Forming structures from CAD solid models

• US 6,811,744 B2
• Filed: 04/22/2002
• Issued: 11/02/2004
• Est. Priority Date: 07/07/1999
• Status: Expired due to Term

• Current Assignee: Optomec Design Company
• Original Assignee: Optomec Design Company
• Inventors: Keicher, David M., Smith, Mark E., Bullen, James L., Dullea, Kevin J., Love, James W., Gorman, Pierrette H.
• Primary Examiner(s): JENKINS, DANIEL J
• Application Number:
  US10/128,658
• Publication Number:
  US 20030206820A1
• Time in Patent Office: 925 Days
• Field of Search: 419/5, 419/9, 419/6, 419/7, 264/112, 264/610, 264/629, 264/670
• US Class Current: 419/5
• CPC Class Codes: B05B 7/14 designed for spraying particulate materials B05B7/16 takes precedence
• CPC Class Codes: B22F 10/25 Direct deposition of metal particles, e.g. direct metal deposition [DMD] or laser engineered net shaping [LENS]
• CPC Class Codes: B22F 10/31 Calibration of process steps or apparatus settings, e.g. before or during manufacturing
• CPC Class Codes: B22F 10/385 Overhang structures
• CPC Class Codes: B22F 10/80 Data acquisition or data processing
• CPC Class Codes: B22F 12/30 Platforms or substrates
• CPC Class Codes: B22F 12/48 in height, e.g. perpendicular to the deposition plane
• CPC Class Codes: B22F 12/52 Hoppers
• CPC Class Codes: B22F 12/53 Nozzles
• CPC Class Codes: B22F 2203/03 for feed-back
• CPC Class Codes: B22F 2203/11 temperature, temperature profile
• CPC Class Codes: B22F 2999/00 Aspects linked to processes or compositions used in powder metallurgy
• CPC Class Codes: B23K 2103/04 Steel or steel alloys
• CPC Class Codes: B23K 2103/05 Stainless steel
• CPC Class Codes: B23K 2103/12 Copper or alloys thereof
• CPC Class Codes: B23K 2103/14 Titanium or alloys thereof
• CPC Class Codes: B23K 2103/26 Alloys of Nickel and Cobalt and Chromium
• CPC Class Codes: B23K 2103/50 Inorganic material, e.g. metals, not provided for in B23K2103/02 – B23K2103/26
• 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 33/02 : with incorporated heating or cooling means
• CPC Class Codes: B29C 33/046 : using gas
• CPC Class Codes: B29C 33/3842 : Manufacturing moulds, e.g. shaping the mould surface by machining
• CPC Class Codes: B29C 41/20 : incorporating preformed parts or layers, e.g. moulding inserts or for coating articles
• CPC Class Codes: B29C 45/7312 : Construction of heating or cooling fluid flow channels
• 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 64/371 : using an environment other than air, e.g. inert gas
• CPC Class Codes: B29C 64/40 : Structures for supporting 3D objects during manufacture and intended to be sacrificed after completion thereof
• CPC Class Codes: B29C 70/68 : by incorporating or moulding on preformed parts, e.g. inserts or layers , e.g. foam blocks mould constructions therefor B29C33/12; joining preformed parts by moulding B29C65/70
• CPC Class Codes: B33Y 10/00 : Processes of additive manufacturing
• CPC Class Codes: F28F 7/02 : Blocks traversed by passages for heat-exchange media F28D7/0008 takes precedence
• CPC Class Codes: Y02P 10/25 : Process efficiency

Abstract

A method and apparatus for embedding features and controlling material composition in a three-dimensional structure (130) is disclosed. The invention enables the control of material characteristics, within a structure (130) made from a plurality of materials, directly from computer rendering of solid models of the components. The method uses stereolithography and solid model computer file formats to control a multi-axis head (480) in a directed material deposition process (123). Material feedstock (126, 127) is deposited onto a pre-heated substrate (19). Depositions (15) in a layer-by-layer pattern, defined by solid models (141, 146), create a three-dimensional article having complex geometric details. Thermal management of finished solid articles (250-302), not available through conventional processing techniques, is enabled by embedded voids (152) and/or composite materials (126, 127), which include dissimilar metals (210, 216). Finished articles control pressure drop and produce uniform coolant flow and pressure characteristics. High-efficiency heat transfer is engineered within a solid structure by incorporating other solid materials with diverse indexes. Embedding multi-material structures (132, 134) within a normally solid component (141) produces articles with diverse mechanical properties. Laser and powder delivery systems (420, 170) are integrated in a multi-axis deposition head (480) having a focused particle beam (502) to reduce material waste.

Claims

1. A method comprising the steps of:

defining a solid model (141, 146) which describes a finished three-dimensional structure (130), said solid model (141, 146) having embedded features, in a computer-aided design program stored on a control computer (129);

depositing a layer (15) of material feedstock (126, 127) on a substrate (19) using a directed material deposition process (123);

said deposition process (123) controlled by said computer-aided design program; and

using a deposition process that employs more than three axes of motion such that the part build axis can be varied during said deposition process to allow unsupported overhangs to be built on said solid model (141, 146).