Apparatuses, systems and methods for three-dimensional printing

• US 9,573,193 B2
• Filed: 12/11/2015
• Issued: 02/21/2017
• 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:
  US14/967,118
• Publication Number:
  US 20160121399A1
• Time in Patent Office: 438 Days
• Field of Search: 219/121.16, 219/121.17, 219/121.65, 219/121.66, 219/121.37, 219/121.38, 2191216-12162, 219/121.85, 264/255, 264/308, 264/497, 148/513, 148/514, 148/516, 148/525, 419/1, 419/25, 425/174.4, 430/269, 700/98, 700/119, 700/120, 757/65, 757/69
• 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. An apparatus for forming a three-dimensional object, comprising a controller that is programmed to:

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

(b) direct an energy beam generated by an energy source to the powder bed to transform at least a portion of the powder material to a transformed material that subsequently hardens to yield the three-dimensional object, wherein the energy beam is operatively coupled to the controller; and

(c) direct a cooling member disposed adjacent to at least one of the first layer and 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 vertical direction of the energy beam, wherein upon removal of thermal energy the transformed material solidifies to form at least a portion of the three-dimensional object, and wherein the cooling member is operatively coupled to the controller.

2. The apparatus of claim 1, 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 the energy beam, which energy beam has a first energy per unit area (S₁), and (2) use the cooling member 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.

3. The apparatus of claim 1, wherein the controller is programmed to control an average temperature of the second layer of powder material.

4. The apparatus 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.

5. The apparatus of claim 1, wherein the cooling member is movable, and wherein the controller is programmed to direct movement of the cooling member.

6. The apparatus of claim 5, wherein the cooling member is movable to or from a position that is between the energy source and the powder bed.

7. The apparatus of claim 1, wherein the cooling member is separated from the powder bed by a gap.

8. The apparatus of claim 7, wherein the gap is at a spacing between the cooling member and an exposed surface of the powder bed, which spacing is less than or equal to about 50 millimeters.

9. The apparatus of claim 7, wherein the gap is at an adjustable spacing between the cooling member and the powder bed.

10. The apparatus of claim 9, wherein the controller is programmed to regulate the adjustable spacing.

11. The apparatus of claim 1, wherein the controller comprises a multi core processor.

12. An apparatus for forming a three-dimensional object, comprising:

(a) a powder bed;

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

(c) an energy source that provides an energy beam to the powder bed, which energy beam transforms at least a portion of the powder bed to a transformed material that subsequently hardens to yield the three-dimensional object, wherein the energy beam is disposed adjacent to the powder bed; and

(d) a first cooling member that removes 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 vertical direction of the energy beam wherein upon removal of thermal energy, the transformed material solidifies to form at least a portion of the three-dimensional object, and wherein the cooling member is disposed adjacent to the first layer or the second layer.

13. The apparatus of claim 12, wherein the first cooling member comprises a material with a thermal conductivity of at least about 20 Watts per meter per degree Kelvin (W/mK).

14. The apparatus of claim 12, wherein the first cooling member is disposed above the exposed surface of the powder bed.

15. The apparatus of claim 12, wherein the first cooling member is passive.

16. The apparatus of claim 15, wherein the enclosure further comprises a second cooling member disposed outside of the enclosure, which second cooling member comprises a heat exchanger.

17. The apparatus of claim 16, wherein the second cooling member comprises a cooling liquid.

18. The apparatus of claim 12, wherein the first cooling member cools through mechanical contact.

19. The apparatus of claim 12, wherein the first cooling member is movable to or from a position that is between the energy source and the powder bed.

20. The apparatus of claim 12, wherein the first cooling member is movable.

21. The apparatus of claim 12, wherein the first cooling member is separated from the powder bed by a gap.

22. The apparatus of claim 21, wherein the gap is at a spacing between the heat sink and an exposed surface of the powder bed, which spacing is less than or equal to about 50 millimeters.

23. The apparatus of claim 21, wherein the gap is at an adjustable spacing between the cooling member and the powder bed.

24. The apparatus of claim 12, wherein the first cooling member further comprises a cleaner that removes the powder material or debris from a surface of the heat sink, wherein the cleaner is located adjacent to the cooling member.

25. The apparatus of claim 12, further comprising a collector that collects at least one of a remainder of the powder material and debris from the first cooling member or from the powder bed, wherein the collector is located adjacent to the cooling member.