Apparatuses, systems and methods for three-dimensional printing

• US 10,507,549 B2
• Filed: 02/17/2017
• Issued: 12/17/2019
• Est. Priority Date: 06/20/2014
• Status: Active Grant

• Current Assignee: Velo3D, Inc.
• Original Assignee: Velo3D, Inc.
• Inventors: Buller, Benyamin, Milshtein, Erel, Chua, Thai Cheng
• Primary Examiner(s): Zhu, Weiping
• Application Number:
  US15/436,558
• Publication Number:
  US 20170189963A1
• Time in Patent Office: 1,033 Days
• Field of Search: 419 53
• CPC Class Codes: B22F 10/12 by photopolymerisation, e.g. stereolithography [SLA] or digital light processing [DLP]
• CPC Class Codes: B22F 10/18 by mixing binder with metal in filament form, e.g. fused filament fabrication [FFF]
• CPC Class Codes: B22F 10/20 Direct sintering or melting
• 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 10/30 Process control
• CPC Class Codes: B22F 10/32 of the atmosphere, e.g. composition or pressure in a building chamber
• CPC Class Codes: B22F 10/47 characterised by structural features
• CPC Class Codes: B22F 10/50 Treatment of workpieces or articles during build-up, e.g. treatments applied to fused layers during build-up
• CPC Class Codes: B22F 10/73 of powder
• CPC Class Codes: B22F 12/52 Hoppers
• CPC Class Codes: B22F 12/57 Metering means
• CPC Class Codes: B22F 12/60 Planarisation devices; Compression devices
• CPC Class Codes: B22F 12/90 Means for process control, e.g. cameras or sensors
• CPC Class Codes: B22F 2003/1054 by microwave
• CPC Class Codes: B22F 2003/248 Thermal after-treatment
• CPC Class Codes: B22F 2201/20 Use of vacuum
• CPC Class Codes: B22F 2202/01 Use of vibrations
• CPC Class Codes: B22F 2202/05 Use of magnetic field
• CPC Class Codes: B22F 2998/10 Processes characterised by the sequence of their steps
• CPC Class Codes: B22F 2999/00 : Aspects linked to processes or compositions used in powder metallurgy
• CPC Class Codes: B22F 3/003 : Apparatus, e.g. furnaces in general F27B
• CPC Class Codes: B22F 3/004 : Filling molds with powder feeding material to presses in general B30B15/302
• CPC Class Codes: B22F 3/105 : by using electric current other than for infrared radiant energy, laser radiation or plasma B22F3/11 takes precedence; by ultrasonic bonding B22F3/115 takes precedence
• CPC Class Codes: B22F 3/24 : After-treatment of workpieces or articles B22F3/1146 takes precedence
• CPC Class Codes: B22F 7/00 : Manufacture of composite layers, workpieces, or articles, comprising metallic powder, by sintering the powder, with or without compacting wherein at least one part is obtained by sintering or compression application of coating layers by use of metal powders, see C23C
• CPC Class Codes: B23K 10/006 : Control circuits therefor circuits for plasma torches H05H1/36
• CPC Class Codes: B23K 10/027 : Welding for purposes other than joining, e.g. build-up welding
• CPC Class Codes: B23K 15/002 : Devices involving relative movement between electronbeam and workpiece
• CPC Class Codes: B23K 15/0026 : Auxiliary equipment
• 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 2103/50 : Inorganic material, e.g. metals, not provided for in B23K2103/02 – B23K2103/26
• CPC Class Codes: B23K 2103/52 : Ceramics
• CPC Class Codes: B23K 26/0853 : Devices involving movement of the workpiece in at least in two axial directions, e.g. in a plane
• CPC Class Codes: B23K 26/1224 : in vacuum
• CPC Class Codes: B23K 26/123 : in an atmosphere of particular gases
• CPC Class Codes: B23K 26/144 : the fluid stream containing particles, e.g. powder
• CPC Class Codes: B23K 26/16 : Removal of by-products, e.g. particles or vapours produced during treatment of a workpiece by a fluid stream B23K26/142
• CPC Class Codes: B23K 26/22 : Spot welding
• CPC Class Codes: B23K 26/32 : taking account of the properties of the material involved
• CPC Class Codes: B23K 26/342 : Build-up welding
• CPC Class Codes: B23K 26/346 : in combination with welding or cutting covered by groups B23K5/00 - B23K25/00, e.g. in combination with resistance welding
• CPC Class Codes: B23K 26/70 : Auxiliary operations or equipment
• CPC Class Codes: B23K 26/702 : Auxiliary equipment
• 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: B28B 17/0072 : Product control or inspection
• CPC Class Codes: B28B 17/0081 : Process control
• 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 64/171 : 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 64/194 : during lay-up
• CPC Class Codes: B29C 64/214 : Doctor blades
• CPC Class Codes: B29C 64/245 : Platforms or substrates support structures intended to be sacrificed after manufacture B29C64/40
• CPC Class Codes: B29C 64/255 : Enclosures for the building material, e.g. powder containers
• CPC Class Codes: B29C 64/264 : Arrangements for irradiation
• CPC Class Codes: B29C 64/268 : using laser beams; using electron beams [EB]
• CPC Class Codes: B29C 64/35 : Cleaning
• 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: C04B 2235/6026 : Computer aided shaping, e.g. rapid prototyping
• CPC Class Codes: C04B 35/522 : Graphite C04B35/536 takes precedence
• CPC Class Codes: C04B 35/5626 : based on tungsten carbides
• CPC Class Codes: C04B 35/565 : based on silicon carbide
• CPC Class Codes: C04B 35/64 : Burning or sintering processes C04B33/32 takes precedence ; powder metallurgy B22F
• CPC Class Codes: C22C 38/00 : Ferrous alloys, e.g. steel alloys cast-iron alloys C22C37/00
• CPC Class Codes: C22C 38/02 : containing silicon
• CPC Class Codes: C22C 38/44 : with molybdenum or tungsten
• CPC Class Codes: C22C 38/58 : with more than 1.5% by weight of manganese
• CPC Class Codes: H05B 6/68 : for monitoring or control
• CPC Class Codes: H05B 6/80 : Apparatus for specific applications stoves or ranges F24C7/02
• CPC Class Codes: Y02P 10/20 : Recycling
• CPC Class Codes: Y02P 10/25 : Process efficiency

