CN105579218B - 用于激光烧结系统的改进的粉末分配 - Google Patents
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Abstract
提供用于基于设计数据且由可烧结粉末制造三维物体的激光烧结系统和相应的激光烧结方法,上述激光烧结系统包括:进料斗,用于将可烧结粉末供应到激光烧结系统的构建室;粉末分配装置,用于将可烧结粉末分配在部件床上的层中;以及位于部件床的与进料斗相对置处的返回粉末装置,其中返回粉末装置能选择性地移动以能够使粉末的一部分从粉末分配装置的一侧移送到另一侧。
Description
相关申请的交叉引用
本申请根据美国法典第35卷( 35 U.S.C. )119(e)款要求2013年3月15日提交的系列号为 61/793,870的美国临时申请的优先权。
技术领域
本发明涉及激光烧结系统,更特别地涉及用于提高部件质量并减少丢弃已使用过但未烧结的粉末的激光烧结系统设备和方法。
背景技术
激光烧结是根据数字数据制造三维物体的加法制造的一种形式。如本领域中已知的,激光烧结用激光加热粉末层,典型地为聚合物或金属粉末,以使粉末颗粒以预定图案彼此熔合从而限定正被制造的物体的横截面层。这种技术在美国专利第4,863,538、5,155,321、5,252,264、5,352,405、6,815,636、7,569,174以及 7,807,947中公开,其揭露内容通过引用全部并入本文中。
伴随激光烧结的一个问题是在构建过程中激光衰减,由此在图像平面(可烧结粉末暴露于激光束的表面)处的激光功率发生变化(典型地为减小)。这种激光功率变化可归因于很多问题,并可导致部件从底部到顶部(沿着z轴)为不同颜色、或者沿着z轴具有不同机械性能。
伴随激光烧结、特别是被加热到接近熔点温度的聚合物的激光烧结所伴随的另一问题是,未熔融的可烧结粉末在粉末产生具有非期望质量(例如表面上的“桔皮现象”)、着色或降低的机械性能的部件之前,仅可被再利用一定次数。结果就是,激光烧结机器的操作者必须丢弃一定数量的已使用过的激光烧结粉末以保持部件质量。
发明内容
本发明的多种实施方式解决上述需求,并实现提高部件质量并减少丢弃可烧结粉末的需要的其它优点。本发明的一个实施方式包括用于施加粉末层的方法,以减小可导致降低部件强度或精度并提高层内粉末密度的表面结构的可能性。特定实施方式使用“两次通过(two pass)”途径(也称作“双APL”(APL = Apply Powder Layer,译为APL =施加粉末层))”,从而通过与传统(现有技术)施加粉末层相似地在第一次通过时分配粉末层来铺设单个粉末层(借助于反向旋转的辊子或其它粉末分配装置),但然后与现有技术不同,将辊子以分配余留粉末来填充间隙并使粉末层表面弄平的第二次通过移动回来。为了分配来自第一次通过的余留粉末,将返回粉末装置(例如活塞)设置在部件床(part bed)(对粉末进行激光烧结的区域)的与进料斗沉积粉末之处相对置的侧部上。返回粉末装置降低以容许余留粉末通过辊子下方,并在辊子通过后抬升,使得辊子可分配余留粉末。将在第二次通过之后剩余的任何余留粉末沉积进位于部件床侧部上的粉末返回槽。通过使用双次通过技术,粉末层改善了均匀性并具有更好致密性以用于更精确激光烧结。
