Continuous Linear Production in a Selective Laser Sintering System

• US 20120067501A1
• Filed: 09/21/2010
• Published: 03/22/2012
• Est. Priority Date: 09/21/2010
• Status: Active Grant

• Current Assignee: The Boeing Co.
• Original Assignee: The Boeing Co.
• Inventors: Lyons, Brett Ian
• Granted Patent: US 9,522,501 B2
• Time in Patent Office: Days
• US Class Current: 156/64
• 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 10/73 of powder
• CPC Class Codes: B22F 12/10 Auxiliary heating means
• CPC Class Codes: B22F 12/20 Cooling means
• CPC Class Codes: B22F 12/224 for motion along a direction within the plane of a layer
• CPC Class Codes: B22F 12/33 translatory in the deposition plane
• CPC Class Codes: B22F 12/50 Means for feeding of material, e.g. heads
• 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: B28B 17/0081 Process control
• 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 64/35 Cleaning
• CPC Class Codes: B29C 64/357 Recycling
• CPC Class Codes: B29C 64/393 for controlling or regulating additive manufacturing processes
• CPC Class Codes: B29C 64/40 Structures for supporting 3D objects during manufacture and intended to be sacrificed after completion thereof
• 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 50/02 for controlling or regulating additive manufacturing processes
• CPC Class Codes: Y02P 10/25 Process efficiency

Abstract

A method and apparatus for forming objects. Layers of precursor material may be placed on top of each other. The layers of precursor material may be selectively cured as the layers of precursor material are placed on top of each other to form an object and a frame associated with the object.

Claims

1. A method for forming objects, the method comprising:

placing layers of precursor material on top of each other; and

selectively curing the layers of precursor material as the layers of precursor material are placed on the top of each other to form an object and a frame associated with the object.

2. The method of claim 1, wherein the frame comprises a plurality of base structures, wherein the step of placing the layers of precursor material on the top of each other comprises:

moving the frame to allow a new layer of precursor material to be placed on a prior layer of precursor material in the layers of precursor material that have been selectively cured.

3. The method of claim 2, wherein the frame comprises a plurality of base structures, wherein the step of placing the layers of precursor material on the top of each other further comprising:

placing the new layer of precursor material on the prior layer of precursor material.

4. The method of claim 3, wherein the step of selectively curing the layers of precursor material as the layers of precursor material are placed on the top of each other to form the object and the frame associated with the object comprises:

determining whether a new base structure in the frame is needed;

responsive to a determination that the new base structure is needed, selectively curing the new layer of precursor material to form a portion of the object and a portion of the new base structure; and

responsive to an absence of the determination that the new base structure is needed, selectively curing the new layer of precursor material to form the portion of the object without forming the portion of the new base structure.

5. The method of claim 2 further comprising:

responsive to the determination that the new base structure is needed, repeating the steps of;

moving the frame to allow the new layer of precursor material to be placed on the prior layer of precursor material in the layers of precursor material that has been selectively cured;

placing the new layer of precursor material on the prior layer of precursor material; and

selectively curing the new layer of precursor material to form the portion of the object and the portion of the new base structure until the new base structure is completed.

6. The method of claim 2 further comprising:

responsive to the absence of the determination that the new base structure is needed, repeating the steps of;

moving the frame to allow the new layer of precursor material to be placed on the prior layer of precursor material in the layers of precursor material that have been selectively cured;

placing the new layer of precursor material on the prior layer of precursor material; and

selectively curing the new layer of precursor material to form the portion of the object without the new base structure until the new base structure is needed.

7. The method of claim 2 wherein the step of responsive to the determination that the new base structure is needed,

selectively curing the new layer of precursor material to form the portion of the object and the portion of the new base structure comprises:

responsive to the determination that the new base structure is needed,

selectively curing the new layer of precursor material to form the portion of the object and the portion of the new base structure.

8. The method of claim 7 further comprising:

separating each portion of the object from an associated base structure connected to the each portion the object.

9. The method of claim 2 further comprising:

forming a base structure; and

placing the base structure in a movement system prior to placing the layers of precursor material on the base structure.

10. The method of claim 1 further comprising:

maintaining a desired temperature for the object as the object is formed in a chamber.

11. The method of claim 10, wherein the step of maintaining the desired temperature for the object as the object is formed in the chamber comprises:

maintaining the desired temperature for the object in different locations as the object is formed in the chamber using a plurality of heating and cooling elements.

12. The method of claim 1 further comprising:

cooling uncured precursor material to change a density of the uncured precursor material such that a flow of gas through the precursor material is reduced.

13. The method of claim 2, wherein a movement system holds and moves the frame along an axis.

14. The method of claim 8, wherein a separation system separates the each portion of the object from the associated base structure connected to the each portion the object.

