Three-dimensional printing of three-dimensional objects

• US 10,357,829 B2
• Filed: 03/01/2018
• Issued: 07/23/2019
• Est. Priority Date: 03/02/2017
• Status: Active Grant

• Current Assignee: Velo3D, Inc.
• Original Assignee: Velo3D, Inc.
• Inventors: Spink, Brian Charles, Murphree, Zachary Ryan, Lappas, Tasso, Symeonidis, Kimon, Mendelsberg, Rueben Joseph
• Primary Examiner(s): Krupicka, Adam
• Application Number:
  US15/909,809
• Publication Number:
  US 20180250775A1
• Time in Patent Office: 509 Days
• Field of Search: None
• CPC Class Codes: B22F 10/00 Additive manufacturing of workpieces or articles from metallic powder apparatus or devices therefor B22F12/00
• CPC Class Codes: B22F 10/18 by mixing binder with metal in filament form, e.g. fused filament fabrication [FFF]
• CPC Class Codes: B22F 10/25 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 10/366 Scanning parameters, e.g. hatch distance or scanning strategy
• CPC Class Codes: B22F 10/368 Temperature or temperature gradient, e.g. temperature of the melt pool
• CPC Class Codes: B22F 10/38 to achieve specific product aspects, e.g. surface smoothness, density, porosity or hollow structures
• CPC Class Codes: B22F 10/385 Overhang structures
• CPC Class Codes: B22F 10/47 characterised by structural features
• CPC Class Codes: B22F 12/43 pulsed; frequency modulated
• CPC Class Codes: B22F 12/45 Two or more
• CPC Class Codes: B22F 12/90 Means for process control, e.g. cameras or sensors
• CPC Class Codes: B22F 2203/00 Controlling
• CPC Class Codes: B22F 2203/11 temperature, temperature profile
• CPC Class Codes: B22F 2207/17 density or porosity gradients
• CPC Class Codes: B22F 2999/00 Aspects linked to processes or compositions used in powder metallurgy
• CPC Class Codes: B22F 3/11 Making porous workpieces or articles
• CPC Class Codes: B22F 5/00 Manufacture of workpieces or articles from metallic powder characterised by the special shape of the product
• CPC Class Codes: B22F 7/002 of porous nature
• CPC Class Codes: B23K 15/0013 Positioning or observing workpieces, e.g. with respect to the impact; Aligning, aiming or focusing electronbeams
• 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 15/06 : within a vacuum chamber B23K15/04 takes precedence
• CPC Class Codes: B23K 15/10 : Non-vacuum electron beam-welding or cutting
• CPC Class Codes: B23K 2103/00 : Materials to be soldered, welded or cut
• CPC Class Codes: B23K 26/0006 : taking account of the properties of the material involved B23K26/32, B23K26/40 take precedence
• CPC Class Codes: B23K 26/032 : using optical means
• CPC Class Codes: B23K 26/034 : Observing the temperature of the workpiece
• 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 26/0608 : in the same heat affected zone [HAZ] B23K26/0613, B23K26/0619 take precedence
• CPC Class Codes: B23K 26/0626 : Energy control of the laser beam B23K26/0622 takes precedence
• CPC Class Codes: B23K 26/0643 : comprising mirrors
• CPC Class Codes: B23K 26/082 : Scanning systems, i.e. devices involving movement of the laser beam relative to the laser head
• CPC Class Codes: B23K 26/0876 : in at least two axial directions
• CPC Class Codes: B23K 26/10 : using a fixed support , i.e. involving moving the laser beam
• CPC Class Codes: B23K 26/1224 : in vacuum
• CPC Class Codes: B23K 26/123 : in an atmosphere of particular gases
• CPC Class Codes: B23K 26/127 : in an enclosure
• CPC Class Codes: B23K 26/34 : Laser welding for purposes other than joining
• CPC Class Codes: B23K 26/342 : Build-up welding
• CPC Class Codes: B23K 26/354 : by melting
• CPC Class Codes: B23K 26/355 : Texturing
• CPC Class Codes: B23K 26/703 : Cooling arrangements by using a fluid stream B23K26/14
• CPC Class Codes: B23K 26/704 : Beam dispersers, e.g. beam wells
• CPC Class Codes: B23K 37/06 : for positioning the molten material, e.g. confining it to a desired area
• 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 40/10 : Pre-treatment
• CPC Class Codes: B33Y 50/02 : for controlling or regulating additive manufacturing processes
• CPC Class Codes: B33Y 80/00 : Products made by additive manufacturing
• CPC Class Codes: C22C 1/0458 : Alloys based on titanium, zirconium or hafnium
• 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: G05B 2219/49013 : Deposit layers, cured by scanning laser, stereo lithography SLA, prototyping
• CPC Class Codes: Y02P 10/25 : Process efficiency