本发明的其它实施方式包括激光功率测量装置,所述激光功率测量装置能够测量构建室内的激光功率。典型的激光烧结系统不包括激光功率测量装置(测量只是由维护人员在维护期间完成),或者在激光束进入构建室之前测量激光功率。激光烧结系统的构建室典型地非常热,并且包括可负面影响表面的烟尘。本发明提供位于构建室内的激光功率测量装置以确定输送到粉末层的激光功率,以调整或控制扫描速度和/或其它参数,从而确保输送到可烧结粉末的功率一致,以避免部件质量或精度降低或发生其它变化。在一些实施方式中,激光功率测量装置定位在激光窗下方(典型地位于构建室的激光进入构建室所穿过的顶板上),但位于加热可烧结粉末(主要通过辐射)的加热器上方,使得该装置不阻挡输送到粉末的热和/或变得过热。通过尽可能地使激光功率测量装置移离激光束集中的图像平面,激光不怎么集中,因而感测装置能较好地经受得住激光而不会受到激光负面影响。在一些实施方式中,激光功率测量装置包括可移动镜件,所述可移动镜件从激光扫描区域之外的位置延伸进可将激光引导至镜件从而将激光引导至感测装置的位置。一旦测量完,镜件可缩回离开激光路径。在一些实施方式中,在施加新粉末层期间进行激光功率测量,使得用于部件的构建时间不增加。在其它实施方式中,激光功率测量装置是位于可移动(例如可转动的)臂上的传感器,所述传感器可选择性地定位以使激光直接投射到所述传感器上。
本发明的另外的其它实施方式包括滑道装置,以在产生少量或不产生粉尘的情况下使粉末沉积到辊子和部件床之间。特定实施方式的滑道装置是位于进料斗下方的刚性狭槽,所述刚性狭槽延伸至粉末沉积的表面附近,以最小化粉末必须降落的距离,因此使产生的粉尘量最小化。滑道装置是可旋转的,使得它不干涉辊子的运动。滑道也定位为使得它不阻挡激光束离开部件床。在一些实施方式中,滑道包括对待沉积的粉末预加热的加热器元件。
本发明的其它实施方式包括定位于静止辊子位置(在激光扫描操作期间辊子停放之处)下方或接近处的辊子加热器,使得辊子表面可被加热到期望温度。辊子加热器可替代地包括滑道加热器,所述滑道加热器预加热滑道内的粉末,并且也加热辊子表面。辊子可旋转,使得辊子加热器均匀地加热辊子表面以防止辊子表面上出现温度梯度,辊子表面上的温度梯度可导致粉末不期望地粘附到辊子的一些但非全部的表面上,这就导致粉末悬挂在辊子后面,而这进一步造成非均匀粉末表面,上述非均匀粉末表面最终导致最终部件的粗糙表面或其它缺陷。
本发明的又另外的实施方式包括空气洗涤器,所述空气洗涤器清洁构建室内部的空气(主要包括氮气)。通过洗涤器冷却空气,以有助于过滤器移除气载污染物。再循环回构建室内的洗涤器排出空气排放进保持加热器(其通过辐射和对流加热粉末)的加热器支架,以(i)再加热相对冷的再循环空气,以及(ii)冷却加热器支架和加热器,使得加热器不过热。加热器支架沿着面朝外的表面设有排放孔,使得空气以不产生可负面影响激光烧结工艺的显著涡流或其它不期望气流的方式,循环回所述室内。因此,本发明的多种实施方式对激光烧结系统和工艺提供显著改进,这使得部件质量提高且浪费材料减少。
附图说明
因此在概括描述了本发明后,现在将参照附图,这些附图不一定按比例绘出,而是表示为例示性和非限制性的,其中:
图1是根据本发明一个实施方式的激光烧结系统的立体图;
图2是图1的激光烧结系统的侧面截面图;
图3A是图1的激光烧结系统的辊子、进料斗、滑道、辊子加热器以及其它部分的放大侧面截面图,其中滑道位于下部位置;
图3B是图1的激光烧结系统的辊子、进料斗、滑道、辊子加热器以及其它部分的放大侧面截面图,其中滑道位于上部位置;
图4A是图1的实施方式的进料斗和滑道的放大立体图,其中滑道位于下部位置;
图4B是图1的实施方式的进料斗和滑道的放大立体图,其中滑道位于上部位置;
图5A是图1的激光烧结系统的上部部分的侧面截面图,示出位于缩回位置的激光功率测量装置;
图5B是图1的激光烧结系统的上部部分的侧面截面图,示出位于延伸位置的激光功率测量装置;
图6A-6C是本发明另一实施方式的激光功率测量装置(位于延伸位置)的放大立体图,其中激光功率测量装置的镜件包括穿过激光窗(未示出)下方的密封开口突伸进构建室内的伸缩管;
