Additive manufacturing system having laser and dispenser on common support

• US 10,391,707 B2
• Filed: 03/30/2018
• Issued: 08/27/2019
• Est. Priority Date: 09/16/2015
• Status: Active Grant

• Current Assignee: Applied Materials Incorporated
• Original Assignee: Applied Materials Incorporated
• Inventors: Ng, Hou T., Zehavi, Raanan, Patibandla, Nag B.
• Primary Examiner(s): Del Sole, Joseph S
• Assistant Examiner(s): Nguyen, Thu Khanh T
• Application Number:
  US15/942,116
• Publication Number:
  US 20180222114A1
• Time in Patent Office: 515 Days
• 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 10/28 Powder bed fusion, e.g. selective laser melting [SLM] or electron beam melting [EBM]
• CPC Class Codes: B22F 12/13 to preheat the material
• CPC Class Codes: B22F 12/45 Two or more
• CPC Class Codes: B22F 12/48 in height, e.g. perpendicular to the deposition plane
• CPC Class Codes: B22F 12/55 Two or more means for feeding material
• CPC Class Codes: B22F 12/60 Planarisation devices; Compression devices
• CPC Class Codes: B22F 12/88 Handling of additively manufactured products, e.g. by robots
• CPC Class Codes: B22F 3/003 Apparatus, e.g. furnaces in general F27B
• 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 64/20 Apparatus for additive manufacturing; Details thereof or accessories therefor
• CPC Class Codes: B29C 64/205 Means for applying layers
• CPC Class Codes: B29C 64/209 Heads; Nozzles
• CPC Class Codes: B29C 64/232 for motion along the axis orthogonal to the plane of a layer
• CPC Class Codes: B29C 64/236 for motion in a direction within the plane of a layer
• CPC Class Codes: B29C 64/264 Arrangements for irradiation
• CPC Class Codes: B29C 64/295 Heating elements
• CPC Class Codes: B29C 64/307 Handling of material to be used in additive manufacturing
• CPC Class Codes: B29C 64/336 of two or more materials
• 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: 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 50/02 : for controlling or regulating additive manufacturing processes
• CPC Class Codes: B33Y 70/00 : Materials specially adapted for additive manufacturing
• CPC Class Codes: Y02P 10/25 : Process efficiency

Abstract

An additive manufacturing system includes a platen to support an object being manufactured, a dispenser to deliver a plurality of successive layers of a powder over the platen, and energy source configured to fuse at least a portion of the powder. The dispenser is configured to deliver the powder in a linear region that extends along a first axis. The dispenser and actuator are supported by a support structure, and the actuator is coupled to the support structure to move the support structure along a second axis perpendicular to the first axis such that the dispenser and energy source move as a single unit with the support structure and the linear region sweeps along the second axis to deposit the powder along a swath over the platen to form a layer of powder.

Claims

1. An additive manufacturing system, comprising:

a platen having a top surface to support an object being manufactured;

a support structure;

a dispenser to deliver a plurality of successive layers of a powder on the platen, the dispenser configured to deliver the powder on the platen simultaneously in a linear region that extends and is elongated along a first axis;

an actuator coupled to the support structure to move the support structure along a second axis parallel to the top surface and perpendicular to the first axis; and

an energy source configured to fuse at least a portion of the powder on the platen;

wherein the dispenser and energy source are secured to the support structure such that the dispenser and energy source move as a single unit with the support structure over the platen along the second axis and such that the linear region sweeps along the second axis to deposit the powder along a swath over the platen to form a layer of powder.

2. The system of claim 1, comprising a vertical actuator to move the support structure along a vertical axis perpendicular to the top surface, and a controller coupled to the vertical actuator, dispenser and energy source configured to cause the vertical actuator to move the support to lift the dispenser and energy source away from the top surface after each of the plurality of successive layers is delivered.

3. The system of claim 2, wherein the platen is configured to be vertically immobile.

4. The system of claim 3, wherein the controller is configured to cause the actuator to move the support by distance approximately equal to a thickness of a fused portion of a layer.

5. The system of claim 1, wherein the energy source is configured to generate a beam that is scanned relative to the energy source across the platen and is modulated to control which voxels are fused.

6. The system of claim 5, wherein the energy source comprises a laser and the beam is a laser beam.

7. The system of claim 6, comprising a mirror to scan the laser beam across the platen.

8. The system of claim 7, wherein mirror is configured to deflect the laser beam to control a position of the laser beam on the layer of powder along the first axis.

9. The system of claim 7, wherein the mirror comprises a mirror galvometer.

10. The system of claim 1, comprising a powder spreader to spread powder already delivered to the layer of powder by the dispenser, the spreader extending along the first axis.

11. The system of claim 10, wherein the spreader is secured to the support structure such that the dispenser, energy source and spreader move as a single unit with the support structure over the platen along the second axis.

12. The system of claim 10, wherein the spreader comprises a roller to compact the layer of powder.

13. The system of claim 10, wherein the spreader comprises a blade to level the layer of powder.

14. The system of claim 1, comprising a housing enclosing a vacuum chamber, and wherein the platen and dispenser assembly are positioned in the vacuum chamber.

15. A method of additive manufacturing, comprising:

flowing a powder from a dispenser in a linear region on a platen, the linear region extending along a first axis, the dispenser supported by a support structure;

selectively heating, by an energy source supported by the support structure, the powder to a temperature sufficient to cause the powder to fuse;

moving the support structure along a second axis perpendicular to the first axis and parallel to a top surface of the platen such that the dispenser and energy source move as a single unit with the support structure over the platen along the second axis and such that the linear region sweeps along the second axis to deposit the powder along a swath over the platen to form a layer of powder.

16. The method of claim 15, comprising moving the support structure continuously while flowing the powder.

17. The method of claim 15, wherein selectively heating the layer of powder comprises generating a beam, scanning the beam across the platen, and modulating the beam to control which voxels are fused.

18. The method of claim 17, wherein the beam is a laser beam.

19. The method of claim 18, wherein scanning comprises scanning the laser beam with a mirror.

20. The method of claim 17, wherein scanning comprises scanning the beam along the first axis.

21. The method of claim 15, comprising spreading the layer of powder with a spreader that is attached to the support structure and moves with the dispenser and energy source.

22. The method of claim 21, wherein spreading the layer of powder comprises leveling the layer of powder with a blade that is attached to the support structure and moves with the dispenser and energy source.

23. The method of claim 15, wherein the powder is metallic particles.

24. The method of claim 23, wherein the metallic particles comprise titanium or stainless steel, or combinations thereof.

25. The method of claim 15, comprising flowing the powder and selectively heating the layer of powder in a vacuum environment.