15. A method for forming aircraft parts, the method comprising:

placing layers of precursor material on a base structure for a frame in which the layers of precursor material are selected from one of a powder, a liquid, a metal powder, a ceramic powder, and a plastic powder;

selectively curing the layers of precursor material using a curing system selected from one of a heating system, a laser, and an electron beam after placing the layers of precursor material on the base structure to form a portion of an aircraft part and a portion of the frame to form a prior layer of precursor material;

moving the frame to allow a new layer of precursor material to be placed on the prior layer of precursor material in the layers of precursor material that have been selectively cured;

placing the new layer of precursor material on the prior layer of precursor material;

determining whether a new base structure in the frame is needed;

responsive to a determination that the new base structure is needed, selectively curing the new layer of precursor material to form an additional portion of the aircraft part and a portion of the new base structure;

responsive to the determination that the new base structure is needed, repeating the steps of moving the frame to allow the new layer of precursor material to be placed on the prior layer of precursor material in the layers of precursor material that have been selectively cured;

placing the new layer of precursor material on the prior layer of precursor material; and

selectively curing the new layer of precursor material to form a portion of the aircraft part and the portion of the new base structure until the base structure is completed;

responsive to an absence of the determination that the new base structure is needed, selectively curing the new layer of precursor material to form the additional portion of the aircraft part without forming the new base structure;

responsive to the absence of the determination that the new base structure is needed, repeating the steps of moving the frame to allow the new layer of precursor material to be placed on the prior layer of precursor material in the layers of precursor material that have been selectively cured;

placing the new layer of precursor material on the prior layer of precursor material; and

selectively curing the new layer of precursor material to form the portion of the aircraft part without the new base structure until the new base structure is needed;

maintaining a desired temperature for the aircraft part as the aircraft part is formed in different locations in a chamber using a plurality of heating and cooling elements;

cooling uncured precursor material to change a density of the uncured precursor material such that a flow of gas through the precursor material is reduced; and

separating each portion of the aircraft part from an associated base structure connected to the each portion of the aircraft part using a separation system.

16. An apparatus comprising:

a chamber;

a curing system configured to cure portions of layers of precursor material deposited in the chamber to form an object and a frame connected to the object; and

a movement system configured to engage the frame and move the frame and the object connected to the frame as a new layer of precursor material is placed on a prior layer of precursor material.

17. The apparatus of claim 16, wherein the frame comprises a plurality of base structures.

18. The apparatus of claim 17, wherein the frame comprises a plurality of connectors.

19. The apparatus of claim 16 further comprising:

a separation system configured to separate the object from a base structure.

20. The apparatus of claim 19, wherein the separation system is configured to separate the object from the base structure as the base structure and the object are moved by the movement system.

21. The apparatus of claim 16, wherein the movement system comprises a plurality of gears having first teeth configured to engage second teeth formed on sides of a base structure.

22. The apparatus of claim 16 further comprising:

a precursor deposition system configured to deposit the new layer of precursor material on the prior layer of precursor material.

23. The apparatus of claim 16 further comprising:

a temperature control system configured to control a temperature of at least one of the object and the frame.

24. The apparatus of claim 23, wherein the temperature control system comprises:

a plurality of heating and cooling elements configured to heat and cool walls of the chamber to control the temperature of the at least one of the object and the frame.

25. The apparatus of claim 23, wherein the temperature control systems is configured to cool uncured precursor material that has been deposited to change a density of the uncured precursor material such that a flow of gas through the precursor material is reduced.

26. The apparatus of claim 16 further comprising:

a recycling system configured to recycle the portions of layers of precursor material that remain uncured.

27. The apparatus of claim 17, wherein the plurality of base structures are for the frame configured to support the object during formation of the object in the chamber.

28. The apparatus of claim 16, wherein the curing system is selected from at least one of a heating system, a laser, and an electron beam.

29. The apparatus of claim 16, wherein the precursor material is selected from one of a powder, a liquid, a metal powder, and a ceramic powder.

30. A laser sintering apparatus comprising:

a chamber;

a curing system configured to cure portions of layers of precursor material deposited in the chamber to form an aircraft part and a frame connected to the aircraft part in which the frame comprises a plurality of base structures and a plurality of connectors and configured to support the aircraft part during formation of the aircraft part in the chamber and in which the curing system is selected from at least one of a heating system, a laser, and an electron beam;

a movement system configured to engage the frame and move the frame connected to the aircraft part as a new layer of precursor material is placed on a prior layer of precursor material in which the movement system comprises a plurality of gears having first teeth configured to engage second teeth formed on sides of the plurality of base structures;

a precursor deposition system configured to deposit the new layer of precursor material on the prior layer of precursor material;

a temperature control system configured to control a temperature of at least one of the aircraft part and the frame in which the temperature control system comprises a plurality of heating and cooling elements configured to heat and cool walls of the chamber to control the temperature of the at least one of the aircraft part and the frame and in which the temperature control system is configured to cool uncured precursor material that has been deposited to change a density of the uncured precursor material such that a flow of gas through the precursor material is reduced;

a separation system configured to separate the aircraft part from a base structure in which the separation system is configured to separate the aircraft part from the base structure as the base structure and the aircraft part are moved by the movement system; and

a recycling system configured to recycle the portions of layers of precursor material that remain uncured in which the layers of precursor material are selected from one of a powder, a liquid, a metal powder, and a ceramic powder.