图7A是图1的激光烧结系统的洗涤器的放大立体图,示出洗涤器的内部通道和过滤器、以及位于顶部上的止回阀和位于侧面上的鼓风机马达;
图7B示出图7A的洗涤器的放大侧视图,示出单个洗涤器入口和双洗涤器出口(每个出口与一个加热器支架流体连通);
图7C是图7A的洗涤器的放大立体图,示出洗涤器入口和洗涤器出口、以及用于冷却待洗涤(待过滤)的空气的散热器和风扇;
图8是图1的激光烧结系统的放大立体图,示出加热器支架(黄色),来自洗涤器出口的冷却空气穿过加热器支架被再引入构建室内以对空气加热(利用加热器的废热)并有助于冷却加热器;还示出将洗涤器入口连接至位于加热器支架上方的构建室内的开口的管系统/管道;
图9是图1的激光烧结系统的放大立体图,示出加热器、加热器支架、以及位于加热器支架侧面上的供已预加热空气沿不负面影响粉末层的方向流入构建室内的通道;以及
图10是图1的激光烧结系统的放大立体图,示出位于抬升位置的返回粉末装置,其中返回粉末装置位于部件床的与进料斗和滑道相对置侧部上。
具体实施方式
下文将参照附图更充分描述本发明,图中示出本发明的一些但非全部的实施方式。实际上,本发明可以很多不同形式实施,并不应理解为局限于本文阐述的实施方式;而是,提供这些实施方式,以使该揭露内容将满足可适用的法律要求。虽然关联特定类型的激光烧结系统描述并在附图中示出了用于提供提高部件质量和减少粉末丢弃的设备和方法,但预想到各种设备和方法的功能可应用于期望基于表示待制造部件的数字数据由粉末形成三维物体(部件)的任何现今已知或以后设计出的粉末熔融系统。通篇相似参考标号表示相似元件。
参见图1至10,图示出根据本发明实施方式的激光烧结系统,其包括相对于现有技术的激光烧结系统而言很多新的改进处,这些改进处提高部件质量并减少粉末丢弃。这些本领域内以前未知或未使用的发明,通过为可烧结粉末提供一致能量输送、以使整个部件沿所有方向(x轴(从构建室内的一侧到另一侧)、y轴(从构建室内的前部到后部)以及z轴(从构建室内的底部到顶部))材料性能改善并且一致,使部件质量显著提高。而且,本发明、特别是与双APL有关的那些,提供密度提高的并且不具有或具有极小的凸部、凹部或空穴的粉末层,上述粉末层提供对已经过激光烧结的颗粒的较好流动控制,这就能够使更精确更强部件形成,并且能够使粉末被再利用(粉末用于激光烧结构建工艺中但不被烧结)于更多构建工艺,因此显著地降低了对未使用过粉末(未经受过构建工艺的新的/新制造的粉末)的需要以及丢弃已使用过粉末的需要。因此,本发明显著地降低与部件激光烧结有关的成本,这使得通过激光烧结制成的部件更经济实惠,并且本发明最终使激光烧结相对于通过其它加法制造技术、减法制造技术以及其它传统制造技术制成的部件而言,变得更具竞争力。
例示的实施方式设计为用于利用聚酰胺粉末、或PEEK(聚醚醚酮)粉末或其它聚合物粉末的聚合物系统;然而,本发明的其它实施方式可与根据数字数据形成三维物体所使用的诸如金属、复合物、陶瓷、以及其它任何粉末材料等其它材料一起使用。
现转到图1的实施例,激光烧结系统10包括构建室12、可移动部件床推车14、以及激光组件16,激光组件16包括激光、扫描镜、以及与现有技术的激光烧结系统相似的其它光学器件。激光烧结系统10也包括控制面板18或其它用户界面,例如触摸屏式计算机或平板电脑,用于由操作者控制和/或监控激光烧结系统。图1也示出激光烧结系统10的未位于构建室12内的部分,例如粉末进料斗20和洗涤器22,其中粉末从粉末进料斗20供应至构建室,洗涤器22清洁并使构建室内的空气(主要是氮气)再循环。
