Process for quality control for a powder based layer building up process

• US 20040173946A1
• Filed: 03/08/2004
• Published: 09/09/2004
• Est. Priority Date: 03/07/2003
• Status: Abandoned Application

• Current Assignee: Daimler AG (Mercedes-Benz Group AG)
• Original Assignee: Daimler AG (Mercedes-Benz Group AG)
• Inventors: Pfeifer, Rolf, Shen, Jialin, Zeppelin, Didier von
• Application Number:
  US10/795,668
• Publication Number:
  US 20040173946A1
• Time in Patent Office: Days
• US Class Current: 264/497
• CPC Class Codes: B22F 10/14 by jetting of binder onto a bed of metal powder
• CPC Class Codes: B22F 10/20 Direct sintering or melting
• CPC Class Codes: B22F 12/33 translatory in the deposition plane
• CPC Class Codes: B22F 12/41 characterised by the type, e.g. laser or electron beam
• CPC Class Codes: B22F 12/67 Blades
• CPC Class Codes: B22F 12/90 Means for process control, e.g. cameras or sensors
• CPC Class Codes: B22F 2203/03 for feed-back
• 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: B29C 2037/90 Measuring, controlling or regulating
• 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: 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

Process for production of three dimensional bodies of particles by a layer buildup process (powder based generative rapid prototyping process), wherein the layer buildup is monitored by an optical control device, which evaluates the light intensity or color differences within and between deposited or hardened particle layers, as well as a suitable optical control device, and further yet, particles or binder liquid particularly suited for optical quality control.

Claims

1. Process for producing three dimensional bodies including the multiple succession of the steps

a) applying a layer of particles, via a dispensing device, upon a substrate

b) flattening the applied layer with a flattening device

c) hardening the layer by adhesion of the particles with introduction of binder liquid or hardening the layer by melting or sintering the particles under the influence of intensive radiation in defined areas within the layer, thereby characterized,

that after steps a), b) and/or c) an optical image of the applied, flattened and/or hardened layer is recorded, wherein the image is suited for revealing particle defect sites located in the layer plane or particle layer defects.

2. Process according to claim 1, thereby characterized, as a result of step c) a change in the lightness and/or the color is brought about in defined areas.

3. Process according to claim 2, thereby characterized, that the binder liquid used for adhering the particles includes colorant.

4. Process according to claim 2, thereby characterized, that the particles contain colorant, which changes in color and/or lightness upon exposure to binder liquid.

5. Process according to one of the preceding claims, thereby characterized, that the evaluation of the image intensity and/or color of the image reveals particle defect locations or particle layer defects, from which corrective measures can be derived.

6. Process according to claim 1, thereby characterized, following the revolution of the particle defect sites or particle layer defects, between steps a) and c) additional particles are applied at or in the vicinity of the defect sites or upon the entire particle layer.

7. Process according to claim 6, thereby characterized, that the additional particles are applied by a dispensing device with its own focal area.

8. Process according to claim 1, thereby characterized, that following the revolution of the particle defect sites or particle layer defects, between steps a) and c) particles are removed at or in the vicinity of the defect location or the entire particle layer is removed.

9. Process according to claim 8, thereby characterized, that the particles to be removed are removed by a blower or a vacuum device with a focal area.

10. Process according to claim 1, thereby characterized, the image or memory map is used for a new determination of the defined area of the adhesion, melting or sinter in step c).

11. Coated particles for producing three dimensional bodies with a generative rapid prototyping process with utilization of binder liquids, which cause hardening of particle layers in defined areas, thereby characterized, that the coating of the particles contains a dyestuff soluble in the binder liquid.

12. Particle according to claim 11, thereby characterized, that the coating includes substances, which change their color under the influence of binder liquid.

13. Binder liquid for producing three dimensional bodies by means of a generative rapid prototyping process with use of particle layers which are hardenable in defined areas by a binder liquid, thereby characterized, that the binder liquid contains dyestuffs.

14. Particles according to claim 13, thereby characterized, that the binder liquid includes substances which change their color under the influence of the particles or during the hardening reaction of the particles.

15. Coated particles for producing three dimensional bodies by means of a generative rapid prototyping process which utilization of laser radiation, which causes melting or sintering of particle layers in defined areas, thereby characterized, that the coating is decomposed by the laser radiation at least partially with darkening.

16. Device for producing three dimensional bodies with at least one generative rapid prototyping process, including

a particle reservoir

a flattening device

a hardening device and

a control device, thereby characterized, that the control device includes at least one camera, with which an optical image of the entire surface of the 3D-body to be generated is reproducible.

17. Device according to claim 16, thereby characterized, that at least two spaced apart cameras are provided, of which the individual images can be assimilated into a joint three dimensional image.

18. Device according to claim 16, thereby characterized, that at least one beam projector is provided, which eliminates the applied layer in strips.

19. Device according to claim 16, thereby characterized, that the hardening device includes at least one print nozzle for binder liquid.

20. Device according to claim 16, thereby characterized, that the hardening device is a laser light source.

21. Device according to claim 16, thereby characterized, that the hardening device is a UV-spot radiator or an electron emitter.