Method and apparatus for producing a three-dimensional article

• US 10,583,483 B2
• Filed: 09/19/2016
• Issued: 03/10/2020
• Est. Priority Date: 10/15/2015
• Status: Active Grant

• Current Assignee: Arcam Ab (Danaher Corporation)
• Original Assignee: Arcam Ab (Danaher Corporation)
• Inventors: Karlsson, Kristofer
• Primary Examiner(s): Del Sole, Joseph S
• Assistant Examiner(s): Hohenbrink, Jr., Lawrence D.
• Application Number:
  US15/268,865
• Publication Number:
  US 20170106570A1
• Time in Patent Office: 1,268 Days
• Field of Search: 425375
• CPC Class Codes: B22F 10/10 Formation of a green body
• CPC Class Codes: B22F 10/28 Powder bed fusion, e.g. selective laser melting [SLM] or electron beam melting [EBM]
• CPC Class Codes: B22F 12/00 Apparatus or devices specially adapted for additive manufacturing; Auxiliary means for additive manufacturing; Combinations of additive manufacturing apparatus or devices with other processing apparatus or devices
• CPC Class Codes: B22F 12/226 for rotary motion
• CPC Class Codes: B22F 12/50 Means for feeding of material, e.g. heads
• CPC Class Codes: B22F 12/67 Blades
• 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 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: B23K 15/0086 welding for purposes other than joining, e.g. built-up welding
• CPC Class Codes: B23K 15/02 Control circuits therefor
• CPC Class Codes: B23K 26/342 Build-up welding
• CPC Class Codes: B23K 26/70 Auxiliary operations or equipment
• 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 64/20 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 64/214 Doctor blades
• CPC Class Codes: B29C 64/218 Rollers
• CPC Class Codes: B29C 64/255 Enclosures for the building material, e.g. powder containers
• CPC Class Codes: B29C 64/259 : Interchangeable
• CPC Class Codes: B29C 64/321 : Feeding
• CPC Class Codes: B29C 64/329 : using hoppers
• CPC Class Codes: B29L 2009/00 : Layered products
• 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: Y02P 10/25 : Process efficiency

Abstract

A pivoted powder pushing device is provided, comprising a first portion and a contact member, wherein: the contact member is configured to operatively engage a grip arm of the distribution member when the distribution member is positioned at least in part above the base surface, and the first portion is moved via the engagement of the grip arm and the contact member in a first direction opposite a direction of travel of the distribution member, such that the first portion of said pivoted powder pushing device passes under said distribution member. An associated apparatus, method, and computer program product are also provided.

Claims

1. A pivoted powder pushing device (125) for bringing a portion of powder from a base surface (130) of an apparatus (100) for producing a three-dimensional object layer by layer using a powdery material which can be solidified by irradiation thereof with an energy beam and to a position between a distribution member (185) and a working area (190) of said apparatus, said pivoted powder pushing device (125) comprising:

a first portion (170), and

a contact member (154),

wherein;

the contact member (154) is configured to operatively engage a grip arm (150) of the distribution member (185) when the distribution member (185) is positioned at least in part above the base surface (130), and

the first portion (170) is moved via the engagement of the grip arm (150) and the contact member (154) in a first direction opposite a direction of travel of the distribution member (185), such that the first portion (170) of said pivoted powder pushing device (125) passes under said distribution member (185) and extends above a plane of a working table (195) when positioned between the distribution member (185) and the working area (190).

2. The device according to claim 1, wherein said pivoted powder pushing device (125) is electrically actuated and controlled by a control unit.

3. The device according to claim 1, wherein a pivot axle (140) for said pivoted powder pushing device (125) is provided above said base surface (130).

4. The device (1) according to claim 1, wherein said pivoted powder pushing device (125) interrupts powder flow from a powder storage unit (110) onto said base surface (130) during a portion of its pivoted stroke.

5. The device (1) according to claim 1, wherein said base surface (130) has a curved shape.

6. The device (1) according to claim 1, wherein:

the distribution member (185) is moveable in a translational fashion, and

the first portion (170) of said pivoted powder pushing device (125) is moveable in a curved trajectory.

7. The device (1) according to claim 1, wherein the contact between the contact member (154) and the grip arm (150) occurs only when the distribution member (185) is positioned over the base surface (130).