图2是该激光烧结系统的截面图,图示出系统的附加结构,包括构建室12的内部和外部。返回粉末接收器24接收在双APL工艺过程中未使用的粉末。沉积进返回粉末接收器24内的粉末(未示出)可存储以备以后在后续构建工艺中使用、或者自动地再循环回进料斗20以在同一或后续构建工艺中使用。图2也图示出位于构建室12内部的部件和系统,诸如辊子26、滑道28、对粉末层进行激光烧结所在的图像平面30(部件床31的顶层)、以及返回粉末装置32(也在图10中示出),返回粉末装置32在图示实施方式中包括返回粉末活塞。本发明的其它实施方式包括备选的返回粉末装置,其将粉末的一部分从粉末分配装置的一侧移送到粉末分配装置的另一侧,以备用于辊子或其它粉末分配装置的第二次通过。激光功率测量装置34也在图2中示出,并定位于激光窗36和加热器38之间(沿着z轴)。
本发明的特定实施方式使用双APL技术以将可烧结粉末分配在多个层中。双APL是对于分配在部件床上的每个粉末层,辊子两次移动经过部件床31的工艺。现有技术系统典型地使用辊子或其它粉末分配装置的单次通过,其它粉末分配装置例如为刮片或刮片状结构,当上述刮片或刮片状结构移动经过部件床时,上述刮片或刮片状结构保持粉末并沉积粉末。这种系统典型地在部件床的两侧上都设有进料斗或供应粉末活塞,而其它现有技术系统设有单个进料斗、但伴随第一次通过沉积第一层粉末并伴随第二次通过沉积第二层粉末(通过将粉末沉积在辊子组件(或其它粉末分配装置)的顶部上并且在部件床的与进料斗相对的一侧上排出粉末)。还有其它现有技术系统使用单次通过的辊子或其它粉末分配装置以在单次通过时施加粉末层,然后只是在返回运动过程中将粉末分配装置复位到其初始位置而不施加粉末层,这是因为在沿返回方向的前沿上没有粉末提供。然而,如下文和所附文献中所提及的,使用将粉末在第一和第二次通过时施加的两次通过的双APL工艺,已经发现粉末密度显著提高,以及施加的粉末层表面的质量也提高了。粉末层中的粉末密度是重要的,这是因为已经发现当在激光烧结过程中更好地控制临时熔融材料的流注量(流量)时,对较致密粉末的加热和激光烧结更稳定。由双APL提供的提高的层密度,能够使已使用过的粉末被用于更多的构建工艺,这是因为即使粉末质量随着粉末经受的各构建工艺而略微降级,已使用过的粉末也依然能产生具有满意的部件质量(例如,与如果太多粉被使用太多次,则再利用粉末可导致诸如已熟知的“桔皮现象”等粗糙表面的现有技术相比,表面质量光滑)以及满意的强度的部件。因此,由双APL工艺提供的较高密度粉末层显著地减少必须被废弃的已使用可烧结粉末的总量,因此在提供具有较好质量和强度的部件的同时,降低与激光烧结相关的成本。
双APL技术包括以下大体步骤:
1)将粉末从进料斗20(经由滑道28)沉积到辊子26与部件床31之间;
2)辊子移动经过部件床以在部件床上分配初始粉末层;
3)返回粉末装置32位于降低位置,使得当辊子在返回粉末装置上方移动时,从第一次通过部件床上方的余留的任何粉末沉积进由返回粉末装置产生的间隙内,使得辊子在位于返回粉末装置上方的粉末上移动经过;
4)返回粉末装置升起,使得位于返回粉末装置上方的粉末位于辊子和部件床之间;
5)辊子移动经过部件床以将余留粉末分配进任何间隙、空穴或其它缺失粉末的部分内,以使粉末的任何波浪状部分或其它凸起部分弄平,并且增加粉末层密度;以及
6)辊子复位到其原始位置(图2所示)时,进行激光扫描步骤。
双APL可区别于现有技术,这是因为它包括分配粉末的两次通过,这不是显而易见的,原因在于两次通过需要用于各层的附加时间,相对于现有技术单次通过系统而言,这就增加了用于各部件的构建时间,如果其它所有参数保持恒定,则各部件的构建时间的增加降低了激光烧结系统的生产能力。在所附参考文件中提供了与粉末密度和部件强度有关的附加信息。
