Method for additive manufacturing

• US 9,676,032 B2
• Filed: 08/05/2014
• Issued: 06/13/2017
• Est. Priority Date: 09/20/2013
• Status: Active Grant

• Current Assignee: Arcam Ab (Danaher Corporation)
• Original Assignee: Arcam Ab (Danaher Corporation)
• Inventors: Hellestam, Calle
• Primary Examiner(s): DUNN, COLLEEN P
• Application Number:
  US14/452,294
• Publication Number:
  US 20150086409A1
• Time in Patent Office: 1,043 Days
• Field of Search: None
• CPC Class Codes: B22F 10/28 Powder bed fusion, e.g. selective laser melting [SLM] or electron beam melting [EBM]
• CPC Class Codes: B22F 10/366 Scanning parameters, e.g. hatch distance or scanning strategy
• CPC Class Codes: B22F 10/368 Temperature or temperature gradient, e.g. temperature of the melt pool
• CPC Class Codes: B22F 10/85 for controlling or regulating additive manufacturing processes
• 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: 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 17/0081 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 64/386 Data acquisition or data processing for additive manufacturing
• 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 50/02 for controlling or regulating additive manufacturing processes
• CPC Class Codes: G05B 19/4099 Surface or curve machining, making 3D objects, e.g. desktop manufacturing
• CPC Class Codes: G05B 2219/49023 3-D printing, layer of powder, add drops of binder in layer, new powder
• CPC Class Codes: Y02P 10/25 Process efficiency

Abstract

A method for forming a three-dimensional article comprising applying a first powder layer on a work table; directing a first energy causing said first powder layer to fuse in first selected locations to form a first cross section where said first energy beam is fusing a first region with parallel scan lines in a first direction and a second region with parallel scan lines in a second direction; fusing at least one of the scan lines in said first region in said first direction immediately before fusing at least one of said scan lines in said second region in said second direction; applying a second powder layer and directing the energy beam causing said second powder layer to fuse in second selected locations where the energy beam is fusing said first region with parallel scan lines in a third direction and said second region in a fourth direction.

Claims

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

providing at least one model of said three-dimensional regions;

applying 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 the corresponding at least one model to form a first cross section of said three-dimensional regions, where said first energy beam is fusing a first region with parallel scan lines in a first direction and a second region with parallel scan lines in a second direction;

fusing at least one of said scan lines in said first region in said first direction immediately before fusing at least one of said scan lines in said second region in said second direction;

applying a second powder layer on the at least partially fused first powder layer;

directing the first energy beam over said work table causing said second powder layer to fuse in second selected locations according to the corresponding at least one model to form a second cross section of said three-dimensional regions, where the first energy beam is fusing said first region with parallel scan lines in a third direction and said second region with parallel scan lines in a fourth direction; and

after fusing at least one of said scan lines in said second region in said second direction, fusing at least one of said scan lines in said first region in said third direction immediately before fusing at least one of said scan lines in another region in said fourth direction,

wherein said first and second regions are provided in two separate three-dimensional articles.

2. The method according to claim 1, wherein said another region is said second region.

3. The method according to claim 1, wherein said another region is a third region.

4. The method according to claim 3, wherein said third region is within one of said two separate three-dimensional articles.

5. The method according to claim 3, wherein said third region is provided in a third separate three-dimensional article.

6. The method according to claim 1, wherein said first and second directions are parallel.

7. The method according to claim 1, wherein said third and fourth directions are parallel.

8. The method according to claim 1, wherein at least one of said first or second directions is rotated an angle α

with respect to at least one of said third or fourth directions, where 1°

≦

α

≦

179°

.

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

10. The method according to claim 1, wherein said powder is metallic powder.

11. The method according to claim 1, wherein the scan lines in at least one layer of at least one three-dimensional article are straight lines.

12. The method according to claim 1, wherein the scan lines in at least one layer of at least one three-dimensional region are meandering.

13. The method according to claim 1, wherein the scan lines in at least one layer of the second region are further fused with a second energy beam emanating from a second energy beam source.

14. The method according to claim 13, wherein said first energy beam source is a first electron beam source and said second energy beam source is a first laser beam source.

15. The method according to claim 13, wherein said first energy beam source is a first electron beam source and said second energy beam source is a second electron beam source.

16. The method according to claim 13, wherein said first energy beam source is a first laser beam source and said second energy beam source is a second laser beam source.

17. The method according to claim 13, wherein said first and second energy beams are fusing at least said first and second three-dimensional regions simultaneously.

18. The method according to claim 1, wherein at least one of said first or second directions is rotated a perpendicular angle with respect to at least one of said third or fourth directions.

19. The method according to claim 18, wherein said first direction is perpendicular to said third direction and said second direction is perpendicular to said fourth direction.

20. The method according to claim 1, wherein said powder is selected from a group consisting of metallic powder, polymer powder, and ceramic powder.

21. The method according to claim 1, wherein said steps are performed via a controlling computer.