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Method for additive manufacturing

  • US 10,434,572 B2
  • Filed: 11/19/2014
  • Issued: 10/08/2019
  • Est. Priority Date: 12/19/2013
  • Status: Active Grant
First Claim
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1. A method for forming at least one three-dimensional article through successive fusion of parts of a powder bed, which parts correspond to successive cross sections of the at least one three-dimensional article, said method comprising the steps of:

  • providing a model of said at least one three dimensional article;

    applying a first powder layer on a work table;

    directing at least one energy beam over said work table causing said first powder layer to fuse in selected locations according to said model to form a first cross section of said three-dimensional article;

    applying a second powder layer on said work table;

    directing the at least one energy beam over said work table along an intended beam path causing said second powder layer to fuse in selected locations according to said model to form a second cross section of said three-dimensional article; and

    determining a local thickness spanning at least two surfaces or layers by;

    detecting a first topography of a surface onto which a new powder layer is to be applied;

    detecting a second topography of a surface of the new powder layer;

    subtracting said second topography with said first topography resulting in a third topography; and

    adding a distance said work table is lowered to said third topography resulting in said thickness of said new powder layer,wherein;

    said second layer is bonded to said first layer;

    the local thickness is detected along the intended beam path; and

    an energy beam parameter is varied depending on the detected local thickness of said second powder layer along the intended beam path and in order to melt said second powder layer and to remelt at least a predetermined thickness of said first cross section.

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