Method and apparatus for additive manufacturing

• US 9,415,443 B2
• Filed: 04/03/2014
• Issued: 08/16/2016
• Est. Priority Date: 05/23/2013
• Status: Active Grant

• Current Assignee: Arcam Ab (Danaher Corporation)
• Original Assignee: Arcam Ab (Danaher Corporation)
• Inventors: Ljungblad, Ulric, Snis, Anders
• Primary Examiner(s): KLEMANSKI, HELENE G
• Application Number:
  US14/244,503
• Publication Number:
  US 20140348691A1
• Time in Patent Office: 866 Days
• Field of Search: 419/53, 264/497, 425/78, 425/174.4
• US Class Current: 1/1
• 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 12/45 Two or more
• CPC Class Codes: B29C 64/153 using layers of powder being selectively joined, e.g. by selective laser sintering or melting
• 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

A method for forming a three-dimensional article through successive fusion of parts of a powder bed, which parts corresponds to successive cross sections of the three-dimensional article, said method comprising the steps of: providing a model of said three dimensional article, providing a first powder layer on a work table, directing a first energy beam from a first energy beam source over said work table causing said first powder layer to fuse in first selected locations according to said model to form a first cross section of said three-dimensional article, directing a second energy beam from a second energy beam source over said work table causing said first powder layer to fuse in second selected locations according to said model to form the first cross section of said three-dimensional article, wherein said first and second locations of said first powder layer are at least partially overlapping each other.

Claims

1. A method for forming a three-dimensional article through successive fusion of parts of a powder bed, which parts correspond to successive cross sections of the three-dimensional article, said method comprising the steps of:

providing a model of said three dimensional article;

applying a first powder layer on a work table;

directing a first energy beam from a first energy beam source over said work table, said directing of said first energy beam causing said first powder layer to fuse in first selected locations according to said model, so as to form a first part of the first cross section of said three-dimensional article;

directing a second energy beam from a second energy beam source over said work table, said directing of said second energy beam causing said first powder layer to fuse in second selected locations according to said model, so as to form a second part of the first cross section of said three-dimensional article, wherein said first and second locations of said first powder layer are at least partially overlapping each other in a first overlapping zone;

fusing said first and second locations of said first powder layer simultaneously via said first and second energy beam from said first and second energy beam source, respectively;

overlapping a spot of said first energy beam at least partially with a spot of said second energy beam during at least one occasion of said fusing of said first overlapping zone; and

maintaining the sum of power of the first and second beam in said first overlapping zone at a predetermined value, wherein the individual power of each of the first and the second beams in said first overlapping zone is half that of each of the first and the second beams outside said first overlapping zone or said predetermined value is equal to the individual power of at least one of the first or the second beam outside said first overlapping zone.

2. A method for forming a three-dimensional article through successive fusion of parts of a powder bed, which parts correspond to successive cross sections of the three-dimensional article, said method comprising the steps of:

providing a model of said three dimensional article;

applying a first powder layer on a work table;

directing a first energy beam from a first energy beam source over said work table, said directing of said first energy beam causing said first powder layer to fuse in first selected locations according to said model, so as to form a first part of the first cross section of said three-dimensional article;

directing a second energy beam from a second energy beam source over said work table, said directing of said second energy beam causing said first powder layer to fuse in second selected locations according to said model, so as to form a second part of the first cross section of said three-dimensional article, wherein said first and second locations of said first powder layer are at least partially overlapping each other in a first overlapping zone;

fusing said first and second locations of said first powder layer simultaneously via said first and second energy beam from said first and second energy beam source, respectively;

overlapping a spot of said first energy beam at least partially with a spot of said second energy beam during at least one occasion of said fusing of said first overlapping zone;

varying the power of said first beam linearly from 100% to 0% starting at a first end of said overlapping zone and ending at a second end of said overlapping zone; and

simultaneously varying the power of said second beam linearly from 0% to 100% starting at the first end of said first overlapping zone and ending at the second end of said overlapping zone.

3. The method according to claim 2, wherein a sum of said variable power of said first and said second beams between said first and said second ends of said overlapping zone is maintained at a predetermined value.

4. The method according to claim 3, wherein said predetermined value is a constant value.

5. The method according to claim 3, wherein said predetermined value is equal to the individual power of at least one of the first or the second beam outside said first overlapping zone.