Apparatuses, systems and methods for three-dimensional printing

• US 9,254,535 B2
• Filed: 06/19/2015
• Issued: 02/09/2016
• Est. Priority Date: 06/20/2014
• Status: Active Grant

• Current Assignee: Velo3D, Inc.
• Original Assignee: Velo3D, Inc.
• Inventors: Buller, Benyamin, Milshtein, Erel
• Primary Examiner(s): Heinrich, Samuel M
• Application Number:
  US14/745,081
• Publication Number:
  US 20150367447A1
• Time in Patent Office: 235 Days
• Field of Search: 419/1, 419/25, 425/174.4, 430/269, 264/255, 264/308, 264/497, 700/98, 700/119, 700/120, 757/65, 757/69, 148/513, 148/514, 148/516, 148/525, 219/121.16, 219/121.17, 219/121.65, 219/121.66, 219/121.37, 219/121.38
• US Class Current: 1/1
• CPC Class Codes: B22F 10/12 by photopolymerisation, e.g. stereolithography [SLA] or digital light processing [DLP]
• CPC Class Codes: B22F 10/18 by mixing binder with metal in filament form, e.g. fused filament fabrication [FFF]
• CPC Class Codes: B22F 10/20 Direct sintering or melting
• 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 10/28 Powder bed fusion, e.g. selective laser melting [SLM] or electron beam melting [EBM]
• CPC Class Codes: B22F 10/30 Process control
• CPC Class Codes: B22F 10/32 of the atmosphere, e.g. composition or pressure in a building chamber
• CPC Class Codes: B22F 10/47 characterised by structural features
• CPC Class Codes: B22F 10/50 Treatment of workpieces or articles during build-up, e.g. treatments applied to fused layers during build-up
• CPC Class Codes: B22F 10/73 of powder
• CPC Class Codes: B22F 12/52 Hoppers
• CPC Class Codes: B22F 12/57 Metering means
• CPC Class Codes: B22F 12/60 Planarisation devices; Compression devices
• CPC Class Codes: B22F 12/90 Means for process control, e.g. cameras or sensors
• CPC Class Codes: B22F 2003/1054 by microwave
• CPC Class Codes: B22F 2003/248 Thermal after-treatment
• CPC Class Codes: B22F 2201/20 Use of vacuum
• CPC Class Codes: B22F 2202/01 Use of vibrations
• CPC Class Codes: B22F 2202/05 Use of magnetic field
• CPC Class Codes: B22F 2998/10 Processes characterised by the sequence of their steps
• CPC Class Codes: B22F 2999/00 : Aspects linked to processes or compositions used in powder metallurgy
• CPC Class Codes: B22F 3/003 : Apparatus, e.g. furnaces in general F27B
• CPC Class Codes: B22F 3/004 : Filling molds with powder feeding material to presses in general B30B15/302
• CPC Class Codes: B22F 3/105 : by using electric current other than for infrared radiant energy, laser radiation or plasma B22F3/11 takes precedence; by ultrasonic bonding B22F3/115 takes precedence
• CPC Class Codes: B22F 3/24 : After-treatment of workpieces or articles B22F3/1146 takes precedence
• CPC Class Codes: B22F 7/00 : Manufacture of composite layers, workpieces, or articles, comprising metallic powder, by sintering the powder, with or without compacting wherein at least one part is obtained by sintering or compression application of coating layers by use of metal powders, see C23C
• CPC Class Codes: B23K 10/006 : Control circuits therefor circuits for plasma torches H05H1/36
• CPC Class Codes: B23K 10/027 : Welding for purposes other than joining, e.g. build-up welding
• CPC Class Codes: B23K 15/002 : Devices involving relative movement between electronbeam and workpiece
• CPC Class Codes: B23K 15/0026 : Auxiliary equipment
• CPC Class Codes: B23K 15/0086 : welding for purposes other than joining, e.g. built-up welding
• CPC Class Codes: B23K 15/0093 : characterised by the properties of the materials to be welded
• CPC Class Codes: B23K 15/02 : Control circuits therefor
• CPC Class Codes: B23K 2103/50 : Inorganic material, e.g. metals, not provided for in B23K2103/02 – B23K2103/26
• CPC Class Codes: B23K 2103/52 : Ceramics
• CPC Class Codes: B23K 26/0853 : Devices involving movement of the workpiece in at least in two axial directions, e.g. in a plane
