Method and apparatus for additive manufacturing

• US 9,505,172 B2
• Filed: 11/19/2013
• Issued: 11/29/2016
• Est. Priority Date: 12/17/2012
• Status: Active Grant

• Current Assignee: Arcam Ab (Danaher Corporation)
• Original Assignee: Arcam Ab (Danaher Corporation)
• Inventors: Ljungblad, Ulric
• Primary Examiner(s): Del Sole, Joseph S.
• Assistant Examiner(s): ROBITAILLE, JOHN P
• Application Number:
  US14/443,016
• Publication Number:
  US 20150306819A1
• Time in Patent Office: 1,106 Days
• US Class Current: 1/1
• 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 12/226 for rotary motion
• CPC Class Codes: B22F 12/45 Two or more
• CPC Class Codes: B22F 12/52 Hoppers
• CPC Class Codes: B22F 12/90 Means for process control, e.g. cameras or sensors
• CPC Class Codes: B23P 15/006 turbine wheels
• CPC Class Codes: B23P 6/007 using only additive methods, e.g. build-up welding
• 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: B29C 64/153 using layers of powder being selectively joined, e.g. by selective laser sintering or melting
• CPC Class Codes: B29C 64/241 for rotary motion
• CPC Class Codes: B29C 64/268 using laser beams; using electron beams [EB]
• CPC Class Codes: B29C 64/277 using multiple radiation means, e.g. micromirrors or multiple light-emitting diodes [LED]
• CPC Class Codes: B29C 64/295 Heating elements
• CPC Class Codes: B29C 64/329 using hoppers
• 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: F01D 5/34 Rotor-blade aggregates of unitary construction , e.g. formed of sheet laminae; discs formed of sheet laminae F01D5/028; ceramic materials F01D5/284, composite materials F01D5/282
• CPC Class Codes: F05D 2230/22 by sintering
• CPC Class Codes: F05D 2230/234 Laser welding
• CPC Class Codes: F05D 2230/31 Layer deposition
• CPC Class Codes: Y02P 10/25 : Process efficiency

Abstract

The present invention relates to a method for forming a three-dimensional article through successive fusion of applied powder. Said method comprising the steps of: providing at least one powder hopper comprising powder to be used for forming said three-dimensional article, providing a predetermined amount of powder at a build support, directing an energy beam over said build support causing at least a portion of said powder to sinter and causing at least a portion of said powder to bond to said build support, directing an energy beam over said build support causing said powder to fuse in selected locations according to a model to form a first portion of said three-dimensional article, rotating said build support around an axis of rotation for creating said three-dimensional article, which three-dimensional article is build up layer by layer in a radial direction with respect to said axis of rotation.

Claims

1. A method for forming a three-dimensional article through successive fusion of applied powder, said method comprising the steps of

providing at least one powder hopper comprising powder to be used for forming said three-dimensional article;

providing a predetermined amount of powder at a build support, wherein an axis of rotation of said build support is provided in a horizontal direction;

directing an energy beam over said build support causing at least a portion of said powder to sinter and causing at least a portion of said powder to bond to said build support;

directing an energy beam over said build support causing said powder to fuse in selected locations according to a model to form a first portion of said three-dimensional article;

rotating said build support around said axis of rotation for creating said three-dimensional article, which three-dimensional article is build up layer by layer in a radial direction with respect to said axis of rotation;

providing powder continuously throughout the forming of the three-dimensional article; and

sintering newly applied powder continuously in order to attach said powder on at least one of said build support or a previously manufactured layer of the three-dimensional article.

3. The method according to claim 1, further comprising the step of providing said powder hopper movable in a radial direction with respect to said axis of rotation.

6. The method according to claim 3, further comprising the steps of measuring the distance between said outer surface of said three-dimensional article and said opening of said powder hopper and using said measured distance for moving said powder hopper to a predetermined position.

7. The method according to claim 3, further comprising the steps of calculating the position of said outer surface of said three-dimensional article and using said calculated position for moving said powder hopper to a predetermined position.