现转向图3A-4B,本发明的特定实施方式包括滑道28,滑道28定位于进料斗20与位于辊子原始位置(在激光扫描操作期间辊子定位之处)和部件床之间的表面之间,使得新供应的粉末在辊子经过部件床的第一次通过之前可沉积在辊子前部处。图示实施方式的滑道包括沿着y轴(系统的从前到后)延伸的狭槽,上述狭槽绕沿着y轴对齐的轴可旋转。滑道28可自动地旋转,或者它可由辊子的运动而移动,例如通过与移动辊子26的位于辊子组件42上的至少一个销40接触。例如,辊子组件42的辊子26或其它部分可在经过部件床的第一次通过(第一APL)开始时将滑道从图3A和4A所示的下部位置推动到图3B和4B中的上部位置,且辊子组件的销40或其它部分可在经过部件床的第二次通过(第二APL)结束时将滑道推回到下部位置,使得当辊子位于原始位置时,滑道一直位于下部位置。滑道可被弹簧加载或以另外方式被偏置从而停留在上部位置,除非它借助于辊子组件的销40或其它部分保持在下部位置。
滑道28仅作用为导管,从而以最小化粉尘或其它气载颗粒物产生的方式将从进料斗释放的粉末沉积到辊子附近。图示实施方式是简单狭槽,但本发明的其它实施方式包括备选的滑道,上述备选的滑道类似地减少沉积粉末的粉尘产生、扩散、或其它不期望运动。滑道28也包括滑道加热器44,滑道加热器44预加热滑道内的粉末,使得沉积的粉末较接近在由激光熔融/融化粉末颗粒之前、粉末在部件床上扩散时其必须获得的温度。通过预加热粉末,可减少构建工艺时间。而且,位于该区域内的滑道加热器或其它加热器可用于预加热辊子。特定实施方式的辊子加热器,不管其是滑道加热器或其它加热器,可将辊子的表面温度保持在期望水平,使得辊子以期望方式分配粉末。当在粉末层的激光烧结过程中辊子位于原始位置时,辊子缓慢地转动(回转),使得辊子表面被均匀地加热。本发明的其它实施方式包括备选的辊子加热器来加热辊子表面。
现在转向本发明特定实施方式的自动激光校准,图5A-6C图示激光功率测量装置,其可选择性地确定被输送到可烧结粉末层的激光功率(和能量)。因为构建室是热的,并且包含可使诸如激光窗等表面失去透明性的烟和气,所以现有技术的系统不测量构建室内部的激光功率,而是替代地在激光束进入构建室之前(在激光束进入构建室的上游)测量激光功率,或者在周期性维护期间测量激光功率。因为在单个构建工艺期间,激光窗的透明性和构建室内部的空气可改变,因此本发明的特定实施方式在构建过程中,周期性地测量构建室内部的激光功率以确定激光功率的变化,使得激光可被调整/校准从而确保粉末层正在接收期望量的能量(例如通过改变激光功率、或者改变激光束移动经过粉末层的扫描速度)。
图示实施方式的激光功率测量装置34包括现有技术中已知类型的激光功率传感器、以及伸缩镜46,伸缩镜46可选择性地位于激光路径内以将激光束反射到用于测量目的的传感器。如图5A所示,位于缩回位置的镜件46处于激光束运动范围之外,使得激光功率测量装置不阻挡激光束离开部件床。如图5B所示,位于延伸位置的镜件46位于激光束运动范围之内,例如位于中心处,使得激光束可选择性地投射到位于激光功率测量装置34内部的传感器。图6A-6C图示出激光功率测量装置34的一个实施方式,其中镜件46借助于中空伸缩轴移动,绕着上述中空伸缩轴的进入构建室12的入口密封上述中空伸缩轴。本发明的其它实施方式包括备选的用于测量构建室内部的激光束功率的激光功率测量装置。
因为加热器38是辐射加热器,且不需要或不期望加热激光功率测量装置,以及为了不阻挡辐射热加热粉末层,因此本发明使激光功率测量装置定位在加热器上方并位于激光窗36附近;然而,本发明的其它实施方式包括激光功率测量装置,所述激光功率测量装置位于构建室内的激光可与激光功率测量装置光学通信的任何位置。
