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Additive manufacturing of three-dimensional articles

  • US 9,919,361 B2
  • Filed: 03/06/2017
  • Issued: 03/20/2018
  • Est. Priority Date: 12/16/2013
  • Status: Active Grant
First Claim
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1. A method for forming a three-dimensional article through successively depositing individual layers of powder material that are fused together so as to form the article, said method comprising the steps of:

  • i) providing at least one electron beam source emitting an electron beam for at least one of heating or fusing said powder material, where said electron beam source comprises a cathode, an anode, and a grid between said cathode and anode;

    ii) controlling the electron beam source in at least two modes during said formation of said three dimensional article, the at least two modes comprising a first mode and a second mode;

    iii) applying a predetermined accelerator voltage between said cathode and said anode;

    iv) applying at least one of a predetermined number of different grid voltages between said grid and said cathode for producing a corresponding predetermined number of electron beam current values while the electron beam source is in the first mode;

    v) while applying the at least one of the predetermined number of different grid voltages, fusing the powder material;

    vi) measuring an electron beam current during the second mode of the at least two modes;

    vi) at least one of creating or updating a look-up table or mathematical function during the second mode of the at least two modes based on the measured electron beam current, wherein said look-up table or mathematical function defines a relationship between a desired electron beam current and an applied grid voltage; and

    vii) subsequent to creating or updating the look-up table or mathematical function, repeating steps iv-v, wherein the at least one of the predetermined number of different grid voltages is selected from the look-up table or mathematical function.

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