Abstract

The present disclosure provides three-dimensional (3D) objects, 3D printing processes, as well as methods, apparatuses and systems for the production of a 3D object. Methods, apparatuses and systems of the present disclosure may reduce or eliminate the need for auxiliary supports. The present disclosure provides three dimensional (3D) objects printed utilizing the printing processes, methods, apparatuses and systems described herein.

Claims

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

(a) receiving a request to generate the metallic three-dimensional object;

(b) printing the metallic three-dimensional object layerwise according to a model of the metallic three-dimensional object, which printing comprises utilizing a dispenser, wherein the metallic three-dimensional object comprises a material having at least one member selected from the group consisting of an elemental metal, and a metal alloy; and

(c) providing the metallic three-dimensional object for delivery to a user without trimming the metallic three-dimensional object, wherein the metallic three-dimensional object deviates from the model of the metallic three-dimensional object by at most about 100 micrometers plus a fundamental length scale of the metallic three-dimensional object divided by 2500.

2. The method of claim 1, wherein printing the metallic three-dimensional object is performed without iterative printing and/or without corrective printing.

3. The method of claim 1, wherein the metallic three-dimensional object comprises a plurality of layers, wherein the layers of the metallic three-dimensional object have a radius of curvature of at least 5 centimeters.

4. The method of claim 3, wherein the metallic three-dimensional object comprises a plurality of layers, wherein one or more layers of the plurality of layers of the metallic three-dimensional object have a radius of curvature of at least 50 centimeters.

5. The method of claim 1, wherein the metallic three-dimensional object comprises a surface having an arithmetic average of roughness profile (Ra) of at most 200 micrometers.

6. The method of claim 1, wherein the metallic three-dimensional object comprises a cavity or a hanging plane.

7. The method of claim 1, wherein the metallic three-dimensional object comprises at least one layer of hardened material, wherein the metallic three-dimensional object comprises a surface that faces a platform above which the metallic three-dimensional object is disposed during printing, and wherein during printing, an acute angle between a straight line on the surface of the metallic three-dimensional object and a direction normal to an average layering plane (N) of the at least one layer of hardened material, is from about 45 degrees to 90 degrees.

8. The method of claim 7, wherein, with X and Y being points on the surface of the metallic three-dimensional object, (i) the surface of the metallic three-dimensional object that intersects a sphere of radius XY at positions X and Y is devoid of an auxiliary support feature, and (ii) X and Y are spaced apart by at least about two (2) millimeters.

9. The method of claim 1, wherein in (c), the metallic three-dimensional object is provided for delivery to the user without polishing of the metallic three-dimensional object.

10. The method of claim 1, further comprising receiving an item of value from the user in exchange for the metallic three-dimensional object.

11. The method of claim 1, wherein printing the metallic three-dimensional object comprises utilizing an energy beam.

12. The method of claim 1, wherein during printing, the metallic three-dimensional object is devoid of auxiliary support.

13. The method of claim 1, wherein printing the metallic three-dimensional object is performed without iterative printing.

14. The method of claim 1, wherein the user is a customer.

15. The method of claim 1, wherein the metallic three-dimensional object comprises a cavity.

16. The method of claim 1, wherein printing the metallic three-dimensional object layer wise comprises use of powder three-dimensional printing.

17. The method of claim 16, wherein the powder three-dimensional printing comprises using a powder bed that is supported by a platform.

18. The method of claim 17, wherein the powder three-dimensional printing comprises fusing a portion of powder material that forms the powder bed to print the metallic three-dimensional object.

19. The method of claim 18, wherein fusing comprises melting, sintering, or bonding.

20. The method of claim 19, wherein melting comprises entirely transforming powder material to a liquid state.