Method for additive manufacturing

• US 9,789,563 B2
• Filed: 11/19/2014
• Issued: 10/17/2017
• Est. Priority Date: 12/20/2013
• Status: Active Grant

• Current Assignee: Arcam Ab (Danaher Corporation)
• Original Assignee: Arcam Ab (Danaher Corporation)
• Inventors: Elfstroem, Isak, Hellestam, Calle, Fager, Mattias
• Primary Examiner(s): Heinrich, Samuel M
• Application Number:
  US14/547,538
• Publication Number:
  US 20150174695A1
• Time in Patent Office: 1,063 Days
• Field of Search: 21912113, 21912114, 21912116, 21912117, 21912135, 21912163-12166, 21912185
• CPC Class Codes: B22F 10/28 Powder bed fusion, e.g. selective laser melting [SLM] or electron beam melting [EBM]
• CPC Class Codes: B22F 12/30 Platforms or substrates
• CPC Class Codes: B22F 12/44 characterised by the configuration of the radiation means
• CPC Class Codes: B22F 12/52 Hoppers
• CPC Class Codes: B22F 12/84 Parallel processing within single device
• CPC Class Codes: B22F 12/90 Means for process control, e.g. cameras or sensors
• CPC Class Codes: B23K 15/0086 welding for purposes other than joining, e.g. built-up welding
• CPC Class Codes: B23K 15/02 Control circuits therefor
• CPC Class Codes: B23K 15/10 Non-vacuum electron beam-welding or cutting
• CPC Class Codes: B23K 26/08 Devices involving relative movement between laser beam and workpiece
• 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 64/182 in parallel batches
• CPC Class Codes: B29C 64/393 for controlling or regulating additive manufacturing processes
• CPC Class Codes: Y02P 10/25 Process efficiency

Abstract

The invention relates to a method for forming a three-dimensional article through successive fusion of locations of a powder bed. The method comprising: providing a model of said three-dimensional article; applying a powder layer on a work table; determining a maximum scan length of an energy beam; directing said energy beam from a first energy beam source over said work table with constant energy causing said first powder layer to fuse in first selected locations according to said model to form a first cross section of said three-dimensional article, wherein locations with a shorter scan length than said maximum scan length is provided with a time sink before and/or after said scan line so that the time period between each two adjacent scan lines is constant throughout the manufacture of said three-dimensional article.

Claims

1. A method for forming a three-dimensional article through successive fusion of locations of a powder bed, which locations correspond to successive cross sections of the three-dimensional article, said method comprising the steps of:

providing a model of said three-dimensional article;

applying a first powder layer on a work table;

determining a maximum scan line time of an energy beam for a first cross section of the three-dimensional article; and

directing said energy beam from a first energy beam source over said work table with a constant energy causing said first powder layer to fuse in first selected locations according to said model to form said first cross section of said three-dimensional article, wherein;

said first energy beam is fusing said selected locations with scan lines in a first direction; and

locations with a shorter scan line time than said maximum scan line time are provided with a time sink at least one of before or after said scan line so that the scan line time plus the time sink is constant for said first cross section of said three-dimensional article.

2. The method according to claim 1, wherein said maximum scan line time for said energy beam is determined for the entire three-dimensional article.

3. The method according to claim 2, wherein said determination of said maximum scan line time is performed before starting the manufacture of the three-dimensional article.

4. The method according to claim 1, wherein said scan line time plus said time sink is constant throughout the three-dimensional article.

5. The method according to claim 1, wherein said scan line time plus said time sink has a first value for a first cross section of said three-dimensional article and said scan line time plus said time sink has a second value for a second cross section of said three-dimensional article, where said first and second values are different.

6. The method according to claim 1, wherein said scan lines in said first direction are at least one of straight or meandering scan lines.

7. The method according to claim 1, wherein every second scan line is in a direction opposite to the other scan lines.

8. The method according to claim 1, further comprising the step of varying the scan speed of at least one scan line.

9. The method according to claim 1, further comprising the step of fixing the scan speed of at least one scan line.

10. The method according to claim 1, wherein said energy beam is switched off during said time sink.

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

setting an energy density per time unit for said energy beam during said time sink to a predetermined level which will leave powder material in a non-sintered and non-fused state; and

directing said energy beam outside said selected locations during said time sink.

12. The method according to claim 11, wherein at least one of said energy beam is defocused, the scanning speed is increased, the power of the energy beam is lowered, or dithering said energy beam occurs during said time sink for leaving said powder material outside said selected locations non-fused and non-sintered.

13. The method according to claim 1, wherein said energy beam is at least one of an electron beam or a laser beam.

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

15. The method according to claim 1, wherein the scan lines in at least one layer of at least a first three-dimensional article are fused with a first energy beam from a first energy beam source and a second energy beam from a second energy beam source.

16. The method according to claim 1, wherein the scan lines in at least one layer of at least a first three-dimensional article are fused with a first energy beam from a first energy beam source and the scan lines in at least one layer of at least a second three-dimensional article are fused with a second energy beam from a second energy beam source.

17. The method according to claim 15, wherein said first energy beam is emanating from a first electron beam source and said second energy beam is emanating from a first laser beam source.

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

19. The method according to claim 15, wherein said first energy beam is emanating from a first laser beam source and said second energy beam is emanating from a second laser beam source.

20. The method according to claim 16, wherein said first and second energy beams are fusing at least one of said first or said second three-dimensional article(s) simultaneously.

21. The method according to claim 1, wherein all scan lines in the three dimensional article are provided with a time sink at least one of before or after the scan line.

22. The method according to claim 1, wherein at least one scan line in the three dimensional article is not provided with a time sink at least one of before or after the scan line.

23. A program element configured and arranged when executed on a computer a method for forming a three-dimensional article through successive fusion of locations of a powder bed, which locations correspond to successive cross sections of the three-dimensional article, said method comprising the steps of:

providing a model of said three-dimensional article;

applying a first powder layer on a work table;

determining a maximum scan length of an energy beam for each cross section of said three-dimensional article; and

directing said energy beam from a first energy beam source over said work table with a constant scan speed and constant energy causing said first powder layer to fuse in first selected locations according to said model to form a first cross section of said three-dimensional article, where said first energy beam is fusing said selected locations with parallel scan lines in a first direction, wherein locations with a shorter scan length than said maximum scan length is provided with a time sink at least one of before or after said scan line so that the time period between each two adjacent scan lines is constant throughout the manufacture of said three-dimensional article.

24. A computer readable medium having stored thereon the program element according to claim 23.

25. A non-transitory computer program product comprising at least one non-transitory computer-readable storage medium having computer-readable program code portions embodied therein, the computer-readable program code portions comprising:

an executable portion configured for, upon receipt of a model of at least one three dimensional article, applying a first powder layer on a work table so as to initiate forming said three-dimensional article through successive fusion of locations of a powder bed, which locations correspond to successive cross sections of the three-dimensional article;

an executable portion configured for determining a maximum scan line time of an energy beam for a first cross section of the three-dimensional article; and

an executable portion configured for directing said energy beam from a first energy beam source over said work table with a constant energy causing said first powder layer to fuse in first selected locations according to said model to form said first cross section of said three-dimensional article, wherein;

said first energy beam is fusing said selected locations with scan lines in a first direction; and

locations with a shorter scan line time than said maximum scan line time are provided with a time sink at least one of before or after said scan line so that the scan line time plus the time sink is constant for said first cross section of said three-dimensional article.