Skillful three-dimensional printing

• US 10,286,603 B2
• Filed: 12/09/2016
• Issued: 05/14/2019
• Est. Priority Date: 12/10/2015
• Status: Active Grant

• Current Assignee: Velo3D, Inc.
• Original Assignee: Velo3D, Inc.
• Inventors: Buller, Benyamin, Lappas, Tasso, Milshtein, Erel, Mendelsberg, Rueben, Symeonidis, Kimon, Lappen, Alan Rick
• Primary Examiner(s): Kastler, Scott R
• Assistant Examiner(s): Luk, Vanessa T.
• Application Number:
  US15/374,616
• Publication Number:
  US 20170165754A1
• Time in Patent Office: 886 Days
• 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) irradiating an exposed surface of the material bed at a first position using an energy beam during a first time period of at least one millisecond, to transform the pre-transformed material at the first position to a transformed material to form a first tile as part of the three-dimensional object, which first position is along a path-of-tiles, wherein during the first time period, the energy beam is stationary or substantially stationary such that it at most undergoes back and forth movement with respect to the first position on the exposed surface;

(c) translating the energy beam to a second position of the exposed surface along the path-of-tiles, which second position is different from the first position, wherein the energy beam is translated during an intermission without transforming the pre-transformed material along the path-of-tiles, wherein during the intermission, the energy beam irradiates a portion of the material bed that is not along the path-of-tiles; and

(d) irradiating the exposed surface of the material bed at the second position with the energy beam at the second position during a second time period of at least one millisecond, to transform the pre-transformed material at the second position to a transformed material to form a second tile as part of the three-dimensional object, wherein during the second time period, the energy beam is stationary or substantially stationary such that it at most undergoes back and forth movement with respect to the second position on the exposed surface.

2. The method of claim 1, wherein the first time period is equal to the second time period.

3. The method of claim 1, wherein in (c) the energy beam is translated within a time period of at least 1 millisecond.

4. The method of claim 1, wherein a diameter of a cross section of the energy beam is at least 50 micrometers.

5. The method of claim 1, wherein the second tile contacts the first tile.

6. The method of claim 5, wherein the second tile at least partially overlaps the first tile.

7. The method of claim 1, wherein the second tile at least partially overlaps the first tile.

8. The method of claim 1, further comprising dispensing a layer of the pre-transformed material by removing an excess of pre-transformed material from the exposed surface of the material bed using a gas flow and cyclonically separating the pre-transformed material from the gas flow.

9. The method of claim 1, wherein in (b), the energy beam that is stationary or substantially stationary comprises spatial oscillations of the energy beam that are smaller than a diameter of the energy beam.

10. The method of claim 1, wherein the three-dimensional object comprises one or more layers with a radius of curvature of at least five centimeters.

11. The method of claim 1, wherein the three-dimensional object has a porosity of at most 10%.

12. The method of claim 1, wherein the second position is directly adjacent to and separated from the first position by a pre-transformed material gap.

13. The method of claim 1, further comprising (e) translating the energy beam to a third position of the exposed surface along the path-of-tiles, which third position follows the second position along the path-of-tiles and is different from the first position and different from the second position, which energy beam is translated during an intermission without transforming the pre-transformed material along the path-of-tiles;

and (f) irradiating the exposed surface of the material bed by the energy beam at the third position during a third time period to transform the pre-transformed material at the third position to a transformed material to form a third tile as part of the three-dimensional object, which third tile contacts the second tile, wherein during the third time period, the energy beam is stationary or substantially stationary such that it at most undergoes back and forth movement with respect to the third position on the exposed surface, wherein the third tile follows the second tile that follows the first tile along the path-of-tiles.

14. The method of claim 13, wherein the first tile, second tile, and third tile are successively arranged in a single file.

15. The method of claim 14, wherein a diameter of a cross section of the energy beam is at least 50 micrometers.

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

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

(b) irradiating an exposed surface of the material bed at a first position using an energy beam during a first time period, to transform the pre-transformed material at the first position to a transformed material to form a first tile as part of the three-dimensional object, which first position is along a path-of-tiles, which energy beam has a power density of at most 8000 Watts per millimeter squared, wherein during the first time period, the energy beam is stationary or substantially stationary such that it at most undergoes back and forth movement with respect to the first position on the exposed surface;

(c) translating the energy beam to a second position of the exposed surface along the path-of-tiles, which second position is different from the first position, which energy beam is translated during an intermission without transforming the pre-transformed material along the path-of-tiles, wherein during the intermission, the energy beam irradiates a portion of the material bed that is not along the path-of-tiles; and

(d) irradiating the exposed surface of the material bed at the second position with the energy beam at the second position during a second time period to transform the pre-transformed material at the second position to a transformed material to form a second tile as part of the three-dimensional object, wherein during the second time period, the energy beam is stationary or substantially stationary such that it at most undergoes back and forth movement with respect to the second position on the exposed surface,

wherein the first time period and/or second time period is of at least one tenth (0.1) of a millisecond.

