Method and apparatus for producing three-dimensional objects

• US 9,782,933 B2
• Filed: 02/10/2015
• Issued: 10/10/2017
• Est. Priority Date: 01/03/2008
• Status: Active Grant

• Current Assignee: Arcam Ab (Danaher Corporation)
• Original Assignee: Arcam Ab (Danaher Corporation)
• Inventors: Jonasson, Daniel, Larsson, Morgan, Ackelid, Ulf, Snis, Anders, Lock, Tomas
• Primary Examiner(s): Daniels, Matthew
• Assistant Examiner(s): Shafi, Leith S
• Application Number:
  US14/618,748
• Publication Number:
  US 20150151490A1
• Time in Patent Office: 973 Days
• Field of Search: 425174, 4251744, 4251746, 4251748 R, 4251748 E, 264400, 264497, 264406-412
• CPC Class Codes: B22F 10/20 Direct sintering or melting
• CPC Class Codes: B22F 10/36 of energy beam parameters
• CPC Class Codes: B22F 12/57 Metering means
• CPC Class Codes: B22F 12/90 Means for process control, e.g. cameras or sensors
• CPC Class Codes: B22F 2203/03 for feed-back
• CPC Class Codes: B22F 2999/00 Aspects linked to processes or compositions used in powder metallurgy
• 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 64/268 using laser beams; using electron beams [EB]
• CPC Class Codes: B29C 64/393 for controlling or regulating additive manufacturing processes
• CPC Class Codes: B29L 2009/00 Layered products
• CPC Class Codes: B33Y 30/00 Apparatus for additive manufacturing; Details thereof or accessories therefor
• CPC Class Codes: Y02P 10/25 Process efficiency

Abstract

The invention concerns an apparatus (1) for producing three-dimensional objects (6) layer by layer using a powdery material which can be solidified by irradiating it with a beam (4) of charged particles, said apparatus (1) comprising means for successive application of powder layers to a work table, and a radiation gun (3) for delivering said beam (4) of charged particles, wherein the inventive apparatus (1) comprises a powder-lifting detection device (10, 10a, 10b, 10c, 10d, 10e) capable of generating a signal (S) upon detection of lifting of powdery material from the working area (5).

Claims

1. An apparatus for producing three-dimensional objects layer by layer using a powdery material which can be solidified by irradiating the powdery material with a beam of charged particles, said apparatus comprising:

a powder supply portion configured for successive application of one or more layers of a powdery material to a work table to define a powder bed;

a radiation gun configured for delivering said beam of charged particles and successively irradiating at least a part of the working area where the powdery material are applied, so as to fuse together successive layers of said three-dimensional object; and

at least one detection device having a field of view focused above and across the work table on a volume spaced apart from the defined powder bed, such that neither the field of view nor the focused volume intersect any portion of the powder bed,

wherein the at least one detection device is configured for;

generating a powder-lifting detection signal upon detection of at least a portion of said powdery material having lifted from the working area and moving around above and spaced apart from the defined powder bed; and

based upon the generated detection signal, automatically interrupting the irradiation of at least a part of the working area where the powdery material lifting has occurred.

2. The apparatus according to claim 1, wherein the detection signal created by the at least one detection device is used for automatically triggering interruption of the irradiation of at least a part of the working area where powder lifting occurs.

3. The apparatus according to claim 1, wherein the at least one detection device comprises a powder-lifting detection unit that is configured for generating a primary signal that varies with varying amounts of powder particles being detected moving around above and spaced apart from the defined powder bed.

4. The apparatus according to claim 1, wherein the at least one detection device comprises a capacitor having two plates over which a voltage is applied.

5. The apparatus according to claim 1, wherein the at least one detection device comprises a conductive cup and an electronic component configured for measuring a current and producing the detection signal.

6. The apparatus according to claim 1, wherein the at least one detection device comprises a camera directed at an angle relative to the working area.

7. The apparatus according to claim 6, wherein the at least one detection device further comprises an image processing unit configured for analyzing a signal from the camera so as to determine whether powder-lifting occurs, and based upon detection thereof, to generate the detection signal.

8. The apparatus according to claim 1, wherein the at least one detection device comprises an X-ray detector with a field of view directed above and across the working area.

9. The apparatus according to claim 1, wherein:

the at least one detection device comprises a laser source configured for generating a laser beam directed above and across the working area; and

said detection of said powder lifting is based upon at least one of a detection of a decrease in an intensity of the laser beam or an increase in a scattering of the laser beam.

10. The apparatus according to claim 1, wherein:

the at least one detection device comprises a first detection device that is sensitive to powder-lifting events and configured for generating the powder-lifting detection signal;

the apparatus further comprises a second detection device, the second detection device being insensitive to powder-lifting events; and

wherein a difference signal from the first and second detection devices is used for generating the detection signal.

11. The apparatus according to claim 10, wherein the second detection device comprises a capacitor having two plates over which a voltage is applied.

18. The apparatus according to claim 1, wherein the at least one detection device is positioned such that the field of view is focused along a plane parallel to the defined powder bed.

19. The apparatus according to claim 2, wherein the at least one detection device is positioned such that the field of view is focused along a plane parallel to the defined powder bed.

12. An apparatus for producing three-dimensional objects layer by layer using a powdery material which can be solidified by irradiating the powdery material with a beam of charged particles, said apparatus comprising:

a powder supply portion configured for successive application of powder layers to a work table to define a powder bed;

a radiation gun for delivering said beam of charged particles; and

at least one detection device having a field of view focused above and across the work table on a volume spaced apart from the defined powder bed, such that neither the field of view nor the focused volume intersect any portion of the powder bed,

wherein the at least one detection device is configured for generating a detection signal upon detection of at least a portion of powdery material having lifted from the working area and moving around above and spaced apart from the defined powder bed.

13. The apparatus according to claim 12, wherein the detection signal created by the detection device is used for automatically triggering interruption of the irradiation of at least a part of the working area where powder lifting occurs.

14. The apparatus according to claim 12, wherein the detection device comprises a detection unit that is configured for generating a primary signal that varies with varying amounts of powder particles present at least one of above or beside the working area.

15. The apparatus according to claim 12, wherein the detection device comprises a capacitor having two plates over which a voltage is applied.

16. The apparatus according to claim 12, wherein:

the at least one detection device comprises a first detection device that is sensitive to powder-lifting events and configured for generating the powder-lifting detection signal;

the apparatus further comprises a second detection device, the second detection device being insensitive to powder-lifting events; and

wherein a difference signal from the two detection devices is used for generating the detection signal.

17. The apparatus according to claim 16, wherein the second detection device comprises a capacitor having two plates over which a voltage is applied.