CARTRIDGE FOR AN ADDITIVE MANUFACTURING APPARATUS AND METHOD

• US 20140265049A1
• Filed: 03/14/2014
• Published: 09/18/2014
• Est. Priority Date: 03/15/2013
• Status: Abandoned Application

• Current Assignee: MatterFab, Corp.
• Original Assignee: MatterFab, Corp.
• Inventors: Burris, Matthew, Dolgner, Andrew
• Application Number:
  US14/213,686
• Publication Number:
  US 20140265049A1
• Time in Patent Office: Days
• US Class Current: 264/497
• CPC Class Codes: B22F 10/28 Powder bed fusion, e.g. selective laser melting [SLM] or electron beam melting [EBM]
• CPC Class Codes: B22F 10/36 of energy beam parameters
• CPC Class Codes: B22F 10/39 Traceability, e.g. incorporating identifier into a workpiece or article
• CPC Class Codes: B22F 10/73 of powder
• CPC Class Codes: B22F 12/226 for rotary motion
• CPC Class Codes: B22F 12/38 Housings, e.g. machine housings
• CPC Class Codes: B22F 12/41 characterised by the type, e.g. laser or electron beam
• CPC Class Codes: B22F 12/43 pulsed; frequency modulated
• CPC Class Codes: B22F 12/44 characterised by the configuration of the radiation means
• CPC Class Codes: B22F 12/45 Two or more
• CPC Class Codes: B22F 12/47 parallel to the deposition plane
• CPC Class Codes: B22F 12/90 Means for process control, e.g. cameras or sensors
• CPC Class Codes: B22F 3/105 by using electric current other than for infrared radiant energy, laser radiation or plasma B22F3/11 takes precedence; by ultrasonic bonding B22F3/115 takes precedence
• CPC Class Codes: B23K 26/034 Observing the temperature of the workpiece
• CPC Class Codes: B23K 26/0608 in the same heat affected zone [HAZ] B23K26/0613, B23K26/0619 take precedence
• CPC Class Codes: B23K 26/082 Scanning systems, i.e. devices involving movement of the laser beam relative to the laser head
• CPC Class Codes: B23K 26/0821 using multifaceted mirrors, e.g. polygonal mirror
• CPC Class Codes: B23K 26/083 Devices involving movement of the workpiece in at least one axial direction
• CPC Class Codes: B23K 26/127 in an enclosure
• CPC Class Codes: B23K 26/342 Build-up welding
• 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 64/277 : using multiple radiation means, e.g. micromirrors or multiple light-emitting diodes [LED]
• CPC Class Codes: B29C 64/393 : for controlling or regulating additive manufacturing processes
• CPC Class Codes: B33Y 10/00 : Processes of additive manufacturing
• CPC Class Codes: Y02P 10/25 : Process efficiency

Abstract

One variation of a method for constructing a three-dimensional structure within a additive manufacturing apparatus includes: reading an identifier from a cartridge transiently loaded into the additive manufacturing apparatus; based on the identifier, retrieving from a computer network a laser fuse profile for powdered material contained within the cartridge; leveling a volume of powdered material dispensed from the cartridge into a layer of substantially uniform thickness across a build platform within the additive manufacturing apparatus; and selectively fusing regions of the layer according to a fuse parameter defined in the laser fuse profile.

Claims

1. A method for constructing a three-dimensional structure within an additive manufacturing apparatus, the method comprising:

reading an identifier from a cartridge transiently loaded into the additive manufacturing apparatus;

based on the identifier, retrieving from a computer network a laser fuse profile for powdered material contained within the cartridge;

leveling a volume of powdered material dispensed from the cartridge into a layer of substantially uniform thickness across a build platform within the additive manufacturing apparatus; and

selectively fusing regions of the layer according to a fuse parameter defined in the laser fuse profile.

2. The method of claim 1, further comprising, based on the identifier, retrieving from the computer network a laser anneal profile for powdered material contained within the cartridge, and selectively annealing fused regions of the layer according to an anneal parameter defined in the laser anneal profile.

3. The method of claim 2, wherein retrieving the laser fuse profile comprises receiving a fuse scan speed and a laser fuse power, wherein retrieving the laser anneal profile comprises receiving an anneal scan speed and a laser anneal power, wherein selectively fusing regions of the layer comprises scanning a first energy beam of the laser fuse power across the layer at the fuse scan speed, and further comprising annealing fused regions of the layer by scanning a second energy beam of the laser anneal power across the layer at the anneal scan speed.

4. The method of claim 1, wherein retrieving the laser fuse profile comprises receiving a target fuse temperature range for powdered material contained within the cartridge, and wherein selectively fusing regions of the layer comprises detecting a temperature of a first fused region of the layer and modulating a power of an energy beam projected toward a second region of the layer adjacent the first fused region based on the temperature of the first fused region and the target fuse temperature range.

5. The method of claim 1, wherein retrieving the laser fuse profile comprises receiving a target layer thickness from a remote database over the computer network, wherein leveling the volume of powdered material into the layer comprises dispensing the volume of powdered material corresponding to the target layer thickness and a dimension of the build platform and leveling the volume of material at a substantially constant thickness approximating the target layer thickness across the build platform.

6. The method of claim 1, wherein reading the identifier from the cartridge comprises scanning a code applied on an exterior of the cartridge and translating the code into an alphanumeric identifier, wherein retrieving the laser fuse profile comprises receiving identification of a type and an age of powdered material contained within the cartridge, and checking the type and the age of powdered material contained within the cartridge against a material type and a maximum material age specified for the three-dimensional structure.