Abstract

The present disclosure provides three-dimensional (3D) printing methods, apparatuses, systems and/or software to form one or more three-dimensional objects, some of which may be complex. The three-dimensional objects may be formed by three-dimensional printing using one or more methodologies. In some embodiments, the three-dimensional object may comprise an overhang portion, such as a cavity ceiling, with diminished deformation and/or auxiliary support structures.

Claims

1. A three-dimensional object, comprising:

a plurality of layers of solid material that are stacked and bonded together to form a shape of the three-dimensional object, which plurality of layers of solid material comprises;

a core characterized as having a first microstructure comprising a first plurality of grains associated with being formed at a first solidification rate; and

a skin portion coupled with the core, which skin portion comprises;

(i) a second microstructure comprising a second plurality of grains associated with being formed at a second solidification rate that is different than the first solidification rate, and

(ii) an exterior surface corresponding to at least a fraction of an exterior surface of the three-dimensional object

wherein the second plurality of grains are aligned and the first plurality of grains are misaligned.

2. The three-dimensional object of claim 1, wherein a layer of the skin portion comprises a melt pool across a width of the skin portion.

3. The three-dimensional object of claim 1, wherein the skin portion comprises a melt pool, wherein an alignment line (1) runs through a central portion of the melt pool, (2) is parallel to the exterior surface, and/or (3) is at the exterior surface.

4. The three-dimensional object of claim 3, wherein with respect to the alignment line:

the second plurality of grains are aligned, and the first plurality of grains are misaligned.

5. The three-dimensional object of claim 3, wherein grains of the second plurality of grains align at a non-zero angle relative to the alignment line.

6. The three-dimensional object of claim 5, wherein the first plurality of grains is different from the second plurality of grains by at least one aspect selected from the group consisting of:

(a) a fundamental length scale, (b) chemical makeup, (c) crystal structure, (d) metallurgical microstructure, (e) coherence length, (d) grain size, and (e) spatial placement relative to the alignment line.

7. The three-dimensional object of claim 5, wherein relative to the first plurality of grains, the second plurality of grains have (a) a larger fundamental length scale, (b) larger coherence length, (c) larger grain size, and/or (d) more organized spatial placement relative to the alignment line.

8. The three-dimensional object of claim 7, wherein an average fundamental length scale of the second plurality of grains is about 1.5 times greater than an average fundamental length scale of grains of the first plurality of grains.

9. The three-dimensional object of claim 5, wherein the first microstructure is characterized by a first grain, wherein the second microstructure is characterized by a second grain that has at least one aspect that is different than the first grain, which at least one aspect is selected from the group consisting of:

(a) a fundamental length scale, (b) chemical makeup, (c) crystal structure, (d) metallurgical microstructure, and (e) spatial placement relative to the alignment line.

10. The three-dimensional object of claim 9, wherein the fundamental length scale is selected from the group consisting of:

a length and a width.

11. The three-dimensional object of claim 1, wherein the skin portion is bonded with the core.

12. The three-dimensional object of claim 1, wherein the skin portion has a thickness ranging from about 20 micrometers to about 1000 micrometers.

13. The three-dimensional object of claim 1, wherein the second solidification rate is slower than the first solidification rate.

14. The three-dimensional object of claim 1, wherein the first solidification rate is associated with a first cooling rate, wherein the second solidification rate is associated with a second cooling rate different than the first cooling rate.

