Method of applying multiple materials with selective laser melting on a 3D article
First Claim
1. A method for manufacturing an article formed of at least a first metallic powder material and a second material, in accordance with three-dimensional CAD data of a model of the article, including CAD cross-sectional data of said model, the method comprising forming the article by:
- depositing layers of the first metallic powder material, including successively depositing several layers of the first metallic powder material one on top of the other, and heating each layer of first metallic powder material to a specified temperature with a focused laser or electron beam applied to a given area corresponding to a selected cross-sectional area of the model, said heating performed before depositing a next layer, wherein said heating comprises guiding the beam over each layer of first metallic powder material in accordance with the CAD cross-sectional data of the selected cross-sectional area of the model so that each layer of powder is fixed to the layer below;
directly applying at least one tape, sheet or foil, of the second material to the first material of the article, the second material being different from the material of the first metallic powder and the at least one tape, sheet or foil having a varying thickness over at least one of a width or length of the at least one tape, sheet, or foil; and
heating the second material with a focused laser or electron beam to a specified temperature such that the at least one tape, sheet or foil, is made molten by the laser or electron beam, wherein the focused beam is applied to a given area corresponding to a selected cross-sectional area of the model to form a new layer of second material on the article.
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Accused Products
Abstract
In a method for manufacturing an article (1), particularly a prototype of a product or component, a tool prototype or spare part, by using selected laser melting, for the application onto the article (1) of a layer (13) or portion of a second metallic material, which is different from the material of the first metallic powder (4), a tape (12), sheet (14), foil or three-dimensional pre-form (18) of a second material is applied to the article (1) and is heated by a focused laser or electron beam (6) to a specified temperature such that the tape (12), sheet (14), foil or pre-form, respectively, are made molten by the electron laser beam (6), wherein the focused beam (6) is applied to a given area corresponding to a selected cross-sectional area of the model of the article (1) under formation of a new layer or part made of second material integral with the article (1).
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Citations
17 Claims
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1. A method for manufacturing an article formed of at least a first metallic powder material and a second material, in accordance with three-dimensional CAD data of a model of the article, including CAD cross-sectional data of said model, the method comprising forming the article by:
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depositing layers of the first metallic powder material, including successively depositing several layers of the first metallic powder material one on top of the other, and heating each layer of first metallic powder material to a specified temperature with a focused laser or electron beam applied to a given area corresponding to a selected cross-sectional area of the model, said heating performed before depositing a next layer, wherein said heating comprises guiding the beam over each layer of first metallic powder material in accordance with the CAD cross-sectional data of the selected cross-sectional area of the model so that each layer of powder is fixed to the layer below; directly applying at least one tape, sheet or foil, of the second material to the first material of the article, the second material being different from the material of the first metallic powder and the at least one tape, sheet or foil having a varying thickness over at least one of a width or length of the at least one tape, sheet, or foil; and heating the second material with a focused laser or electron beam to a specified temperature such that the at least one tape, sheet or foil, is made molten by the laser or electron beam, wherein the focused beam is applied to a given area corresponding to a selected cross-sectional area of the model to form a new layer of second material on the article. - View Dependent Claims (2, 3, 4, 5, 6, 7, 8, 9, 10, 11, 12, 13, 14, 15, 16)
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17. A method for manufacturing an article formed of at least a first metallic powder material and a second material in accordance with three-dimensional CAD data of a model of the article, including CAD cross-sectional data of said model, the method comprising forming the article by:
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depositing layers of the first metallic powder material, including successively depositing several layers of the first metallic powder material one on top of the other, and heating each layer of first metallic powder material to a specified temperature with a focused laser or electron beam applied to a given area corresponding to a selected cross-sectional area of the model, said heating performed before depositing a next layer, wherein said heating comprises guiding the beam over each layer of first metallic powder material in accordance with the CAD cross-sectional data of the selected cross-sectional area of the model so that each layer of powder is fixed to the layer below; directly applying at least two tapes, sheets, or foils of the second material to the first metallic powder material of the article in a same layer, the second material being different from the material of the first metallic powder and at least one of the at least two tapes, sheets, or foils having a thickness of a width or length that varies from a thickness of a width or length of the other of the at least two tapes, sheets, or foils arranged in the same layer; and heating the second material with a focused laser or electron beam to a specified temperature such that the at least two tapes, sheets, or foils is made molten by the laser or electron beam, wherein the focused beam is applied to a given area corresponding to a selected cross-sectional area of the model to form a new layer of second material on the article.
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Specification