• CPC Class Codes: B23K 26/1224 : in vacuum
• CPC Class Codes: B23K 26/123 : in an atmosphere of particular gases
• CPC Class Codes: B23K 26/144 : the fluid stream containing particles, e.g. powder
• CPC Class Codes: B23K 26/16 : Removal of by-products, e.g. particles or vapours produced during treatment of a workpiece by a fluid stream B23K26/142
• CPC Class Codes: B23K 26/22 : Spot welding
• CPC Class Codes: B23K 26/32 : taking account of the properties of the material involved
• CPC Class Codes: B23K 26/342 : Build-up welding
• CPC Class Codes: B23K 26/346 : in combination with welding or cutting covered by groups B23K5/00 - B23K25/00, e.g. in combination with resistance welding
• CPC Class Codes: B23K 26/70 : Auxiliary operations or equipment
• CPC Class Codes: B23K 26/702 : Auxiliary equipment
• CPC Class Codes: B28B 1/001 : Rapid manufacturing of 3D objects by additive depositing, agglomerating or laminating of material selective deposition modelling of metallic powder B22F10/00; rapid manufacturing of 3D objects in general and in particular of plastics B29C64/00
• CPC Class Codes: B28B 17/0072 : Product control or inspection
• CPC Class Codes: B28B 17/0081 : Process control
• 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 64/165 : using a combination of solid and fluid materials, e.g. a powder selectively bound by a liquid binder, catalyst, inhibitor or energy absorber
• CPC Class Codes: B29C 64/171 : specially adapted for manufacturing multiple 3D objects
• CPC Class Codes: B29C 64/188 : involving additional operations performed on the added layers, e.g. smoothing, grinding or thickness control surface shaping B29C59/00; after-treatment of articles without altering their shape B29C71/00
• CPC Class Codes: B29C 64/194 : during lay-up
• CPC Class Codes: B29C 64/214 : Doctor blades
• CPC Class Codes: B29C 64/245 : Platforms or substrates support structures intended to be sacrificed after manufacture B29C64/40
• CPC Class Codes: B29C 64/255 : Enclosures for the building material, e.g. powder containers
• CPC Class Codes: B29C 64/264 : Arrangements for irradiation
• CPC Class Codes: B29C 64/268 : using laser beams; using electron beams [EB]
• CPC Class Codes: B29C 64/35 : Cleaning
• CPC Class Codes: B29C 64/393 : for controlling or regulating additive manufacturing processes
• CPC Class Codes: B29C 64/40 : Structures for supporting 3D objects during manufacture and intended to be sacrificed after completion thereof
• CPC Class Codes: B29K 2105/251 : Particles, powder or granules expandable particles B29K2105/046
• 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 40/20 : Post-treatment, e.g. curing, coating or polishing
• CPC Class Codes: B33Y 50/02 : for controlling or regulating additive manufacturing processes
• CPC Class Codes: B33Y 70/00 : Materials specially adapted for additive manufacturing
• CPC Class Codes: B33Y 80/00 : Products made by additive manufacturing
• CPC Class Codes: C04B 2235/6026 : Computer aided shaping, e.g. rapid prototyping
• CPC Class Codes: C04B 35/522 : Graphite C04B35/536 takes precedence
• CPC Class Codes: C04B 35/5626 : based on tungsten carbides
• CPC Class Codes: C04B 35/565 : based on silicon carbide
• CPC Class Codes: C04B 35/64 : Burning or sintering processes C04B33/32 takes precedence ; powder metallurgy B22F
• CPC Class Codes: C22C 38/00 : Ferrous alloys, e.g. steel alloys cast-iron alloys C22C37/00
• CPC Class Codes: C22C 38/02 : containing silicon
• CPC Class Codes: C22C 38/44 : with molybdenum or tungsten
• CPC Class Codes: C22C 38/58 : with more than 1.5% by weight of manganese
• CPC Class Codes: H05B 6/68 : for monitoring or control
• CPC Class Codes: H05B 6/80 : Apparatus for specific applications stoves or ranges F24C7/02
• CPC Class Codes: Y02P 10/20 : Recycling
• CPC Class Codes: Y02P 10/25 : Process efficiency

