Gas flow in three-dimensional printing

• US 10,661,341 B2
• Filed: 11/03/2017
• Issued: 05/26/2020
• Est. Priority Date: 11/07/2016
• Status: Active Grant

• Current Assignee: Velo3D, Inc.
• Original Assignee: Velo3D, Inc.
• Inventors: Romano, Richard Joseph, Tralongo, Joe, Buller, Benyamin, Brudny, Alexander
• Primary Examiner(s): Thrower, Larry W
• Application Number:
  US15/803,686
• Publication Number:
  US 20180126649A1
• Time in Patent Office: 935 Days
• CPC Class Codes: B01D 46/0012 In-line filters
• CPC Class Codes: B08B 15/02 using chambers or hoods covering the area B08B15/002 takes precedence
• CPC Class Codes: B08B 5/04 Cleaning by suction, with or without auxiliary action B08B9/035 takes precedence; suction cleaners A47L
• 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 10/322 of the gas flow, e.g. rate or direction
• CPC Class Codes: B22F 10/77 of gas
• CPC Class Codes: B22F 12/33 translatory in the deposition plane
• CPC Class Codes: B22F 12/70 Gas flow means
• CPC Class Codes: B22F 12/90 Means for process control, e.g. cameras or sensors
• CPC Class Codes: B22F 2201/00 Treatment under specific atmosphere
• CPC Class Codes: B22F 2999/00 Aspects linked to processes or compositions used in powder metallurgy
• 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 64/245 Platforms or substrates support structures intended to be sacrificed after manufacture B29C64/40
• CPC Class Codes: B29C 64/25 Housings, e.g. machine housings
• CPC Class Codes: B29C 64/268 using laser beams; using electron beams [EB]
• CPC Class Codes: B29C 64/35 Cleaning
• CPC Class Codes: B29C 64/371 using an environment other than air, e.g. inert gas
• 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: Y02P 10/25 : Process efficiency

Abstract

The present disclosure provides three-dimensional (3D) printing processes, apparatuses, software, and systems for controlling and/or treating gas borne debris in an atmosphere of a 3D printer.

Claims

1. A system for printing a three-dimensional object, the system comprising:

an energy source configured to generate an energy beam for transforming a pre-transformed material to a transformed material as at least a portion of the three-dimensional object;

a platform configured to support the three-dimensional object during printing; and

an enclosure configured to enclose at least a portion the platform, which enclosure comprises;

(i) a first wall;

(ii) at least one window configured to allow the energy beam to pass through;

(iii) a region recessed in the first wall, which region comprises the at least one window; and

(iv) a second wall that at least partially separates the region from the first wall, which at least one window and second wall at least partially define a volume of the region.

2. The system of claim 1, wherein the second wall is configured to facilitate at least partial shielding of an interior surface of the at least one window from a gas-borne material in the enclosure.

3. The system of claim 1, wherein the at least one window is a plurality of windows.

4. The system of claim 1, further comprising a purging system configured to direct a flow of gas away from the at least one window, wherein the purging system is operatively coupled to the region.

5. The system of claim 4, wherein the purging system comprises one or more channels that are operatively coupled to the second wall.

6. The system of claim 3, wherein windows of the plurality of windows are arranged in a non-parallel alignment relative to a direction of flow of gas above the platform.

7. The system of claim 1, wherein the at least one window is disposed in at least one window holder that comprises a purging system configured to direct a flow of gas in the region.

8. The system of claim 1, wherein the second wall at least partially encloses a volume of the region.

9. The system of claim 1, wherein the at least one window comprises a material having a thermal conductivity higher than that of fused silica.

10. The system of claim 9, wherein the material is substantially transparent to the energy beam with respect to at least one wavelength of the energy beam.

11. The system of claim 1, wherein the at least one window comprises at least one member selected from the group consisting of sapphire, zinc selenide (ZnSe), magnesium fluoride (MgF₂), and calcium fluoride (CaF₂).

12. The system of claim 1, wherein at least one window comprises a material having a thermal conductivity of at least 5 Watts per meter per degrees Celsius (W/(m*°

C)) at 300 Kelvin.

13. The system of claim 1, wherein during printing of the three-dimensional object, the region comprises one or more sensors configured to detect one or more input parameters within the enclosure.

14. The system of claim 1, further comprising at least one sensor configured to detect a gas-borne material.

15. The system of claim 14, wherein the at least one sensor is operatively coupled to the at least one window and/or the region.

16. The system of claim 1, wherein during printing of the three-dimensional object, the enclosure is configured to maintain an internal atmosphere at a positive pressure.

17. The system of claim 1, wherein the region comprises (i) a first sub-region and (ii) a second sub-region that is disposed further way from the first wall as compared to the first sub-region, wherein the at least one window is disposed in the second sub-region.

18. The system of claim 17, wherein the second sub-region comprises a purging system configured to direct a flow of gas away from the at least one window, wherein the purging system is operatively coupled to the region.

19. The system of claim 18, wherein the purging system comprises one or more channels operatively coupled to the region.

20. The system of claim 17, wherein the at least one window is arranged in a non-parallel alignment relative to a direction of flow of gas above the platform.

21. The system of claim 17, wherein the at least one window is a plurality of windows, wherein the second sub-region comprises a plurality of window holders disposed in the second sub-region, which plurality of window holders are operatively coupled to the plurality of windows.

22. The system of claim 21, wherein the plurality of windows are arranged in a non-parallel alignment with respect to the platform.

23. The system of claim 21, wherein at least one of the plurality of window holders comprises a purging system configured to direct a flow of gas away from the at least one window operatively coupled to at least one of the plurality of window holders, wherein the purging system is operatively coupled to the at least one of the plurality of window holders.

24. The system of claim 23, wherein the purging system comprises one or more channels operatively coupled to the at least one of the plurality of window holders.