9. The method according to claim 1, wherein said energy beam is an electron beam and/or a laser beam.

10. The method according to claim 1, wherein said powder is sintered using at least one electron beam and fused using at least said laser beam.

11. The method according to claim 1, wherein said Powder is sintered using at least one laser beam and fused using at least one electron beam.

12. The method according to claim 1, wherein said powder is sintered using a first electron beam source and fused using at least a second electron beam source.

13. The method according to claim 1, wherein said powder is sintered using a first laser beam source and fused using at least a second laser beam source.

14. The method according to claim 1, further comprising the step of refocusing the electron beam and/or the laser beam as the three dimensional article is expanding in a radial direction.

15. The method according to claim 1, further comprising the step of:

moving the electron beam source in a radial direction as the three dimensional article is expanding in said radial direction for keeping the distance between the electron beam source with respect to atop surface of the three-dimensional article at a constant value.

16. The method according to claim 1, further comprising the step of:

moving at least one focusing lens element in a radial direction as the three-dimensional article is expanding in said radial direction for keeping the focal point of the beam source at a top surface of the three-dimensional article.

17. The method according to claim 1, further comprising the step of providing at least one heat source for maintaining the heat of the manufactured three-dimensional article.

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

providing at least a first energy beam source at a first position having a variable distance of focus at a first interval from a centre of said axis of rotation, providing at least a second energy beam source at a second position having a variable distance of focus at a second interval from a centre of said axis of rotation, switching from said at least first energy beam source to said at least second energy beam source when said three-dimensional article has expanded a predetermined distance from said centre of said axis of rotation.

19. The method according to claim 1, wherein-said fusing of a predetermined amount of powder is taking place less than one revolution of said rotation after said sintering of the same predetermined amount of powder has taken place.

20. The method according to claim 1, further comprising the step of providing a first and a second powder compressor in between which said powder is provided on said build support, wherein said first and second powder compressor are separated with a distance T defining the thickness of the three-dimensional article.

21. The method according to claim 20, further comprising the step of attaching said at least one of said first or second powder compressor on said powder hopper.

22. The method according to claim 1, further comprising the step of scanning the laser beam and/or the electron beam in a direction parallel to the axis of rotation.

23. The method according to claim 17, further comprising the step of switching the power on or off for said laser beam source or electron beam source.

24. The method according to claim 1, further comprising the step of rotating said build support continuously or stepwise.

25. The method according to claim 1, further comprising the step of providing said at least one powder hopper and said build support inside a vacuum chamber.

26. The method according to claim 1, further comprising the step of arranging said build support movable in a vertical direction.

2. A method for forming a three-dimensional article through successive fusion of applied powder, said method comprising the steps of:

providing at least one powder hopper comprising powder to be used for forming said three-dimensional article;

providing a predetermined amount of powder at a build support;

directing an energy beam over said build support causing at least a portion of said powder to sinter and causing at least a portion of said powder to bond to said build support;

directing an energy beam over said build support causing said powder to fuse in selected locations according to a model to form a first portion of said three-dimensional article; and

rotating said build support around an axis of rotation for creating said three-dimensional article, which three-dimensional article is build up layer by layer in a radial direction with respect to said axis of rotation,

wherein at least one of;

said powder is sintered using at least one electron beam and fused using at least said laser beam;

said powder is sintered using at least one laser beam and fused using at least one electron beam;

said powder is sintered using a first electron beam source and fused using at least a second electron beam source;

or

said powder is sintered using a first laser beam source and fused using at least a second laser beam source.

4. The method according to claim 2, further comprising the step of keeping a distance between an opening of said powder hopper and an outer surface of said three-dimensional article at constant predetermined value for allowing a predetermined amount of powder to exit from said powder container onto said outer surface of said three-dimensional article.

5. The method according to claim 2, further comprising the step of varying a distance between an opening of said powder hopper and an outer surface of said three-dimensional article for allowing a varying amount of powder to exit from said powder container onto said outer surface of said three-dimensional article.

8. The method according to claim 2, further comprising the step of providing said axis of rotation of said build support in a horizontal direction.

