Apparatus for producing a three-dimensional object

• US 5,753,274 A
• Filed: 03/26/1996
• Issued: 05/19/1998
• Est. Priority Date: 03/30/1995
• Status: Expired due to Term

• Current Assignee: EOS GmbH Electro Optical Systems
• Original Assignee: EOS GmbH Electro Optical Systems
• Inventors: Lohner, Andreas, Wilkening, Christian
• Primary Examiner(s): Woo, Jay H.
• Assistant Examiner(s): SCWARTZ, IURIE
• Application Number:
  US08/622,008
• Time in Patent Office: 784 Days
• Field of Search: 425/174.4, 425/174.2, 425/470, 264/401, 264/497, 264/255, 264/308
• US Class Current: 425/174.4
• CPC Class Codes: B23K 2103/50 Inorganic material, e.g. metals, not provided for in B23K2103/02 – B23K2103/26
• 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 26/32 taking account of the properties of the material involved
• CPC Class Codes: B23K 26/34 Laser welding for purposes other than joining
• CPC Class Codes: B29C 41/42 Removing articles from moulds, cores or other substrates B29C33/444 and B29C37/0017 take precedence
• CPC Class Codes: B29C 64/135 the energy source being concentrated, e.g. scanning lasers or focused light sources
• CPC Class Codes: B29C 64/153 using layers of powder being selectively joined, e.g. by selective laser sintering or melting
• 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 70/00 Materials specially adapted for additive manufacturing
• CPC Class Codes: F28F 3/12 Elements constructed in the shape of a hollow panel, e.g. with channels F28D1/02, F28D1/03 take precedence

Abstract

An apparatus for producing a three-dimensional object by successive solidification of layers of a powder material at points corresponding to a cross-section of said object using electromagnetic or particle radiation comprises support means having an upper side for supporting the object thereon at a determined elevation, elevation adjustment means for varying the elevation, means for applying a layer of the material onto the upper side or onto another layer formed on the upper side, and irradiation means for irradiating the layer of the material at the points corresponding to a cross-section of the object. For reducing the production time of the object the apparatus further comprises a prefabricated base plate on the upper side, the base plate being made of a material which the powder material adheres to when being solidified, and means for removably connecting the base plate to the upper side of the support means.

Claims

1. Apparatus for producing a three-dimensional object by successive solidification of layers of a powder material at points corresponding to a cross-section of said object using electromagnetic or particle radiation, said apparatus comprising:

an opening defined by peripheral walls having a top surface;

a support having an upper surface for supporting the object positioned within said opening;

elevation adjustment means for varying the elevation of said upper surface;

means for applying a layer of said powder material onto said upper surface or onto a solidified layer of said material formed on said upper surface; and

irradiation means positioned above said top surface for irradiating said layer of said powder material at said points corresponding to a cross-section of said object;

said support comprising a removable base plate comprising a presolidified amount of a powder material wherein said upper surface is on said removable base plate;

wherein said elevation means positions the upper surface, or a solidified layer of said material formed on said upper surface, below the top surface by an amount equal to the layer of powder material to be applied.

2. The apparatus of claim 1, wherein said removable base plate has a size corresponding to that of said support.

3. The apparatus of claim 1 wherein said support comprises a plate.

4. The apparatus of claim 1, comprising cooling means formed in said support for removing heat produced in said object and in said base plate when producing said object.

5. The apparatus of claim 4, said cooling means comprising cooling channels formed in said support on a side thereof opposite to said object.

6. The apparatus of claim 1, wherein said removable base plate is connected to said support using fastening means.

7. The apparatus of claim 1, wherein said irradiation means comprises a laser.

8. The apparatus of claim 1, wherein said powder material comprises metal powder, ceramic powder, resin coated metal or ceramic powder or resin coated sand.

9. The apparatus of claim 1, wherein said removable base plate comprises a metal plate having at least one solidified layer of said powder material formed thereon, said metal plate facing the upper side of said support.

10. Apparatus for producing a three-dimensional object by successive solidification of layers of a powder material at points corresponding to a cross-section of said object using electromagnetic or particle radiation, said apparatus comprising:

an opening defined by peripheral walls having a top surface;

a support having an upper surface for supporting the object positioned within said opening;

elevation adjustment means for varying the elevation of said upper surface;

means for applying a layer of said powder material onto said upper surface or onto a solidified layer of said material formed on said upper surface; and

irradiation means positioned above said top surface for irradiating said layer of said powder material at said points corresponding to a cross-section of said object;

said support comprising a removable base plate having a surface layer that is a presolidified amount of a powder material wherein said upper surface is said surface layer;

wherein said elevation means positions the upper surface, or a solidified layer of said material formed on said upper surface, below the top surface by an amount equal to the layer of powder material to be applied.

11. The apparatus of claim 10, wherein said removable base plate has a size corresponding to that of said support.

12. The apparatus of claim 10, wherein said support comprises a plate.

13. The apparatus of claim 10, comprising cooling means formed in said support for removing heat produced in said object and in said base plate when producing said object.