7. A method for constructing a three-dimensional structure within a laser sintering apparatus, the method comprising:

reading a first identifier from a first cartridge transiently loaded into the additive manufacturing apparatus;

reading a second identifier from a second cartridge transiently loaded into the additive manufacturing apparatus;

based on the first identifier, retrieving from a database a first build cycle history datum for powdered material contained within the first cartridge;

based on the second identifier, retrieving from the database a second build cycle history datum for powdered material contained within the second cartridge;

setting a dispense order for the first cartridge and the second cartridge based on the first build cycle history datum and the second build cycle history datum;

dispensing powdered material from the first cartridge into a build chamber within the additive manufacturing apparatus; and

in response to depletion of powdered material within the first cartridge, dispensing powdered material from the second cartridge into the build chamber according to the dispense order.

8. The method of claim 7, further comprising retrieving a laser fuse profile from the database based on the first identifier, the laser fuse profile defining a scan speed, a target layer thickness, and a output power for fusing powdered material dispensed from the first cartridge, wherein dispensing powdered material from the first cartridge into the build chamber comprises dispensing a series of layers of powdered material into the build chamber, each layer in the set of layers approximating the target layer thickness, and further comprising selectively fusing regions of each layer in the set of layer of powdered material by scanning an energy beam of the output power across the build chamber at the scan speed.

9. The method of claim 7, wherein reading the first identifier from the first cartridge comprises receiving a unique cartridge identifier from a radio-frequency identification tag arranged on the first cartridge, and wherein retrieving the first build cycle history comprises passing the unique cartridge identifier to the database over a computer network and receiving a date history of previous build cycles performed with powdered material now stored in the first cartridge, the powdered material in the first cartridge recycled and returned to the first cartridge after completion of a previous build cycle, and wherein setting the dispense order comprises setting dispensation of powdered material from the first cartridge prior to dispensation of powdered material from the second cartridge according to a date of a build cycle associated with powdered material within the first cartridge that precedes an oldest date of a build cycle associated with powdered material within the second cartridge.

10. The method of claim 7, further comprising reading a third identifier from a third cartridge transiently loaded into the additive manufacturing apparatus and retrieving from the database a maximum age of powdered material contained within the third cartridge based on the third identifier, wherein setting the dispense order comprises discarding the third container from supplying powdered material to the build chamber based on a maximum age threshold specified for a current build cycle and the maximum age of powdered material contained within the third cartridge.

11. The method of claim 7, wherein dispensing powdered material from the second cartridge comprises indexing the first cartridge forward from a dispense position into an empty position and indexing the second cartridge forward from a holding position into the dispense position.

12. The method of claim 11, wherein indexing the second cartridge forward from the holding position into the dispense position comprises arcuately indexing a cylindrical carriage, the cylindrical carriage supporting the first cartridge and the second cartridge, an axis of the second cartridge oriented vertically with an outlet at a low point to dispense powdered material into the additive manufacturing apparatus in the dispense position.

13. A cartridge, comprising:

a vessel defining an outlet;

an engagement feature configured to transiently support the vessel within a additive manufacturing apparatus;

a resealable lid arranged over the outlet and configured to transiently engage an element within the additive manufacturing apparatus, the element selectively transitioning the lid between

a closed setting, the resealable lid sealing powdered material in an inert gas environment within the vessel in the closed setting, and

an open setting, the resealable lid releasing powdered material into the vessel in the open setting,

an identifier stored on the vessel and defining a pointer to an electronic database comprising data specific to material contained within the vessel.

14. The cartridge of claim 13, wherein the engagement feature supports the vessel in a first vertical orientation and a second vertical orientation vertically opposed to the first vertical orientation, wherein, with the resealable lid in the open setting, the outlet gravity feeds powdered material out of the vessel in the first vertical orientation and receives gravity-fed recycled powdered material into the vessel in the second vertical orientation.

15. The cartridge of claim 13, further comprising a polymer buffer arranged on an exterior surface of the vessel, and wherein the identifier comprises a radio-frequency identification tag arranged on the polymer buffer opposite the vessel and transmitting a unique serial number in response to proximity of an electromagnetic field generated by the additive manufacturing apparatus.

16. The cartridge of claim 13, wherein the engagement feature locks the vessel in a receiver within the additive manufacturing apparatus, and wherein the identifier comprises a unique serial number printed on an exterior region of the vessel aligned with an optical sensor within the receiver.

17. The cartridge of claim 16, wherein the engagement feature supports the vessel from a linear slide extending from the receiver, the unique serial number scanned across the optical sensor as the vessel is inserted linearly into the receiver along the linear slide.

18. The cartridge of claim 13, further comprising an environmental sensor coupled to an interior volume of the vessel and outputting a signal corresponding to an amount of oxygen detected within the vessel.

19. The cartridge of claim 18, further comprising a wireless transmitter coupled to the vessel and wirelessly broadcasting the identifier and the signal corresponding to the amount of oxygen detected within the vessel.

20. The cartridge of claim 13, wherein the engagement features comprises a threaded cylinder extending from the vessel, arranged about the outlet, and engaging a threaded receiver within the additive manufacturing apparatus, and wherein the resealable lid comprises a slit polymer membrane arranged across the outlet and pierceable by the element to transition the resealable lid from the closed setting to the open setting.