Apparatus for producing a three-dimensional object

• US 8,308,466 B2
• Filed: 02/18/2009
• Issued: 11/13/2012
• Est. Priority Date: 02/18/2009
• Status: Active Grant

• Current Assignee: Arcam Ab (Danaher Corporation)
• Original Assignee: Arcam Ab (Danaher Corporation)
• Inventors: Ackelid, Ulf, Wallgren, Göran
• Primary Examiner(s): BODAWALA, DIMPLE N
• Application Number:
  US13/144,451
• Publication Number:
  US 20110293770A1
• Time in Patent Office: 1,364 Days
• Field of Search: 425/174.4, 425/375, 425/470, 425/471, 264442-444, 264/485, 264494-497, 700/98, 700/119
• US Class Current: 425/174.4
• CPC Class Codes: B22F 10/28 Powder bed fusion, e.g. selective laser melting [SLM] or electron beam melting [EBM]
• CPC Class Codes: B22F 12/41 characterised by the type, e.g. laser or electron beam
• CPC Class Codes: B22F 2998/00 Supplementary information concerning processes or compositions relating to powder metallurgy
• CPC Class Codes: B22F 3/004 Filling molds with powder feeding material to presses in general B30B15/302
• 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 64/205 Means for applying layers
• CPC Class Codes: B29C 64/343 Metering
• CPC Class Codes: B33Y 30/00 Apparatus for additive manufacturing; Details thereof or accessories therefor
• CPC Class Codes: Y02P 10/25 Process efficiency

Abstract

The invention concerns an apparatus (1) for producing a three-dimensional object layer by layer using a powdery material which can be solidified by irradiating it with an energy beam, such as electromagnetic radiation or an electron beam, said apparatus (1) comprising: a working area (3) onto which layers of powdery material are to be placed; a powder storage unit (11) comprising a base surface (13) for supporting a supply of powder (2); and a powder distribution member (6); wherein the base surface (13) extends along a side of the working area (3), wherein the distribution member (6) extends in a direction along the base surface (13) and said side of the working area (3) and is arranged to be moveable in a plane above, and substantially parallel to, the base surface (13) and the working area (3), and wherein the distribution member (6) is arranged to be moveable into a supply of powder (2) placed onto the base surface (13) such as to bring about a transfer of a portion of powder from a side of the distribution member (6) facing away from the working area (3) to an opposite side of the distribution member (6) facing the working area (3), said distribution member (6) further being arranged to be moveable towards and across the working area (3) so as to distribute the portion of powder onto the working area (3). The invention is characterized in that at least a part (15) of the base surface (13) is arranged to be resilient in a vertical direction.

Claims

1. Apparatus for producing a three-dimensional object layer by layer using a powdery material which can be solidified by irradiating it with an energy beam, such as an electromagnetic radiation or an electron beam, said apparatus comprising:

a working area onto which layers of said powdery material are to be placed;

a powder storage unit comprising a base surface adapted for supporting a supply of said powdery material; and

a powder distribution member,

wherein;

the base surface extends along a side of the working area;

the distribution member extends in a direction along the base surface and said side of the working area and is arranged to be moveable in a plane above, and substantially parallel to, the base surface and the working area;

the distribution member is arranged to be moveable into a supply of said powdery material placed onto the base surface such as to bring about a transfer of a portion of said powdery material from a side of the distribution member facing away from the working area to an opposite side of the distribution member facing the working area, said distribution member further being arranged to be moveable towards and across the working area so as to distribute the portion of said powdery material onto the working area; and

at least a part of the base surface comprises a resiliently suspended plate, which is resiliently suspended by at least one spring in vertical direction.

2. Apparatus according to claim 1, wherein the resilient part of the base surface is arranged in such a way that it moves downwards as a result of a downwardly directed force created by the distribution member when moving through a supply of powder placed onto the base surface, and such that the resilient part returns to its original position when the distribution member no longer has any effect on the position of the resilient part.

3. Apparatus according to claim 1, wherein the at least one spring is arranged below the suspended plate.

4. Apparatus according to claim 1, wherein the resilient part of the powder supply base surface comprises a flexible and bendable plate.

5. Apparatus according to claim 1, wherein the resilient part of the powder supply base surface is positioned such that the distribution member passes above at least a part of the plate on its way towards the powder supply.

6. Apparatus according to claim 4, wherein the flexible and bendable plate is a covering foil and arranged on top of the base surface.

7. Apparatus according to claim 1, wherein:

the apparatus further comprises a supply of the powdery material placed onto the base surface; and

the powder supply is arranged in an open manner such that the powder supply forms an angle of repose on a side of the powder supply that faces the working area.

8. Apparatus according to claim 1, wherein the working area is located on a vertically adjustable platform.

9. Apparatus according to claim 1, wherein the apparatus further comprises a radiation source for producing said energy beam.