17. The device (1) according to claim 1, wherein the first portion (170) is configured to inhibit transport of powder in the direction of travel of the distribution member (185) when moving in the first direction.

8. Apparatus (100) for producing a three-dimensional object layer by layer using a powdery material which can be solidified by irradiating it with an energy beam, said apparatus (100) comprising:

a pivoted powder pushing device (125) for bringing a portion of powder from a base surface (130) of said apparatus to a position between a distribution member (185) of said apparatus and a working area (190) of said apparatus,

wherein;

said pivoted powder pushing device (125) comprises a first portion (170) having a front area (178) and a rear area, and a contact member (154),

the contact member (154) is configured to operatively engage a grip arm (150) of the distribution member (185) when the distribution member (185) is positioned at least in part above the base surface (130), and

the front area (178) and the rear area of the first portion (170) are moved via the engagement of the grip arm (150) and the contact member (154) in a first direction opposite a direction of travel of the distribution member (185), such that the first portion (170) of said pivoted powder pushing device (125) passes under said distribution member (185) and extends above a plane of a working table (195) when positioned between the distribution member (185) and the working area (190).

9. The apparatus according to claim 8, wherein said pivoted powder pushing device (125) is electrically actuated and controlled by a control unit.

10. The apparatus according to claim 8, wherein a pivot axle (140) for said pivoted powder pushing device (125) is provided above said base surface (130).

11. The apparatus according to claim 8, wherein said pivoted powder pushing device (125) interrupts powder flow from a powder storage unit (110) onto said base surface (130) during a portion of its pivoted stroke.

12. The apparatus according to claim 8, wherein said base surface (130) has a curved shape.

13. The apparatus according to claim 8, wherein:

the distribution member (185) is moveable in a translational fashion, and

the first portion (170) of said pivoted powder pushing device (125) is moveable in a curved trajectory.

14. The apparatus according to claim 8, wherein the contact between the contact member (154) and the grip arm (150) occurs only when the distribution member (185) is positioned over the base surface (130).

18. The apparatus according to claim 8, wherein the front area (178) and the rear area of the first portion (170) is shaped such that powder is moved in the first direction opposite the direction of travel of the distribution member (185) in response to movement of the first portion (170).

15. A computer-implemented method for producing a three-dimensional article layer by layer using a powdery material which can be solidified by irradiating it with an energy beam, method comprising the steps of:

providing a powder storage unit comprising an opening spaced apart from a base surface, where said base surface is supporting a supply of powder in said powder storage unit;

bringing a predetermined amount of powder from said base surface to a position between said distribution member and said working area with a pivoted powder pushing device; and

moving said distribution member towards and across the working area so as to distribute the portion of powder onto the working area for forming a layer of powder material,

wherein;

said pivoted powder pushing device (125) comprises a first portion (170), and a contact member (154),

the contact member (154) is configured to operatively engage a grip arm (150) of the distribution member (185) when the distribution member (185) is positioned at least in part above the base surface (130), and

the first portion (170) is moved via the engagement of the grip arm (150) and the contact member (154) in a first direction opposite a direction of travel of the distribution member (185), such that the first portion (170) of said pivoted powder pushing device (125) passes under said distribution member (185) and extends above a plane of a working table (195) when positioned between the distribution member (185) and the working area.

16. A computer program product comprising at least one non-transitory computer-readable storage medium having computer-readable program code portions embodied therein, the computer-readable program code portions comprising at least one executable portion configured for:

providing a powder storage unit comprising an opening spaced apart from a base surface, where said base surface is supporting a supply of powder in said powder storage unit;

bringing a predetermined amount of powder from said base surface to a position between said distribution member and said working area with a pivoted powder pushing device; and

moving said distribution member towards and across the working area so as to distribute the portion of powder onto the working area for forming a layer of powder material,

wherein;

said pivoted powder pushing device (125) comprises a first portion (170), and a contact member (154),

the contact member (154) is configured to operatively engage a grip arm (150) of the distribution member (185) when the distribution member (185) is positioned at least in part above the base surface (130), and

the first portion (170) is moved via the engagement of the grip arm (150) and the contact member (154) in a first direction opposite a direction of travel of the distribution member (185), such that the first portion (170) of said pivoted powder pushing device (125) passes under said distribution member (185) and extends above a plane of a working table (195) when positioned between the distribution member (185) and the working area.