet can be varied.

2. Additive manufacturing apparatus according to claim 1, comprising a controller configured to control movement of the gas inlet and gas outlet such that locations of the gas inlet and outlet are altered based upon a scan path of the high energy beam across the working area.

3. Additive manufacturing apparatus according to claim 1, wherein the gas inlet and gas outlet are configured to move such that a distance between the gas inlet and gas outlet can be less than a width of a build platform on which the objects are built.

4. Additive manufacturing apparatus according to claim 1, wherein the gas inlet and gas outlet are configured to move such that a distance between the gas inlet and gas outlet can be less than a width of the working area in which the objects are built.

5. Additive manufacturing apparatus according to claim 1, comprising a gas flow device for controlling the gas flow through the inlet and/or outlet based upon a distance between the gas inlet and gas outlet.

6. Additive manufacturing apparatus according to claim 1, wherein the gas inlet and gas outlet are mounted on an assembly for moving the gas inlet and gas outlet along at least one linear axis.

7. Additive manufacturing apparatus according to claim 6, wherein the gas inlet and gas outlet are mounted on an assembly for rotating the gas inlet and gas outlet about at least one rotary axis.

8. Additive manufacturing apparatus according to claim 1, wherein the gas outlet is arranged to draw gas in a direction substantially parallel to the working area.

9. Additive manufacturing apparatus according to claim 1, wherein the gas inlet is arranged to propel gas in a direction substantially parallel to the working area.

10. Additive manufacturing apparatus according to claim 1, wherein the gas inlet is arranged to propel gas in a direction that is not substantially parallel to the working area.

11. Additive manufacturing apparatus according to claim 1, wherein the gas inlet and/or gas outlet comprise an elongate aperture that extends across an entire width of the working area, the gas inlet and/or gas outlet movable in a linear direction perpendicular to a longitudinal axis of the aperture.

12. Additive manufacturing apparatus according to claim 1, wherein the gas inlet and/or gas outlet comprise an aperture that extends across less than a width of the working area, the gas inlet and/or gas outlet movable in a linear direction perpendicular to a gas flow direction from the gas inlet/into the gas outlet.

13. Additive manufacturing apparatus according to claim 1, wherein the apparatus is a selective laser solidification apparatus, wherein powder layers are successively deposited across the working area in the build chamber and a laser beam is scanned across portions of each powder layer that correspond to a cross-section of the object being constructed to consolidate the portions of the powder.

14. Additive manufacturing apparatus according to claim 1, comprising a controller for controlling a rate of flow at which gas is propelled into the build chamber from the gas inlet based upon a location of the gas inlet and/or gas outlet in the build chamber.

15. Additive manufacturing apparatus according to claim 1, comprising a controller configured to control a rate of flow at which gas is drawn from the build chamber through the gas outlet based upon a location of the gas inlet and/or gas outlet in the build chamber.

16. Additive manufacturing apparatus for building objects by layerwise consolidation of material, the apparatus comprising:

a build chamber containing a working area,

a high energy beam configured to consolidate material deposited in the working area in layers,

a flow device configured to generate a gas flow across at least a part of the working area from a gas inlet to a gas outlet, at least one of the gas inlet and gas outlet arranged to be movable within the build chamber, and

a wiper configured to spread powder across the working area, the wiper mounted to move with at least one of the gas inlet and gas outlet.

17. Additive manufacturing apparatus according to claim 16, wherein the gas inlet and the gas outlet are arranged to be movable within the build chamber during building of the object.

18. Additive manufacturing apparatus according to claim 16, wherein the at least one of the gas inlet and the gas outlet are arranged to be movable within the build chamber during building of the object.

19. Additive manufacturing apparatus for building objects by layerwise consolidation of material, the apparatus comprising:

a build chamber containing a working area,

a high energy beam configured to consolidate material deposited in the working area in layers,

a flow device configured to generate a gas flow across at least a part of the working area from a gas inlet to a gas outlet, at least one of the gas inlet and gas outlet arranged to be movable within the build chamber, and

a probe configured to measure geometry of the object being built, the probe mounted to move on an axis common with the gas inlet and/or gas outlet.

20. Additive manufacturing apparatus according to claim 19, wherein the gas inlet and/or gas outlet that is mounted on a common axis with the probe is arranged to move in a first direction and the probe is arranged to move in the first direction and in a further direction.

21. Additive manufacturing apparatus according to claim 20, wherein the probe is a contact probe.

22. Additive manufacturing apparatus according to claim 19, wherein the gas inlet and the gas outlet are arranged to be movable within the build chamber during building of the object.

23. Additive manufacturing apparatus according to claim 19, wherein the at least one of the gas inlet and the gas outlet are arranged to be movable within the build chamber during building of the object.