METHOD FOR PRODUCING THREE-DIMENSIONAL OBJECTS FROM POWDERS AND DEVICE FOR IMPLEMENTING SAME

• US 20160339639A1
• Filed: 11/17/2014
• Published: 11/24/2016
• Est. Priority Date: 11/21/2013
• Status: Abandoned Application

• Current Assignee: Jury Aleksandrovich Chivel
• Original Assignee: Jury Aleksandrovich Chivel
• Inventors: CHIVEL, Jury Aleksandrovich
• Application Number:
  US15/038,036
• Publication Number:
  US 20160339639A1
• Time in Patent Office: Days
• US Class Current: 1/1
• CPC Class Codes: B22F 10/28 Powder bed fusion, e.g. selective laser melting [SLM] or electron beam melting [EBM]
• CPC Class Codes: B22F 10/73 of powder
• CPC Class Codes: B23K 15/002 Devices involving relative movement between electronbeam and workpiece
• CPC Class Codes: B23K 15/0026 Auxiliary equipment
• CPC Class Codes: B23K 15/0086 welding for purposes other than joining, e.g. built-up welding
• CPC Class Codes: B23K 26/064 by means of optical elements, e.g. lenses, mirrors or prisms
• 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 26/083 Devices involving movement of the workpiece in at least one axial direction
• CPC Class Codes: B23K 26/0869 Devices involving movement of the laser head in at least one axial direction
• CPC Class Codes: B23K 26/142 for the removal of by-products
• CPC Class Codes: B23K 26/144 the fluid stream containing particles, e.g. powder
• 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 64/245 Platforms or substrates support structures intended to be sacrificed after manufacture B29C64/40
• CPC Class Codes: B29C 64/314 Preparation
• CPC Class Codes: B29C 64/35 Cleaning
• CPC Class Codes: B29C 64/357 Recycling
• 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: Y02P 10/20 : Recycling
• CPC Class Codes: Y02P 10/25 : Process efficiency

Abstract

The invention is a method and device for producing three-dimensional objects, having a gradient of properties and multi-material objects, from powders. A method involves the selection of powders of various materials according to diameter, the successive application of layers of powder of a given thickness during the vertical displacement of a piston of a device build chamber with an object to be sintered, and the programmed selective sintering/melting of a given area in the plane of each layer. After sintering, piston is raised, unsintered powder is removed from a layer. The piston is then returned, and a layer of powder having a different diameter and being of a dissimilar material is applied and selectively sintered. When the object-sintering process is finished, the unsintered powder is removed from the build chamber, and the powders are separated according to diameter. The separated powders are returned to feed containers of device for re-use.

Claims

1. A method for producing a three-dimensional object from powders, the objects having with a gradient of properties, comprising:

a successive application of layers of powders of various materials during a vertical displacement of a piston of a build chamber with the object to be sintered and a programmed selective sintering/melting of a given area in a plane of each layer, wherein;

a) the powders of dissimilar materials with different diameters of particles are selected by sieving;

b) a first powder layer with a first thickness being multiple of a maximum particle diameter from a material of the first lawyer is applied;

c) the sintering/melting of the given area in the plane of a first layer is carried out;

d) the piston of the build chamber is raised above a height of the first layer;

e) the unsintered powder is removed from the first layer;

f) the piston of the build chamber is lowered at the height of the layer;

g) a powder of another material is applied and

stages c-f are repeated a necessary number of times according a desired powder composition;

h) the piston of the build chamber s lowered at a height of a next layer with a second thickness being multiple of a maximum particle diameter from a material of this layer and

stages b-g are repeated a necessary number of times for 3D object sintering;

)

i) the piston of the build chamber is lowered down, and all unsintered powders are removed from the build chamber; and

k) unsintered powders are sieved and separated by diameter of the particle of dissimilar materials;

separate a defective powder;

m) all powders are dumped into an individual for each diameter container;

n) all powders are conveyed from their containers into individual for each material feed containers.

3. The method according to claims 1, wherein the selective sintering/melting is carried out by a laser radiation.

4. The method according to claims 1, wherein the selective sintering/melting is carried out by an electron beam.

2. (canceled)

6. The method according to claims 2, wherein the selective sintering/melting is carried out by a laser radiation.

7. The method according to claims 2, wherein the selective sintering/melting is carried out by an electron beam.

5. A device for producing three-dimensional objects with gradient of properties from powders, comprising:

a processing chamber with a window, a laser optically connected with a focusing system and a scanning system, a build chamber with a piston, a powder feeding container, a re-coater powder feeding system, wherein the device is supplemented by N re-coater powder feeding systems forming a unitary re-coater powder feeding module;

the device is supplemented by N powder feeding containers and a surface cleaning system, being constructed with a possibility to move in a direction of a re-coater powder feeding module motion;

the device is supplemented by a system for removing of unsintered powders, a system for powders separation by sieving and a system for powders conveying to the powder feeding containers for re-use.