METHOD AND DEVICE FOR PRODUCING THREE-DIMENSIONAL OBJECTS

• US 20100007062A1
• Filed: 07/27/2006
• Published: 01/14/2010
• Est. Priority Date: 07/27/2006
• Status: Active Grant

• Current Assignee: Arcam Ab (Danaher Corporation)
• Original Assignee: Arcam Ab (Danaher Corporation)
• Inventors: Snis, Anders, Larsson, Morgan
• Granted Patent: US 8,187,521 B2
• Time in Patent Office: Days
• US Class Current: 264/485
• CPC Class Codes: B22F 10/28 Powder bed fusion, e.g. selective laser melting [SLM] or electron beam melting [EBM]
• CPC Class Codes: B22F 10/362 for preheating
• CPC Class Codes: B22F 10/366 Scanning parameters, e.g. hatch distance or scanning strategy
• CPC Class Codes: B22F 10/37 of powder bed aspects, e.g. density
• CPC Class Codes: B22F 2999/00 Aspects linked to processes or compositions used in powder metallurgy
• CPC Class Codes: B22F 3/1017 Multiple heating or additional steps B22F3/101 takes precedence
• CPC Class Codes: B29C 64/153 using layers of powder being selectively joined, e.g. by selective laser sintering or melting
• CPC Class Codes: Y02P 10/25 Process efficiency

Abstract

A method for producing three-dimensional objects from a powder material which is capable of solidification by irradiation with a high-energy beam is disclosed. The method comprises homogeneously pre-heating the powder material by scanning with the high-energy beam along predetermined paths over a pre-heating area so that consecutive paths are separated by a minimum security distance which is adapted to prevent undesirable summation effects in the pre-heating area, and then solidifying the powder material by fusing together the powder material. Apparatus for producing such three-dimensional objects is also disclosed.

Claims

1-11. -11. (canceled)

12. A method for producing three-dimensional objects from a powder material capable of solidification by irradiation with a high-energy beam, said method comprising homogeneously pre-heating said powder material by scanning a predetermined pre-heating area including said powder material with said high-energy beam along a plurality of predetermined paths distributed over said predetermined pre-heating area in a manner such that consecutive paths of said plurality of predetermined paths are separated by at least a predetermined minimum security distance adapted to prevent undesirable summation effects in said predetermined pre-heating area and solidifying said powder material by fusing together said powder material.

13. The method of claim 12 wherein said homogeneously pre-heating includes rescanning said predetermined pre-heating area with said high-energy beam.

14. The method of claim 13 wherein said plurality of predetermined paths comprises a first plurality of predetermined paths and said rescanning comprises scanning said predetermined pre-heating area along a second plurality of predetermined paths distributed over said predetermined pre-heating area in a manner such that consecutive paths of said second plurality of predetermined paths are separated by at least an interspacing distance which is less than said predetermined minimum security distance.

15. The method of claim 12 including increasing the power of said high-energy beam during said homogeneously pre-heating of said powder material.

16. The method of claim 15 wherein said increasing of said power comprises a stepwise increase between consecutive scanning of said plurality of predetermined paths.

17. The method of claim 15 wherein said high-energy beam comprises an electron beam, and wherein said increasing of said power comprises increasing the current of said electron beam.

18. The method of claim 12 wherein each of said plurality of predetermined paths are scanned from one end of said predetermined paths to the other end of said predetermined paths.

19. The method of claim 12 wherein each of said plurality of predetermined paths comprises parallel paths.

20. The method of claim 12 wherein each of said plurality of predetermined paths comprises a straight line.

21. The method of claim 12 wherein said powder material covers a predetermined powder area, and wherein said predetermined pre-heating area is greater than said predetermined powder area by a predetermined security margin.

22. Apparatus for producing three-dimensional objects from a powder material capable of solidification by irradiation with a high-energy beam, said apparatus comprising scanning means for homogeneously pre-heating said powder material by scanning a predetermined pre-heating area including said powder material with said high-energy beam along a plurality of predetermined paths distributed over said predetermined pre-heating area in a manner such that consecutive paths of said plurality of predetermined paths are separated by at least a predetermined minimum security distance adapted to prevent undesirable summation effects in said predetermined heating area and fusing means for solidifying said powder material by fusing together said powder material.