Abstract

The present disclosure provides three-dimensional (3D) objects, 3D printing processes, as well as methods, apparatuses and systems for the production of a 3D object. Methods, apparatuses and systems of the present disclosure may reduce or eliminate the need for auxiliary supports. The present disclosure provides three dimensional (3D) objects printed utilizing the printing processes, methods, apparatuses and systems described herein.

Claims

1. A method for generating a three-dimensional object, comprising:

(a) providing (i) a first layer of powder material in an enclosure at a first time (t₁) and (ii) a second layer of powder material in the enclosure at a second time (t₂) that follows t₁, wherein the second layer of powder material is provided adjacent to the first layer of powder material, wherein the first layer of powder material and second layer of powder material form a powder bed, and wherein the powder material comprises an elemental metal, metal alloy, ceramic, or an allotrope of elemental carbon;

(b) transforming at least a portion of the powder material in the second layer to form a transformed material; and

(c) using a heat sink adjacent to the first layer or the second layer to remove thermal energy from the second layer at a time interval from t₂ to a third time (t₃), wherein the thermal energy is removed along a direction above the powder bed, and wherein upon removal of thermal energy, the transformed material solidifies to form at least a portion of the three-dimensional object.

2. The method of claim 1, wherein during the time interval from t₂ to t₃, an average temperature at a point in the second layer is maintained at less than or equal to about 250°

C.

3. The method of claim 2, wherein during the time interval from t₂ to t₃, the average temperature is maintained at less than or equal to about 100°

C.

4. The method of claim 1, wherein in (b), the transforming is with the aid of an energy beam having a first energy per unit area (S₁), and wherein in (c), during the time interval from t₂ to t₃ thermal energy is removed at a second energy per unit area (S₂) that is at least about 0.3 times S₁.

5. The method of claim 4, wherein the second energy per unit area (S₂) is at least about 0.5 times S₁.

6. The method of claim 1, wherein the thermal energy is removed from a top surface of the powder bed.

7. The method of claim 1, wherein the transforming comprises fusing individual particles of the powder material.

8. The method of claim 7, wherein fusing comprises melting or sintering the individual particles.

9. The method of claim 1, wherein at t₃, a third layer of powder material is provided adjacent to the second layer of powder material.

10. The method of claim 1, wherein the transforming comprises directing an energy beam to at least a portion of the second layer.

11. A system for generating a three-dimensional object, comprising:

an enclosure that accepts a first layer of powder material at a first time (t₁) and a second layer of powder material at a second time (t₂) that follows t₁ to form a powder bed, wherein the second layer of powder material is adjacent to the first layer of powder material, and wherein the powder material comprises an elemental metal, metal alloy, ceramic, or an allotrope of elemental carbon;

a heat sink adjacent to the first layer or the second layer, wherein the heat sink removes thermal energy from the second layer; and

a controller operatively coupled to the heat sink and programmed to (i) transform at least a portion of the powder material in the second layer to form a transformed material, and (ii) use the heat sink to remove thermal energy from the second layer at a time interval from t₂ to a third time (t₃), wherein the thermal energy is removed along a direction above the powder bed, and wherein upon removal of thermal energy, the transformed material solidifies to form at least a portion of the three-dimensional object.

12. The system of claim 11, further comprising an energy source that provides an energy beam to at least a portion of the second layer.

13. The system of claim 12, wherein the controller is operatively coupled to the energy source and programmed to direct the energy beam to at least the portion of the second layer.

14. The system of claim 12, wherein the heat sink is movable to or from a position that is between the energy source and the powder bed.

15. The system of claim 11, wherein the controller is programmed to (1) transform at least a portion of the powder material in the second layer to form a transformed material using an energy beam having a first energy per unit area (S₁), and (2) use the heat sink to remove thermal energy during the time interval from t₂ to t₃ at a second energy per unit area (S₂) that is at least about 0.3 times S₁.

16. The system of claim 15, wherein the second energy per unit area (S₂) is at least about 0.5 times S₁.

17. The system of claim 11, wherein the controller is programmed to use the heat sink to remove the thermal energy from a top surface of the powder bed.

18. The system of claim 11, wherein the controller is programmed to control an average temperature of the second layer of powder material.

19. The system of claim 18, wherein during the time interval from t₂ to t₃, the controller is programmed to maintain an average temperature at a point in the second layer at less than or equal to about 250°

C.

20. The system of claim 19, wherein during the time interval from t₂ to t₃, the controller is programmed to maintain the average temperature at less than or equal to about 100°

C.

21. The system of claim 11, wherein the heat sink is movable.

22. The system of claim 21, wherein the controller is programmed to move the heat sink.

23. The system of claim 11, wherein heat sink is separated from the powder bed by a gap.

24. The system of claim 23, wherein the gap is at a spacing of less than or equal to about 50 millimeters.

25. The system of claim 23, wherein the gap is at an adjustable spacing between the heat sink and the powder bed.

26. The system of claim 25, wherein the controller is programmed to regulate the adjustable spacing.

27. The system of claim 11, wherein the heat sink comprises a material having a thermal conductivity of at least about 20 Watts per meter per degree Kelvin (W/mK).

28. The system of claim 11, wherein the heat sink further comprises a cleaning member that removes the powder material or debris from a surface of the heat sink.

29. The system of claim 11, further comprising a collection member that collects a remainder of the powder material or debris from the heat sink or the powder bed.

30. The system of claim 11, wherein the heat sink comprises one or more openings.