Apparatuses, systems and methods for three-dimensional printing

• US 9,486,878 B2
• Filed: 06/19/2015
• Issued: 11/08/2016
• 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): Roe, Jessee
• Assistant Examiner(s): KESSLER, CHRISTOPHER S
• Application Number:
  US14/745,032
• Publication Number:
  US 20150367419A1
• Time in Patent Office: 508 Days
• 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 a powder bed in an enclosure, wherein the powder bed comprises a powder material having an elemental metal, metal alloy, ceramic, or an allotrope of elemental carbon;

(b) directing an energy beam at the powder material along a path to transform at least a portion of the powder material to form a transformed material, which transformed material hardens into a hardened material as part of the three-dimensional object; and

(c) using a heat sink adjacent to an exposed surface of the powder bed to remove thermal energy from the powder bed, wherein during removal of thermal energy from the powder bed, the heat sink is separated from the exposed surface by a gap, wherein the exposed surface of the powder bed is a top surface of the powder bed, and wherein a relative position of the heat sink with respect to the powder bed is adjustable while directing the energy beam at the powder material along the path.

2. The method of claim 1, wherein the gap is at a spacing between the heat sink and the top surface that is less than or equal to 50 millimeters.

3. The method of claim 1, wherein the transformed material is formed by fusing individual particles of the powder material.

4. The method of claim 3, wherein fusing comprises sintering, melting or binding the individual particles.

5. The method of claim 1, wherein the energy beam comprises an electromagnetic beam or a charged particle beam.

6. The method of claim 5, the energy beam comprises an electromagnetic beam that includes a laser beam.

7. The method of claim 1, further comprising disposing the heat sink within a path of the energy beam that extends from an energy source to the powder bed.

8. The method of claim 7, wherein the directing comprises directing the energy beam from the energy source to the powder bed through at least one opening disposed in the heat sink.

9. The method of claim 1, wherein the gap comprises a gas.

10. The method of claim 1, further comprising controlling a vacuum pressure in the enclosure.

11. The method of claim 10, further comprising controlling the vacuum pressure in the enclosure such that the vacuum pressure is at least 10′

Torr.

12. The method of claim 1, further comprising thermally coupling the heat sink to the powder bed through the gap.

13. The method of claim 1, further comprising adjusting the gap between the heat sink and the exposed surface.

14. The method of claim 13, wherein (c) comprises bringing the heat sink adjacent to the exposed surface of the powder bed to remove thermal energy from the powder bed, and regulating a spacing of the gap based on an energy level of the energy beam that is sufficient to transform the at least a portion of the powder material.

15. The method of claim 13, wherein (c) comprises bringing the heat sink adjacent to the exposed surface of the powder bed to remove thermal energy from the powder bed, and regulating at least one of (i) the gap and (ii) the energy source, to provide an energy level that is sufficient for generating the three-dimensional object at a deviation from a model of the three-dimensional object that is less than or equal to the sum of 25 micrometers and one thousandths of the fundamental length scale of the three-dimensional object.

16. The method of claim 1, wherein the heat sink facilitates removal of the thermal energy from the powder bed via conductive heat transfer.

17. The method of claim 1, further comprising cleaning the heat sink by using a cleaning member that removes the powder material or debris from a surface of the heat sink.

18. The method of claim 17, wherein cleaning the heat sink comprises rotating a brush.

19. The method of claim 17, wherein cleaning comprises using an opening port of the cleaning member.

20. The method of claim 1, further comprising reducing or preventing absorption of the powder material or debris on at least one surface of the heat sink using an anti-stick layer that forms a coating on the at least one surface of the heat sink.

21. The method of claim 1, further comprising collecting a remainder of the powder material or debris from the heat sink and/or the powder bed.

22. The method of claim 21, wherein the collecting comprises using negative pressure.

23. The method of claim 1, wherein upon formation of the hardened material, at least 30 percent of the heat removal occurs from the top surface of the powder bed using the heat sink.

24. The method of claim 1, wherein the heat sink is disposed above the exposed surface of the powder bed.

25. The method of claim 1, further comprising, after (b), cooling using a cooling member that cools by mechanical contact, wherein the cooling member is disposed outside of the enclosure.

26. The method of claim 25, wherein cooling using the cooling member comprises active cooling using a coolant.

27. The method of claim 25, wherein cooling using the cooling member comprises using a cooling liquid.

28. The method of claim 1, further comprising adjusting the relative position of the heat sink with respect to the powder while directing the energy beam at the powder material along the path.

29. The method of claim 1, wherein the relative position of the heat sink with respect to the powder bed is adjustable by tracking the path.