15. The three-dimensional object of claim 1, wherein the core comprises a first set of melt pools, wherein the skin portion comprises a second set of melt pools, wherein an orientation of the second plurality of grains is with respect to:

(I) a rim of a melt pool of the second set of melt pools and/or (II) the exterior surface of the skin portion.

16. The three-dimensional object of claim 1, wherein the exterior surface of the skin portion has an area surface roughness (Sa) of at most about 50 micrometers.

17. A three-dimensional object, comprising:

a plurality of layers of solid material that are stacked and bonded together to form a shape of the three-dimensional object, which plurality of layers of solid material comprises;

a core characterized as having a first microstructure comprising a first plurality of grains associated with being formed at a first solidification rate; and

a skin portion coupled with the core, which skin portion comprises;

(i) a second microstructure comprising a second plurality of grains associated with being formed at a second solidification rate that is different than the first solidification rate, and

(ii) an exterior surface corresponding to at least a fraction of an exterior surface of the three-dimensional object,

wherein the core comprises a first set of melt pools, wherein the skin portion comprises a second set of melt pools, wherein an orientation of the second plurality of grains is with respect to (I) a rim of a melt pool of the second set of melt pools and/or (II) the exterior surface of the skin portion, and wherein melt pools of the second set of melt pools are aligned with the exterior surface of the skin portion.

18. The three-dimensional object of claim 17, wherein a layer of the skin portion comprises a melt pool across a width of the skin portion.

19. The three-dimensional object of claim 17, wherein an alignment line (1) runs through a central portion of a grain of the second plurality of grains, (2) is parallel to the exterior surface, and/or (3) is at the exterior surface.

20. The three-dimensional object of claim 17, wherein relative to the first plurality of grains, the second plurality of grains have (a) a larger fundamental length scale, (b) larger coherence length, (c) larger grain size, and/or (d) more organized spatial placement relative to an alignment line that (1) runs through a central portion of a melt pool of the skin portion, (2) is parallel to the exterior surface, and/or (3) is at the exterior surface.

21. The three-dimensional object of claim 17, wherein the second solidification rate is slower than the first solidification rate.

22. The three-dimensional object of claim 17, wherein the exterior surface of the skin portion has an area surface roughness (Sa) of at most about 50 micrometers.

23. The three-dimensional object of claim 17, wherein the second plurality of grains are aligned and the first plurality of grains are misaligned.

24. A three-dimensional object comprising:

a plurality of layers of solid material that are stacked and bonded together to form a shape of the three-dimensional object, which plurality of layers of solid material comprises;

a core characterized as having a first microstructure comprising a first plurality of grains associated with being formed at a first solidification rate; and

a skin portion coupled with the core, which skin portion comprises;

(i) a second microstructure comprising a second plurality of grains associated with being formed at a second solidification rate that is different than the first solidification rate, and

(ii) an exterior surface corresponding to at least a fraction of an exterior surface of the three-dimensional object,

wherein the skin portion is characterized by a plurality of tiles, wherein centers of successive tiles are substantially uniformly spaced apart from one another.

25. The three-dimensional object of claim 24, wherein at least two successive tiles overlap with each other.

26. The three-dimensional object of claim 24, wherein the second plurality of grains are aligned and the first plurality of grains are misaligned.

27. The three-dimensional object of claim 24, wherein a layer of the skin portion comprises a melt pool across a width of the skin portion.

28. The three-dimensional object of claim 24, wherein relative to the first plurality of grains, the second plurality of grains have (a) a larger fundamental length scale, (b) larger coherence length, (c) larger grain size, and/or (d) more organized spatial placement relative to an alignment line that (1) runs through a central portion of a melt pool of the skin portion, (2) is parallel to the exterior surface, and/or (3) is at the exterior surface.

29. The three-dimensional object of claim 24, wherein the second solidification rate is slower than the first solidification rate.

30. The three-dimensional object of claim 24, wherein the core comprises a first set of melt pools, wherein the skin portion comprises a second set of melt pools, wherein an orientation of the second plurality of grains is with respect to (I) a rim of a melt pool of the second set of melt pools and/or (II) the exterior surface of the skin portion.

31. The three-dimensional object of claim 24, wherein the exterior surface of the skin portion has an area surface roughness (Sa) of at most about 50 micrometers.