Method and apparatus for producing three-dimensional objects

• US 10,369,662 B2
• Filed: 06/23/2016
• Issued: 08/06/2019
• Est. Priority Date: 07/15/2009
• Status: Active Grant

• Current Assignee: Arcam Ab (Danaher Corporation)
• Original Assignee: Arcam Ab (Danaher Corporation)
• Inventors: Ljungblad, Ulric
• Primary Examiner(s): Del Sole, Joseph S
• Assistant Examiner(s): Luk, Emmanuel S
• Application Number:
  US15/190,877
• Publication Number:
  US 20160303687A1
• Time in Patent Office: 1,139 Days
• CPC Class Codes: B22F 10/20 Direct sintering or melting
• CPC Class Codes: B22F 10/368 Temperature or temperature gradient, e.g. temperature of the melt pool
• CPC Class Codes: B22F 12/41 characterised by the type, e.g. laser or electron beam
• CPC Class Codes: B22F 12/50 Means for feeding of material, e.g. heads
• CPC Class Codes: B22F 2207/15 Temperature gradients
• CPC Class Codes: B22F 2998/00 Supplementary information concerning processes or compositions relating to powder metallurgy
• CPC Class Codes: B22F 2999/00 Aspects linked to processes or compositions used in powder metallurgy
• CPC Class Codes: B22F 3/004 Filling molds with powder feeding material to presses in general B30B15/302
• CPC Class Codes: B22F 7/04 with one or more layers not made from powder, e.g. made from solid metal
• 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 26/032 using optical means
• CPC Class Codes: B23K 26/034 Observing the temperature of the workpiece
• CPC Class Codes: B23K 26/342 Build-up welding
• CPC Class Codes: B29C 64/153 using layers of powder being selectively joined, e.g. by selective laser sintering or melting
• CPC Class Codes: B33Y 30/00 Apparatus for additive manufacturing; Details thereof or accessories therefor
• CPC Class Codes: B33Y 50/02 for controlling or regulating additive manufacturing processes
• CPC Class Codes: Y02P 10/25 Process efficiency

Abstract

The invention concerns a method for producing three-dimensional objects (6) layer by layer using a powdery material (7) which can be solidified by irradiating it with a high-energy beam (4), said method comprising the steps of: applying a first layer of powdery material onto a working area (5); solidifying a part of said first layer by irradiating it with a high-energy beam; and applying a second layer (8) of powdery material onto the first, partly solidified layer. The invention is characterized in that the method comprises the step of: determining a rate at which the temperature of the second layer (8) increases after application onto the first layer. The invention also concerns an apparatus configured to operate according to the above method.

Claims

1. Apparatus (1) for producing three-dimensional objects (6) layer by layer using a powdery material (7) which can be solidified by irradiating it with a high-energy beam (4), said apparatus comprising:

a working table onto which layers of said powdery material (7) are to be placed, the powdery material being distributable from a powder distributing member (12);

at least one laser source emitting said high-energy beam (4) for irradiating said powdery material (7);

a temperature sensing device; and

at least one control unit,

wherein said apparatus is configured, via said at least one control unit for;

applying a first layer of said powdery material onto said working area (5);

solidifying a part of said first layer by irradiating it with said high-energy beam;

applying a second layer (8) of said powdery material onto the first, partly solidified layer;

determining a rate at which the temperature of the second layer (8) increases after application onto the first layer;

determining a layer thickness of the second layer based upon the determined rate at which the temperature of the second layer (8) increases after application onto the first layer, wherein the determining of the layer thickness of the second layer involves performing a plurality of sequential temperature measurements before the second layer (8) reaches a maximum temperature (T1), and the maximum temperature (T1) represents a point in time at which a rate that heat is conducted from the first layer equals a rate that heat is radiated away from an upper surface of the second layer (8), such that upon reaching the maximum temperature (T1), the temperature of the second layer (8) is no longer increasing;

comparing the determined temperature increase rate with a reference value; and

if the determined temperature increase rate is lower than or higher than the reference value, reapplying said powdery material onto said working area, said reapplying comprising either applying a new layer of said powdery material or removing a portion of said second layer of said powdery material.

2. Apparatus according to claim 1, wherein the control unit of the apparatus is further configured for performing the plurality of sequential temperature measurements in the same at least one position of said second layer (8).

3. Apparatus according to claim 1, wherein the control unit of the apparatus is further configured for fitting a mathematical function to data obtained from said plurality of sequential temperature measurements.

4. Apparatus according to claim 1, wherein the control unit of the apparatus is further configured for measuring said temperature in said at least one position of said second layer by measuring the temperature in a plurality of positions of said second layer (8), wherein said plurality of positions are distributed over the second layer (8).

5. Apparatus according to claim 1, wherein the temperature sensing device is a thermographic camera (14).

6. Apparatus according to claim 5, wherein the thermographic camera (14) is directed towards an upper surface of the second layer (8).