Systems for three-dimensional printing

• US 9,586,290 B2
• Filed: 03/30/2016
• Issued: 03/07/2017
• Est. Priority Date: 06/20/2014
• Status: Active Grant

• Current Assignee: Velo3D, Inc.
• Original Assignee: Velo3D, Inc.
• Inventors: Buller, Benyamin, Milshtein, Erel, Seelinger, Sherman
• Primary Examiner(s): NGUYEN, PHUONG T
• Application Number:
  US15/085,884
• Publication Number:
  US 20160207109A1
• Time in Patent Office: 342 Days
• Field of Search: 219/121.63, 219/121.64, 219/121.83, 219/121.84, 219/121.85, 219/121.86, 219/74, 118/56, 118/57, 118/100, 118/120, 118/300, 118/308, 118/310, 118/612, 419/2, 419/7, 419/36, 419/27, 419/54
• 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 system for forming a three-dimensional object, comprising:

a powder dispenser that dispenses a powder material to form at least a portion of a powder bed comprising a first exposed surface, which powder bed is adjacent to the powder dispenser that is laterally translatable with respect to the powder bed;

a powder removal member that is disposed above the powder bed and is laterally translatable with respect to the powder bed, wherein the powder removal member planarizes the first exposed surface of the powder bed by removing powder material from the powder bed with the aid of one or more of a magnetic force, electrostatic force, and gas flow, to provide a second exposed surface that is planar, wherein the powder removal member comprises an opening for removing powder material from the powder bed;

an energy source that provides an energy beam that is directed towards the powder bed, which energy beam transforms a portion of the powder bed to form a transformed material as part of the three-dimensional object;

a recycling system disposed adjacent to the powder bed, wherein the recycling system recycles the powder material received from the powder removal member; and

a controller operatively coupled to the powder removal member, wherein the controller is at least programmed to direct the powder removal member to form the planar second exposed surface by substantially removing the powder material that is above the second exposed surface.

2. The system of claim 1, wherein the powder removal member levels the first exposed surface of the powder bed without contacting the first exposed surface.

3. The system of claim 1, wherein the powder removal member levels the exposed surface of the powder bed with the aid of the gas flow that is generated by vacuum.

4. The system of claim 1, wherein the opening is an elongated opening.

5. The system of claim 1, wherein the opening is part of a nozzle.

6. The system of claim 5, wherein the nozzle is a Venturi type nozzle.

7. The system of claim 5, wherein the powder removal member further comprises a narrowing chamber that is (i) different from the nozzle and (ii) flowably connected to the nozzle.

8. The system of claim 7, wherein the narrowing chamber has a conical cross section.

9. The system of claim 5, wherein the powder removal member collects powder material that enters through the nozzle.

10. The system of claim 1, wherein the powder removal member comprises a curved surface that collects powder material that enters the powder removal member.

11. The system of claim 1, wherein the gas flow comprises laminar gas flow.

12. The system of claim 1, wherein the powder dispenser is connected to the powder removal member.

13. The system of claim 1, wherein the controller is programmed to control an amount of force exerted by the powder removal member.

14. The system of claim 1, wherein the controller is programmed to control the gas flow or translational motion of the powder removal member relative to the powder bed.

15. The system of claim 1, wherein the powder removal member is directly adjacent to the powder bed.

16. The system of claim 1, wherein the powder removal member planarizes the first exposed surface of the powder bed by directly removing powder material from the powder bed.

17. A system for forming a three-dimensional object, comprising:

a powder dispenser that dispenses a powder material to form at least a portion of a powder bed adjacent to the powder dispenser, which powder bed comprises a first exposed surface;

a powder removal member disposed above the powder bed and separated from the exposed surface of the powder bed by a gap, wherein the powder removal member planarizes the first exposed surface of the powder bed by removing powder material from the powder bed with the aid of one or more of a magnetic force, electrostatic force, and gas flow, to provide a second exposed surface that is planar, which powder removal member comprises an opening for removing powder material from the powder bed;

an energy source that provides an energy beam that is directed towards the powder bed, which energy beam transforms a portion of the powder bed to form a transformed material as part of the three-dimensional object;

a recycling system disposed adjacent to the powder bed, wherein the recycling system recycles the powder material received from the powder removal member; and

a controller operatively coupled to the powder removal member, wherein the controller is at least programmed to direct the powder removal member to form the planar second exposed surface by substantially removing the powder material that is above the second exposed surface.