17. The method of claim 16, wherein a diameter of a cross section of the energy beam is at least 50 micrometers.

18. The method of claim 16, wherein in (c), the energy beam is translated within a time period of at least 1 millisecond.

19. The method of claim 16, wherein the second tile contacts the first tile.

20. The method of claim 19, wherein the second tile at least partially overlaps the first tile.

21. The method of claim 16, wherein the first time period and/or the second time period is at least 1 millisecond.

22. The method of claim 16, wherein the three-dimensional object has a porosity of at most 10%.

23. The method of claim 16, wherein the three-dimensional object comprises one or more layers with a radius of curvature of at least five centimeters.

24. The method of claim 16, wherein the second position is directly adjacent to and separated from the first position by a pre-transformed material gap.

25. The method of claim 16, further comprising (e) translating the energy beam to a third position of the exposed surface along the path-of-tiles, which third position follows the second position along the path-of-tiles and is different from the first position and different from the second position, which energy beam is translated during an intermission without transforming the pre-transformed material along the path-of-tiles;

and (f) irradiating the exposed surface of the material bed by the energy beam at the third position during a third time period to transform the pre-transformed material at the third position to a transformed material to form a third tile as part of the three-dimensional object, which third tile contacts the second tile, wherein during the third time period, the energy beam is stationary or substantially stationary such that it at most undergoes back and forth movement with respect to the third position on the exposed surface, wherein the third tile follows the second tile that follows the first tile along the path-of-tiles.

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

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

(b) irradiating an exposed surface of the material bed at a first position using an energy beam during a first time period to transform the pre-transformed material at the first position to a transformed material to form a first tile as part of the three-dimensional object, which first position is along a path-of-tiles, wherein during the first time period, the energy beam is stationary or substantially stationary such that it at most undergoes back and forth movement with respect to the first position on the exposed surface, wherein the energy beam is defocused;

(c) translating the energy beam to a second position of the exposed surface along the path-of-tiles, which second position is different from the first position, which energy beam is translated during an intermission without transforming the pre-transformed material along the path-of-tiles, wherein during the intermission, the energy beam irradiates a portion of the material bed that is not along the path-of-tiles, wherein the energy beam is defocused; and

(d) irradiating the exposed surface of the material bed at the second position with the energy beam at the second position during a second time period to transform the pre-transformed material in the second position to a transformed material to form a second tile as part of the three-dimensional object, wherein during the second time period, the energy beam is stationary or substantially stationary such that it at most undergoes back and forth movement with respect to the second position on the exposed surface,

wherein the first time period and/or second time period is of at least one tenth (0.1) of a millisecond, wherein the energy beam is defocused.

27. The method of claim 26, wherein a diameter of a cross section of the energy beam is at least 50 micrometers.

28. The method of claim 26, wherein in (c), the energy beam is translated within a time period of at least 1 millisecond.

29. The method of claim 26, wherein the second tile contacts the first tile.

30. The method of claim 29, wherein the second tile at least partially overlaps the first tile.

31. The method of claim 26, wherein the intermission is at least one (1) millisecond.

32. The method of claim 26, wherein the three-dimensional object comprises one or more layers with a radius of curvature of at least five centimeters.

33. The method of claim 26, wherein during the intermission, the energy beam provides no radiation or provides a reduced amount of radiation along the path-of-tiles, which reduced amount of radiation is insufficient to transform the pre-transformed material along the path-of-tiles.

34. The method of claim 26, wherein the second position is directly adjacent to and separated from the first position by a pre-transformed material gap.

35. The method of claim 26, further comprising (e) translating the energy beam to a third position of the exposed surface along the path-of-tiles, which third position that follows the second position along the path-of-tiles and is different from the first position and different from the second position, which energy beam is translated during an intermission without transforming the pre-transformed material along the path-of-tiles;

and (f) irradiating the exposed surface of the material bed by the energy beam at the third position during a third time period to transform the pre-transformed material at the third position to a transformed material to form a third tile as part of the three-dimensional object, which third tile contacts the second tile, wherein during the third time period, the energy beam is stationary or substantially stationary such that it at most undergoes back and forth movement with respect to the third position on the exposed surface, wherein the third tile follows the second tile that follows the first tile along the path-of-tiles.