Methods and Apparatus for Selectively Combining Particulate Material

• US 20140314613A1
• Filed: 08/01/2012
• Published: 10/23/2014
• Est. Priority Date: 08/05/2011
• Status: Active Grant

• Current Assignee: Loughborough University
• Original Assignee: Loughborough University
• Inventors: Hopkinson, Neil, Thomas, Helen Rhiannon
• Granted Patent: US 10,933,581 B2
• Time in Patent Office: Days
• US Class Current: 419/55
• 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 12/13 to preheat the material
• CPC Class Codes: B22F 12/38 Housings, e.g. machine housings
• CPC Class Codes: B22F 12/55 Two or more means for feeding material
• CPC Class Codes: B22F 12/90 Means for process control, e.g. cameras or sensors
• CPC Class Codes: B22F 3/003 Apparatus, e.g. furnaces in general F27B
• CPC Class Codes: B29C 2035/0838 using laser
• 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 64/295 Heating elements
• 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: 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 of selectively combining particulate material, comprising: (i) providing a layer of particulate material to a part bed; (ii) providing radiation to sinter a portion of the material of the layer; (iii) providing a further layer of particulate material overlying the prior layer of particulate material including the previously sintered portion of material; (iv) providing radiation to sinter a further portion of the material within the overlying further layer and to sinter said further portion with the previously sintered portion of material in the prior layer; (v) successively repeating blocks (iii) and (iv) to form a three-dimensional object; and wherein at least some of the layers of particulate material are pre-heated with a heater prior to sintering a portion of the material of the respective layer, the heater being configured to move relative to, and proximate, the particulate material.

Claims

1. A method of selectively combining particulate material, comprising:

(i) providing a layer of particulate material to a part bed from a particulate material deposition device;

(ii) providing radiation to sinter a portion of the material of the layer;

(iii) providing a further layer of particulate material overlying the prior layer of particulate material including the previously sintered portion of material from the particulate material deposition device;

(iv) providing radiation to sinter a further portion of the material within the overlying further layer and to sinter said further portion with the previously sintered portion of material in the prior layer;

(v) successively repeating blocks (iii) and (iv) to form a three-dimensional object; and

wherein at least some of the layers of particulate material are pre-heated with a heater prior to sintering a portion of the material of the respective layer, the heater being configured to move relative to, and proximate, the particulate material by traversing the part bed surface and following the particulate material deposition device.

2. A method as claimed in claim 1, wherein the heater is configured to move within 100 mm of the particulate material.

3. A method as claimed in claim 1, wherein the heater is arranged to heat at least some of the layers of particulate material to prevent at least one underlying layer of particulate material from cooling to a temperature at which it curls.

6. A method as claimed in claim 1, wherein the heater emits a range of wavelengths with a peak wavelength which is different to that of a radiation source for providing the radiation that initiates sintering.

24. A method as claimed in claim 1, further comprising:

varying the absorption of provided radiation in block (ii) across a selected surface portion of the layer to sinter a portion of the material of the layer; and

varying the absorption of provided radiation in block (iv) across a selected surface portion of the further layer to sinter a further portion of the material within the overlying further layer and to sinter said further portion with the previously sintered portion of material in the prior layer

25. A method as claimed in claim 24, wherein the variation of radiation absorption is obtained by providing an amount of radiation absorbent material over the selected surface portion of the layer and the further layer respectively.

27. A method as claimed in claim 25, wherein the layers of particulate material are pre-heated at least two times by the heater before the radiation absorbent material is provided over the selected surface portion of the layer.

28. A method as claimed in claim 25, wherein the radiation absorption material is provided by a print head, the print head including an associated thermal control device for controlling the temperature of the radiation absorbent material.

31. A method as claimed in claim 25, wherein a device comprises a housing, a first print head for providing a first radiation absorbent material, a roller, and a first source of radiation.

33. A method as claimed in claim 31, wherein the device further comprises a second source of radiation positioned adjacent the roller.

37. A non-transitory computer-readable storage medium encoded with instructions that, when performed by a processor, cause performance of the method of claim 1.

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39. An apparatus for selectively combining particulate material, comprising a controller configured to:

(i) control the provision of a layer of particulate material to a part bed from a particulate material deposition device;

(ii) control the provision of radiation to sinter a portion of the material of the layer;

(iii) control the provision of a further layer of particulate material overlying the prior layer of particulate material including the previously sintered portion of material from the particulate material deposition device;

(iv) control the provision of radiation to sinter a further portion of the material within the overlying further layer and to sinter said further portion with the previously sintered portion of material in the prior layer;

(v) control the successive repeating of blocks (iii) and (iv) to form a three-dimensional object; and

wherein at least some of the layers of particulate material are pre-heated with a heater prior to sintering a portion of the material of the respective layer, the heater being configured to move relative to, and proximate, the particulate material by traversing the part bed surface and following the particulate material deposition device.

40. An apparatus as claimed in claim 39, wherein the heater is configured to move within 100 mm of the particulate material.

41. An apparatus as claimed in claim 39, wherein the heater is arranged to heat at least some of the layers of particulate material to prevent at least one underlying layer of particulate material from cooling to a temperature at which it curls.

44. An apparatus as claimed in claim 39, wherein the heater is configured to emit a range of wavelengths with a peak wavelength which is different to that of a radiation source for providing the radiation.

61. An apparatus as claimed in claim 39, wherein the controller is configured to control:

varying the absorption of provided radiation in block (ii) across a selected surface portion of the layer to sinter a portion of the material of the layer; and

varying the absorption of provided radiation in block (iv) across a selected surface portion of the further layer to sinter a further portion of the material within the overlying further layer and to sinter said further portion with the previously sintered portion of material in the prior layer

62. An apparatus as claimed in claim 61, wherein the variation of radiation absorption is obtained by providing an amount of radiation absorbent material over the selected surface portion of the layer and the further layer respectively.

64. An apparatus as claimed in claim 62, wherein the layers of particulate material are pre-heated at least two times by the heater before the radiation absorbent material is provided over the selected surface portion of the layer.

68. An apparatus as claimed in claim 62, further comprising a device including a housing, a first print head for providing a first radiation absorbent material, a roller, and a first source of radiation.

70. An apparatus as claimed in claim 68, wherein the device further comprises a second source of radiation positioned adjacent the roller.

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