18. The system of claim 17, wherein the gap is dimensioned to permit removal of the powder material from the powder bed to form the second exposed surface.

19. The system of claim 17, further comprising a powder leveling member adjacent to the powder bed and configured to shear the first exposed surface of the powder bed to form a third exposed surface of the powder bed, wherein the powder leveling member comprises a blade, and wherein the gap is disposed between the third exposed surface of the powder bed and a point above the blade.

20. The system of claim 17, wherein the powder removal member planarizes the first exposed surface of the powder bed by directly removing powder material from the powder bed.

21. A system for forming a three-dimensional object, comprising:

a powder dispenser that dispenses a powder material to form at least a portion of a powder bed adjacent to the powder dispenser, which powder bed comprises a first exposed surface;

a powder removal member disposed above the powder bed, wherein the powder removal member planarizes the first exposed surface of the powder bed by removing powder material from the powder bed with the aid of one or more of a magnetic force, electrostatic force, and gas flow, to provide a second exposed surface that is planar, which powder removal member comprises an opening for removing powder material from the powder bed;

a powder reservoir that is (i) flowably connected to the powder removal member and (ii) accepts powder material from the powder removal member, which powder reservoir comprises an opening that allows continuous removal of powder material from the powder reservoir during operation of the powder removal member;

an energy source that provides an energy beam that is directed towards the powder bed, which energy beam transforms a portion of the powder bed to form a transformed material as part of the three-dimensional object;

a recycling system disposed adjacent to the powder bed, wherein the recycling system recycles the powder material received from the powder removal member; and

a controller operatively coupled to the powder removal member, wherein the controller is at least programmed to direct the powder removal member to form the planar second exposed surface by substantially removing the powder material that is above the second exposed surface.

22. The system of claim 21, wherein the powder reservoir is disposed within the powder removal member.

23. The system of claim 21, wherein the powder reservoir comprises a curved surface.

24. The system of claim 21, wherein the powder removal member planarizes the first exposed surface of the powder bed by directly removing powder material from the powder bed.

25. A system for forming a three-dimensional object, comprising:

a powder dispenser that dispenses a powder material to form at least a portion of a powder bed adjacent to the powder dispenser, which powder bed comprises a first exposed surface;

a powder leveling member disposed adjacent to the first exposed surface of the powder bed, wherein the powder leveling member shears the first exposed surface of the powder bed to form a second exposed surface, wherein the powder leveling member comprises a scoop or lift;

a powder removal member disposed adjacent to the powder bed, wherein the powder removal member planarizes the second exposed surface of the powder bed by removing powder material from the powder bed with the aid of one or more of a magnetic force, electrostatic force, and gas flow, to provide a third exposed surface that is planar, which powder removal member comprises an opening for removing powder material from the powder bed;

an energy source that provides an energy beam that is directed towards the powder bed, which energy beam transforms a portion of the powder bed to form a transformed material as part of the three-dimensional object;

a recycling system disposed adjacent to the powder bed, wherein the recycling system recycles the powder material received from the powder removal member; and

a controller operatively coupled to the powder removal member, wherein the controller is at least programmed to direct the powder removal member to form the planar second exposed surface by substantially removing the powder material that is above the second exposed surface.

26. The system of claim 25, wherein at least one of the powder dispenser, the powder leveling member, and the powder removal member is disposed above the powder bed.

27. The system of claim 25, wherein the scoop or lift is part of a blade that is laterally translatable with respect to the powder bed.

28. The system of claim 27, wherein the blade is at an obtuse positive angle with respect to a direction of translation of the blade.

29. The system of claim 25, wherein the powder removal member planarizes the second exposed surface of the powder bed by directly removing powder material from the powder bed.