Powder distribution in additive manufacturing

• US 9,126,167 B2
• Filed: 05/11/2012
• Issued: 09/08/2015
• Est. Priority Date: 05/11/2012
• Status: Active Grant

• Current Assignee: Arcam Ab (Danaher Corporation)
• Original Assignee: Arcam Ab (Danaher Corporation)
• Inventors: Ljungblad, Ulric
• Primary Examiner(s): THEISEN, MARY LYNN F
• Application Number:
  US14/390,978
• Publication Number:
  US 20150054191A1
• Time in Patent Office: 1,215 Days
• US Class Current: 1/1
• CPC Class Codes: B01J 6/005 Fusing
• CPC Class Codes: B22F 10/10 Formation of a green body
• CPC Class Codes: B22F 10/28 Powder bed fusion, e.g. selective laser melting [SLM] or electron beam melting [EBM]
• CPC Class Codes: B22F 10/34 of powder characteristics, e.g. density, oxidation or flowability
• CPC Class Codes: B22F 12/13 to preheat the material
• CPC Class Codes: B22F 12/37 Rotatable
• CPC Class Codes: B22F 12/52 Hoppers
• CPC Class Codes: B22F 12/55 Two or more means for feeding material
• CPC Class Codes: B22F 12/58 for changing the material composition, e.g. by mixing
• 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 64/295 Heating elements
• CPC Class Codes: B29C 64/336 of two or more materials
• 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: Y02P 10/25 Process efficiency

Abstract

An additive manufacturing method for forming a three-dimensional article through successive fusion of parts of at least one layer of a powder bed provided on a work table. Providing at least one rotatable powder container above said work table, said powder container comprising at least one exit for providing powder to a powder table arranged beside said work table, at least one opening inside said container is spatially separated from and connected to said at least one exit. Ejecting a fixed amount of powder from said powder container during at least one predetermined segment of rotational angles of said powder container, from the exit of said powder container onto said powder table, wherein said fixed amount is determined by the shape and size of the at least one opening inside said container. Distributing said powder onto said work table with a powder distributor.

Claims

1. An additive manufacturing method for forming a three-dimensional article through successive fusion of parts of at least one layer of a powder bed provided on a work table, which parts corresponds to successive cross sections of the three-dimensional article, said method comprising the steps of:

providing at least one rotatable powder container above a powder table, said powder container comprising at least one exit for providing powder to the powder table arranged beside said work table, at least one opening inside said container is spatially separated from and connected to said at least one exit;

rotating said powder container;

ejecting a fixed amount of powder from said powder container during at least one predetermined segment of rotational angles of said powder container, as long as more than a predetermined amount of powder is remaining in the container, from the exit of said powder container onto said powder table, wherein said fixed amount is determined based upon the shape and size of the at least one opening inside said container; and

distributing at least a part of said fixed amount of powder from said powder table to said work table with a distributor for forming at least a part of a layer of said powder bed.

2. The method according to claim 1, further comprising the steps of:

providing at least a first container above a powder table, wherein said first container is configured for providing powder beside and in the vicinity of a first end of the working table; and

providing at least a second container above powder table, wherein said second container is configured for providing powder beside and in the vicinity of a second end of the working table.

3. The method according to claim 1, further comprising the step of providing a first type of material in a first container and a second type of material in a second container.

4. The method according to claim 3, wherein said first and second type of material differs in powder grain size only.

5. The method according to claim 3, wherein said first and second type of material differs in material composition.

6. The method according to claim 1, further comprising the step of providing a heater in at least one of said powder containers for drying said powder.

7. The method according to claim 1, wherein said powder is ejected when rotating said powder container in a first direction.

8. The method according to claim 7, further comprising the step of rotating the powder container in a second direction for prohibiting powder ejection.

9. The method according to claim 1, further comprising the step of separating said powder container and vacuum chamber by a valve allowing change of powder container during an additive manufacturing process.

10. The method according to claim 1, further comprising the step of providing at least one guide plate for guiding powder material from the powder container to the working table.

11. An additive manufacturing apparatus for forming a three-dimensional article through successive fusion of parts of at least one layer of a powder bed provided on a work table, which parts corresponds to successive cross sections of the three-dimensional article, said apparatus comprising:

at least one rotatable powder container above said work table, said powder container comprising at least one exit for providing powder to a powder table arranged beside said worktable, and at least one opening inside said container, said at least one opening being spatially separated from and connected to said at least one exit; and

a distributor for distributing at least a part of said fixed amount of powder from said powder table to said work table for forming at least a part of a layer of said powder bed.

12. The additive manufacturing apparatus according to claim 11, wherein:

at least a first container is provided above the powder table;

said first container is configured for providing powder at the powder table beside and in the vicinity of a first end of the working table;

at least a second container is provided above the powder table; and

said second container is configured for providing powder at the powder table beside and in the vicinity of said second end of the working table.

13. The additive manufacturing apparatus according to claim 11, wherein a heater is provided in at least one of said powder containers for drying said powder.

14. The additive manufacturing apparatus according to claim 11, wherein said powder container and vacuum chamber are separated by a valve allowing change of powder container during an additive manufacturing process.

15. The additive manufacturing apparatus according to claim 11, wherein at least one powder guide plate is provided for guiding powder material from the powder container to the working table.