27. An apparatus for forming a three-dimensional article through successive fusion of parts of applied powder, said apparatus comprising:

at least one powder hopper comprising powder to be used for forming said three-dimensional article;

means for providing a predetermined amount of powder on a build support, wherein an axis of rotation of said build support is provided in a horizontal direction;

means for directing an energy beam over said build support causing at least a portion of said powder to sinter and causing at least a portion of said powder to bond to said build support;

means for directing an energy beam over said build support causing said powder to fuse in selected locations according to a model to form a first portion of said three-dimensional article; and

a motor for rotating said build support around said axis of rotation for creating said three-dimensional article, which three-dimensional article is build up layer by layer in a radial direction with respect to said axis of rotation,

wherein powder is provided continuously throughout the forming of the three-dimensional article, and newly applied powder is sintered continuously in order to attach said powder on said build support or a previously manufactured layer of the three-dimensional article.

29. The apparatus according to claim 27, wherein said apparatus further comprising means for providing said powder hopper movable in a radial direction for keeping a distance between said powder hopper and an outer surface of said three-dimensional article at a constant predetermined value.

31. The apparatus according claim 27, wherein at least an electron beam is used for sintering said powder and at least a laser beam is used for fusing said powder.

32. The apparatus according to claim 27, wherein at least a laser beam is used for sintering said powder and at least an electron beam is used for fusing said powder.

33. The apparatus according to claim 27, wherein at least a first electron beam source is used for sintering said powder and at least a second electron beam source is used for fusing said powder.

34. The apparatus according claim 27, wherein at least a first laser beam source is used for sintering said powder and at least a second laser beam source is used for fusing said powder.

35. The apparatus according to claim 27, wherein at least one heat source is provided for maintaining the heat of the manufactured three-dimensional article.

36. The apparatus according to claim 35, wherein said heat source is an IR heater.

37. The apparatus according to claim 27, wherein a first energy beam source is provided at a first position having a variable distance of focus at a first interval from a centre of said axis of rotation, at least a second energy beam source is provided at a second position having a variable distance of focus at least a second interval from a centre of said axis of rotation, a switch for switching from said first energy beam source to said at least second energy beam source when said three-dimensional article has expanded a predetermined distance from said centre of said axis of rotation.

38. The apparatus according to claim 27, wherein a first and a second powder compressor are arranged on said powder hopper essentially in parallel with a radial direction to said radial direction of said axis of rotation, where said powder is provided in between said first and second powder compressor.

39. The apparatus according to claim 27, further comprising means for refocusing the electron beam and/or the laser beam as the three dimensional article is expanding.

40. The apparatus according to claim 27, wherein the electron beam source is movable in a radial direction for keeping a distance between the electron beam source with respect to a top surface of the three dimensional article at a constant value.

41. The apparatus according to claim 27, wherein at least one focusing lens element is arranged movable in a radial direction for keeping a focal point of said laser beam source at a top surface of the three dimensional article.

42. The apparatus according to claim 27, wherein said build support is arranged movable in a vertical direction.

28. An apparatus for forming a three-dimensional article through successive fusion of parts of applied powder, said apparatus comprising:

at least one powder hopper comprising powder to be used for forming said three-dimensional article;

means for providing a predetermined amount of powder on a build support;

means for directing an energy beam over said build support causing at least a portion of said powder to sinter and causing at least a portion of said powder to bond to said build support;

means for directing an energy beam over said build support causing said powder to fuse in selected locations according to a model to form a first portion of said three-dimensional article; and

a motor for rotating said build support around said axis of rotation for creating said three-dimensional article, which three-dimensional article is build up layer by layer in a radial direction with respect to said axis of rotation,

wherein at least one of;

at least an electron beam is used for sintering said powder and at least a laser beam is used for fusing said powder;

at least a laser beam is used for sintering said powder and at least an electron beam is used for fusing said powder;

at least a first electron beam source is used for sintering said powder and at least a second electron beam source is used for fusing said powder;

or

at least a first laser beam source is used for sintering said powder and at least a second laser beam source is used for fusing said powder.

30. The apparatus according to claim 28, wherein said axis of rotation is arranged in a horizontal plane.