14. The apparatus of claim 13, said cooling means comprising cooling channels formed in said support on a side thereof opposite to said object.

15. The apparatus of claim 10, wherein said removable base plate is connected to said support using fastening means.

16. The apparatus of claim 10, wherein said irradiation means comprises a laser.

17. The apparatus of claim 10, wherein said powder material comprises metal powder, ceramic powder, resin coated metal or ceramic powder or resin coated sand.

18. The apparatus of claim 10, wherein said removable base plate comprises a metal plate having at least one solidified layer of said powder material formed thereon, said metal plate facing the upper side of said support.

19. Apparatus for producing a three-dimensional object by successive solidification of layers of a powder material at points corresponding to a cross-section of said object using electromagnetic or particle radiation, said apparatus comprising:

an opening defined by peripheral walls having a top surface;

a support having an upper surface for supporting the object positioned within said opening;

elevation adjustment means for varying the elevation of said upper surface;

means for applying a layer of said powder material onto said upper surface or onto a solidified layer of said material formed on said upper surface; and

irradiation means positioned above said top surface for irradiating said layer of said powder material at said points corresponding to a cross-section of said object;

said support comprising a removable base plate having a surface layer that provides adherence for said object to said base plate;

wherein said elevation means positions the upper surface, or a solidified layer of said material formed on said upper surface, below the top surface by an amount equal to the layer of powder material to be applied.

20. The apparatus of claim 19, wherein said removable base plate has a size corresponding to that of said support.

21. The apparatus of claim 19, wherein said support comprises a plate.

22. The apparatus of claim 19, comprising cooling means formed in said support for removing heat produced in said object and in said base plate when producing said object.

23. The apparatus of claim 22, said cooling means comprising cooling channels formed in said support on a side thereof opposite to said object.

24. The apparatus of claim 19, wherein said removable base plate is connected to said support using fastening means.

25. The apparatus of claim 19, wherein said irradiation means comprises a laser.

26. The apparatus of claim 19, wherein said powder material comprises metal powder, ceramic powder, resin coated metal or ceramic powder or resin coated sand.

27. The apparatus of claim 19, wherein said removable base plate comprises a metal plate having at least one solidified layer of said powder material formed thereon, said metal plate facing the upper side of said support.

28. A removable base plate for use in an apparatus for producing a three-dimensional object by successive solidification of layers of a powder material at points corresponding to a cross-section of said object using electromagnetic or particle radiation, said apparatus comprising (i) an opening defined by peripheral walls having a top surface, (ii) a support cooperating with said removable base plate to provide an upper surface for supporting the object positioned within said opening, (iii) elevation adjustment means for varying the elevation of said upper surface, (iv) means for applying a layer of said powder material onto said upper surface or onto a solidified layer of said material formed on said upper surface, and (v) irradiation means positioned above said top surface for irradiating said layer of said powder material at said points corresponding to a cross-section of said object, said removable base plate comprising a metal plate having thereon a presolidified amount of a powder material wherein said upper surface is on said removable base plate;

wherein said elevation means positions the upper surface, or a solidified layer of said material formed on said upper surface, below the top surface by an amount equal to the layer of powder material to be applied.

29. The removable base plate of claim 28, wherein said layer of said powder material is sintered onto an upper surface of said metal plate.

30. A removable base plate for use in an apparatus for producing a three-dimensional object by successive solidification of layers of a powder material at points corresponding to a cross-section of said object using electromagnetic or particle radiation, said apparatus comprising (i) an opening defined by peripheral walls having a top surface, (ii) a support cooperating with said removable base plate to provide an upper surface for supporting the object positioned within said opening, (iii) elevation adjustment means for varying the elevation of said upper surface, (iv) means for applying a layer of said powder material onto said upper surface or onto a solidified layer of said material formed on said upper surface, and (v) irradiation means positioned above said top surface for irradiating said layer of said powder material at said points corresponding to a cross-section of said object, said removable base plate having a surface layer that is a presolidified amount of a powder material wherein said upper surface is said surface layer;

wherein said elevation means positions the upper surface, or a solidified layer of said material formed on said upper surface, below the top surface by an amount equal to the layer of powder material to be applied.

31. A removable base plate for use in an apparatus for producing a three-dimensional object by successive solidification of layers of a powder material at points corresponding to a cross-section of said object using electromagnetic or particle radiation, said apparatus comprising (i) an opening defined by peripheral walls having a top surface, (ii) a support cooperating with said removable base plate to provide an upper surface for supporting the object positioned within said opening, (iii) elevation adjustment means for varying the elevation of said upper surface, (iv) means for applying a layer of said powder material onto said upper surface or onto a solidified layer of said material formed on said upper surface, and (v) irradiation means positioned above said top surface for irradiating said layer of said powder material at said points corresponding to a cross-section of said object, said removable base plate having a surface layer that provides adherence for said object to said base plate;

wherein said elevation means positions the upper surface, or a solidified layer of said material formed on said upper surface, below the top surface by an amount equal to the layer of powder material to be applied.