Method for producing a three-dimensional object

• US 6,042,774 A
• Filed: 01/29/1998
• Issued: 03/28/2000
• 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: Wilkening, Christian, Lohner, Andreas
• Primary Examiner(s): Fiorilla, Christopher A.
• Application Number:
  US09/015,156
• Time in Patent Office: 789 Days
• Field of Search: 264/497, 264/430, 264/460, 264/461, 264/463
• US Class Current: 264/497
• 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

A method of producing an object by successive solidification of layers of a powder material is disclosed. The method provides a preformed base plate having a metal plate with a solidified layer of a powder material formed thereon. Then, successive layers of said powder material are applied and solidified on the solidified layer of the base plate to form the object. In further detail, the method for produces a three-dimensional by providing a support and a preformed base plate having an upper surface for supporting the object. The base plate is removably attached to the support. Means are provided for adjusting the elevation of said upper surface. A layer of the powder material is applied to the upper surface of the base plate. The powder material is solidified at points corresponding to a cross-section of the object by irradiation with electromagnetic or particle radiation. Then, the applying and solidifying steps are repeated for completing the object.

Claims

1. A method of producing a three-dimensional object by successive solidification of layers of a powder material, the method comprising the steps:

making a base of a material which said powder material adheres to when being solidified,

removably fastening said base to a support means for said object,

applying a layer of said powder material to said base and

solidifying said powder material at points corresponding to a cross-section of said object by irradiation with electromagnetic or particle radiation, and

repeating the applying and solidifying steps for completing the object.

2. The method of claim 1, comprising producing said base by solidifying the same powder material which is used for producing said object and fastening said produced base on said object support.

3. The method of claim 2, comprising solidifying said powder material by action of heat in an oven for forming said base.

4. The method of claim 1, comprising producing said base by solidifying at least one layer of said powder material on a metal plate.

12. The method of claim 1, wherein said irradiation means comprises a laser.

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

14. The method of claim 1, wherein said 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.

5. A method for producing a three-dimensional object by successive solidification of layers of a powder material, the method comprising the steps of:

providing a support;

providing a preformed base plate having an upper surface for supporting said object;

removably attaching said base plate to said support;

providing means for adjusting the elevation of said upper surface;

applying a layer of said powder material to the upper surface of said base plate;

solidifying said powder material at points corresponding to a cross-section of said object by irradiation with electromagnetic or particle radiation; and

repeating the applying and solidifying steps for completing the object

wherein the step of providing said base plate comprises presolidifying an amount of a powder material in forming said base plate.

6. The method of claim 5, wherein said base plate is formed by solidifying said powder material.

7. The method of claim 5, wherein said base plate has a size corresponding to that of said support.

8. The method of claim 5, wherein said support comprises a plate.

9. The method of claim 5, comprising providing cooling means formed in said support for removing heat produced in said object and in said base plate when producing said object.

10. The method of claim 9, said cooling means comprising cooling channels formed in said support on a side thereof opposite to said object.

11. The method of claim 5, further providing fastening means to removably connect said base plate to said support.

15. A method for producing a three-dimensional object by successive solidification of layers of a powder material, the method comprising the steps of:

providing a support;

providing a preformed base plate having an upper surface for supporting said object, the upper surface providing adherence for the powder material to form the object;

removably attaching said base plate to said support;

providing means for adjusting the elevation of said upper surface;

applying a layer of said powder material to the upper surface of said base plate;

solidifying said powder material at points corresponding to a cross-section of said object by irradiation with electromagnetic or particle radiation; and

repeating the applying and solidifying steps for completing the object.

16. The method of claim 15, further comprising producing said preformed base plate by solidifying the same powder material which is used for producing said object and fastening said produced base plate on said support.

17. The method of claim 16, further comprising solidifying said powder material to produce said base plate by action of heat in an oven for forming said base.

18. The method of claim 15, further comprising producing said preformed base plate by solidifying at least one layer of said powder material on a metal plate.

19. A method for producing a three-dimensional object by successive solidification of layers of a powder material, the method comprising the steps of:

providing a support;

providing a preformed base plate having an upper surface for supporting said object;

removably attaching said base plate to said support;

providing means for adjusting the elevation of said upper surface;

applying a layer of said powder material to the upper surface of said base plate;

solidifying said powder material at points corresponding to a cross-section of said object by irradiation with electromagnetic or particle radiation; and

repeating the applying and solidifying steps for completing the object wherein the step of providing said base plate comprises presolidifying a layer of powder material as an upper surface for supporting said object and providing adherence for the powder material forming the object.

20. The method of claim 19, further comprising producing said preformed base plate by solidify the same powder material which is used for producing said object and fastening said produced base plate on said support.

21. The method of claim 20, further comprising solidifying said powder material to produce said base plate by action of heat3in an oven for forming said base.

22. The method of claim 19, further comprising producing said preformed base plate by solidifying at least one layer of said powder material on a metal plate.