Method and apparatus for three-dimensional printing

• US 10,688,733 B2
• Filed: 11/25/2015
• Issued: 06/23/2020
• Est. Priority Date: 11/25/2015
• Status: Active Grant

• Current Assignee: The Boeing Co.
• Original Assignee: The Boeing Co.
• Inventors: Lussier, Matthew, Hunt, Jeffrey H.
• Primary Examiner(s): Ochylski, Ryan M
• Application Number:
  US14/952,055
• Publication Number:
  US 20170144371A1
• Time in Patent Office: 1,672 Days
• CPC Class Codes: B23K 26/032 using optical means
• CPC Class Codes: B23K 26/064 by means of optical elements, e.g. lenses, mirrors or prisms
• CPC Class Codes: B23K 26/342 Build-up welding
• 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: 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 64/268 using laser beams; using electron beams [EB]
• 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: B29K 2025/06 PS, i.e. polystyrene
• CPC Class Codes: B29K 2077/00 Use of PA, i.e. polyamides, e.g. polyesteramides or derivatives thereof, as moulding material
• 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 50/02 for controlling or regulating additive manufacturing processes

Abstract

The present disclosure generally relates to method and apparatuses for 3D printing. The apparatuses include a stationary workpiece stage and an optics assembly adapted to direct laser energy to different locations on the workpiece stage. The optics assembly includes one or more of an intensity-controlling mechanism, a polarization mechanism, a shape-controlling mechanism, and a beam-steering mechanism configured to direct laser energy towards the workpiece stage. The method includes directing an energy beam from a laser towards a workpiece stage while adjusting the direction of the energy beam, adjusting the intensity of the energy beam, adjusting the shape of the energy beam, or adjusting the polarization of the energy beam.

Claims

1. A three-dimensional printing apparatus, comprising:

a material feed cartridge for containing a powdered base material;

a workpiece support for supporting the powdered base material thereon;

a laser for supplying laser energy to the powdered base material;

an imaging device for capturing an image of the workpiece support;

a controller for receiving image data from the imaging device; and

an optics assembly coupled to the controller and adapted to receive instructions therefrom, the optics assembly comprising;

a shape-controlling mechanism including a lens support having a plurality of gear teeth for rotating a lens;

a polarization mechanism; and

an intensity controlling mechanism configured to adjust an intensity of the laser energy supplied from the laser to the powdered base material, wherein the intensity controlling mechanism includes a polarization sensitive element and a plurality of gears that facilitate rotation of the polarization sensitive element.

2. The three-dimensional printing apparatus of claim 1, wherein the workpiece support is stationary when the laser energy is applied to the powdered base material.

3. The three-dimensional printing apparatus of claim 1, wherein the optics assembly further comprises a beam-steering mechanism.

4. The three-dimensional printing apparatus of claim 3, wherein the beam-steering mechanism comprises a plurality of rotatable mirrors.

5. The three-dimensional printing apparatus of claim 4, wherein the plurality of rotatable mirrors is two mirrors, and the two mirrors are rotatable about perpendicular axis.

6. The three-dimensional printing apparatus of claim 3, wherein the beam-steering mechanism comprises a steerable electro-evanescent optical refractor.

7. The three-dimensional printing apparatus of claim 1, wherein the shape-controlling mechanism, the polarization mechanism, the intensity controlling mechanism are adjustable in response to the instructions received by the controller.

8. The three-dimensional printing apparatus of claim 1, wherein the polarization mechanism comprises one or more rotatable polarization sensitive elements.

9. The three-dimensional printing apparatus of claim 8, wherein the one or more rotatable polarization sensitive elements is a plurality of axially aligned rotatable polarization sensitive elements.

10. The three-dimensional printing apparatus of claim 8, wherein the one or more rotatable polarization sensitive elements comprise a half wave plate or a quarter wave plate.

11. The three-dimensional printing apparatus of claim 1, wherein the shape-controlling mechanism comprises one or more rotatable housings each having a circular opening formed therein for accommodating the laser energy.

12. The three-dimensional printing apparatus of claim 11, wherein the shape-controlling mechanism comprises multiple rotatable housings that rotate about different axes.

13. The three-dimensional printing apparatus of claim 11, wherein the shape-controlling mechanism comprises an elliptical-shaped lens.

14. A three-dimensional printing apparatus, comprising:

a material feed cartridge for containing a powdered base material;

a workpiece support for supporting the powdered base material thereon;

a laser for supplying laser energy to the powdered base material;

an imaging device for capturing an image of the workpiece support;

a controller for receiving image data from the imaging device; and

an optics assembly coupled to the controller and adapted to receive instructions therefrom, the optics assembly comprising;

a beam-steering mechanism comprising a plurality of actuatable mirrors;

a shape-controlling mechanism comprising one or more rotatable housings each having a circular opening formed therein for accommodating the laser energy, and a lens support having a plurality of gear teeth for rotating a lens;

a polarization mechanism comprising one or more rotatable polarization sensitive elements each having a gear mechanism that facilitates rotation of each polarization sensitive element; and

an intensity controlling mechanism configured to adjust an intensity of the laser energy supplied from the laser to the powdered base material, wherein the workpiece support is stationary when the laser energy is applied to the powdered base material.

15. The three-dimensional printing apparatus of claim 14, wherein the actuatable mirrors of the beam-steering mechanism are rotatable.

16. The three-dimensional printing apparatus of claim 15, wherein the shape-controlling mechanism comprises multiple rotatable housings that are configured to rotate about different axes.

17. The three-dimensional printing apparatus of claim 16, wherein the one or more rotatable polarization sensitive elements comprise a half wave plate or a quarter wave plate.

18. A method of adjusting a laser during a 3D printing operation, comprising:

providing a powdered base material onto a fixed workpiece support;

directing laser energy from a printing source to the powdered base material on the fixed workpiece support;

capturing an image of the fixed workpiece support;

providing image data of the captured image to a controller;

in response to the controller receiving the image data, providing instructions from the controller to the printing source to adjust one or more parameters of the printing source;

adjusting an intensity of the laser energy supplied to the powdered base material with an intensity-controlling mechanism, wherein the intensity controlling mechanism includes a polarization sensitive element and a plurality of gears that facilitate rotation of the polarization sensitive element; and

adjusting a beam shape of the laser energy using a shape-controlling mechanism that includes a lens support having a plurality of gear teeth for rotating a lens.

19. The method of claim 18, wherein the intensity controlling

mechanism comprises a plurality of polarization units each having the polarization sensitive element disposed therein.

20. The method of claim 19, further comprising adjusting a beam-steering mechanism.