System and method for building three-dimensional objects with metal-based alloys

• US 7,942,987 B2
• Filed: 06/24/2008
• Issued: 05/17/2011
• Est. Priority Date: 06/24/2008
• Status: Active Grant

• Current Assignee: Stratasys Incorporated
• Original Assignee: Stratasys Incorporated
• Inventors: Barnett, John, Zinniel, Robert L., Sampson, Timothy, Crump, S. Scott, Batchelder, J. Samuel
• Primary Examiner(s): Silverman; Stanley
• Assistant Examiner(s): WALCK, BRIAN D
• Application Number:
  US12/145,131
• Publication Number:
  US 20090314391A1
• Time in Patent Office: 1,057 Days
• Field of Search: 148/516, 148/522, 148/523, 148/527, 148/535, 164/4.1, 164/457, 164/900, 219 761- 7617, 222591-594, 266/236, 266/241
• US Class Current: 148/522
• CPC Class Codes: B21C 31/00 Control devices, e.g. for regulating the pressing speed or temperature of metal B21C25/08 takes precedence; Measuring devices, e.g. for temperature of metal, combined with or specially adapted for use in connection with extrusion presses
• CPC Class Codes: B21C 33/02 the metal being in liquid form
• 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 10/32 of the atmosphere, e.g. composition or pressure in a building chamber
• CPC Class Codes: B22F 12/13 to preheat the material
• CPC Class Codes: B22F 12/20 Cooling means
• CPC Class Codes: B22F 2998/00 Supplementary information concerning processes or compositions relating to powder metallurgy
• CPC Class Codes: B22F 3/003 Apparatus, e.g. furnaces in general F27B
• CPC Class Codes: B29C 64/106 using only liquids or viscous materials, e.g. depositing a continuous bead of viscous material
• CPC Class Codes: B29C 64/118 using filamentary material being melted, e.g. fused deposition modelling [FDM]
• CPC Class Codes: B33Y 10/00 Processes of additive manufacturing
• CPC Class Codes: B33Y 40/00 Auxiliary operations or equipment, e.g. for material handling
• CPC Class Codes: B33Y 40/20 Post-treatment, e.g. curing, coating or polishing
• CPC Class Codes: B33Y 70/00 Materials specially adapted for additive manufacturing
• CPC Class Codes: Y02P 10/25 Process efficiency
• CPC Class Codes: Y10S 164/90 Rheo-casting

Abstract

A digital manufacturing system comprises a build chamber, a build platform disposed within the build chamber, at least one extrusion line configured to heat a metal-based alloy up to a temperature between solidus and liquidus temperatures of the metal-based alloy, a deposition head disposed within the build chamber and configured to deposit the heated metal-based alloy onto the build platform in a predetermined pattern, an umbilical having a first end located outside of the build chamber and a second end connected to the deposition head, and at least one gantry assembly configured to cause relative motion between the build platform and the deposition head within the build chamber, where the at least one gantry assembly comprises a motor disposed outside of the build chamber.

Claims

1. A method for building a three-dimensional object in a layer-by-layer manner with a digital manufacturing system, the method comprising:

substantially removing oxygen-containing gases from a build chamber of the digital manufacturing system;

heating the build chamber to one or more temperatures of at least about 400°

C.;

providing an alloy comprising aluminum;

heating the alloy to a temperature that is above a solidus temperature of the alloy and that is below a liquidus temperature of the alloy;

depositing the heated alloy in a predetermined pattern from a deposition head disposed at least partially within the build chamber onto a build platform—

disposed within the build chamber

controlling a flow of the alloy from the deposition head by selectively relaying a coolant from a coolant solenoid located outside of the build chamber to a freeze valve assembly of the deposition head disposed within the build chamber; and

solidifying the deposited alloy.

2. The method of claim 1, wherein the one or more temperatures to which the build chamber is heated range from about 400°

C. to about 700°

C.

3. The method of claim 1, wherein the one or more temperatures to which the build chamber is heated range from about 500°

C. to about 650°

C.

4. The method of claim 1, wherein the alloy comprises from about 90% by weight to about 95% by weight of the aluminum, and from about 5% by weight to about 10% by weight silicon.

5. The method of claim 1, further comprising relaying the heated alloy from a location outside of the build chamber to the deposition head.

6. The method of claim 1, further comprising quenching the solidified alloy.

7. The method of claim 1, wherein the alloy is heated in at least one extrusion line disposed outside of the build chamber, and wherein the method further comprises driving the heated alloy from the at least one extrusion line to the deposition head through a thermally-isolating umbilical.

8. A method for building a three-dimensional object in a layer-by-layer manner with a digital manufacturing system, the method comprising:

substantially removing oxygen-containing gases from a build chamber of the digital manufacturing system;

heating the build chamber to one or more temperatures of at least 400°

C.;

providing a metal-based alloy;

heating the alloy to a temperature that is above a solidus temperature of the alloy and that is below a liquidus temperature of the alloy;

depositing the heated alloy in a predetermined pattern from a deposition head at least partially disposed within the build chamber onto a build platform disposed within the build chamber;

controlling a flow of the alloy from the deposition head by selectively relaying a coolant from a coolant solenoid located outside of the build chamber to a freeze valve assembly of the deposition head disposed within the build chamber; and

solidifying the deposited alloy.

9. The method of claim 8, wherein the one or more temperatures to which the build chamber is heated range from 400°

C. to about 700°

C.

10. The method of claim 8, wherein the one or more temperatures to which the build chamber is heated range from about 500°

C. to about 650°

C.

11. The method of claim 8, wherein the alloy comprises aluminum and silicon.

12. The method of claim 11, wherein the alloy comprises from about 90% by weight to about 95% by weight of the aluminum, and from about 5% by weight to about 10% by weight of the silicon.

13. The method of claim 8, wherein the method further comprises relaying the heated alloy from a location outside of the build chamber to the deposition head.

14. The method of claim 8, wherein the alloy is heated in at least one extrusion line disposed outside of the build chamber, and wherein the method further comprises driving the heated alloy from the at least one extrusion line to the deposition head through a thermally-isolating umbilical.

15. The method of claim 8, further comprising quenching the solidified alloy.