本发明也在某些实施方式中包括洗涤器,以清洁和过滤构建室内部的空气。图7A-7C图示出根据一个实施方式的洗涤器22,其包括初始冷却部分48和过滤部分50。洗涤器22包括洗涤器入口和两个洗涤器出口,通过洗涤器入口从构建室12(例如从加热器38上方和激光窗36下方之处)抽出空气,通过两个洗涤器出口将空气排回到构建室(例如进入如下所述的加热器支架)。冷却部分48是使来自构建室12的相对热空气被冷却的蛇形通道或其它结构,例如通过使用与冷却部分内的通道热连通的散热器和风扇组件56。空气被冷却从而有助于空气中的污染物沉淀。然后,空气流过过滤器部分50,所述过滤器部分50包括将从通过过滤器部分50的空气中的污染物截获的一个或多个过滤器。借助于由鼓风机马达60旋转的鼓风机风扇58,空气循环通过洗涤器22。
图8和9示出将构建室连接到洗涤器入口的管子或管道、以及用于使来自洗涤器的空气回流的一个构建室入口62。构建室入口62与构建室12内的相应加热器支架64流体连通。来自洗涤器的相对较冷的空气流入加热器支架64,以转移来自加热器支架64和加热器38的热,由此(i)有助于冷却加热器,在一些实施方式中是期望冷却加热器的、从而延长加热器的工作寿命和/或增强加热器的性能,以及(ii)预加热回流的已洗涤过的空气。经过预加热的空气从位于各加热器支架64侧面上的孔阵列流出。孔阵列的尺寸形成并定位为最小化构建室内部的湍流或其它不期望的空气流的总量(例如,粉末不应该因为构建室内的空气而移动)。
所附文件还描述了本发明的设备和方法、以及由此产生的测试结果。例如,名称为MP数据的图表示出了相对于现有技术而言在机械性能方面的显著改进。MP数据图表的列代表“循环试验”,其中试验1至4是在不添加任何新粉末的情况下实施,以确定在缺乏新的/新制造的/未使用过的粉末的基础上部件机械性能的劣化。上述循环试验用于做多个ASTM638棒材,以用于根据本领域技术人员已知的工业标准实践对表1中的机械性能进行测试。上述循环试验包括相应量的新制造的(以前未使用过的粉末)、溢出的(以前使用过但从溢出物存储器重新获取的粉末,并且不是部分结块)、以及部分结块的(以前使用过并且从部分结块重新获取的粉末)。上述循环试验是在大体一致的构建参数和部件参数的情况下实施的,包括但不限于60W的填充激光功率(fill laser power)、填充扫描计数1(fill scan countof 1)、12 M/sec的填充扫描速度(fill scan speed)、15W的轮廓激光功率(outline laserpower)、轮廓填充扫描计数1(outline fill scan count of 1)、0.2mm的切片填充扫描间隔(slicer fill scan spacing)、以及烧结扫描1(sinter scan of 1)。如试验1、2和4的结果所显示的,与现有技术的激光烧结设备和方法相比,平均密度、拉伸模量以及拉伸强度的降低量显著增大了。测试数据,例如在MP数据图表中所提供的,表明了可利用本发明的实施方式来降低对未使用粉末的需要以及相应的丢弃使用过粉末的需要。
表1:MP数据
本发明在多种实施方式中将上述设备和方法组合以提高经激光烧结过的部件的部件质量,并延长未使用的可激光烧结粉末的使用寿命。因此,本发明提供显著的技术和资金方面益处,对激光烧结系统的使用者而言,这在以前借助于现有技术是不可实现的。
本文阐述的本发明的很多修改以及其它实施方式将使本发明所属技术领域的人员受益于前文描述以及相关附图所呈现的教示。因此,将会理解,本发明不限于所公开的具体实施方式,上述修改以及其它实施方式意图包括在所附权利要求书的范围内。只要对本发明的修改和改变落入所附权利要求书及其等同例的范围内,本发明就意图涵盖这些修改和改变。虽然本文使用了特定术语,但它们仅作为一般性和描述性意义使用,而非限制目的。
因此,本发明提供具有改进的构建和支撑材料的三维物体生产。本文阐述的本发明的很多修改以及其它实施方式将使本发明所属技术领域的人员受益于前文描述以及相关附图所呈现的教示。因此,将会理解,本发明不限于所公开的具体实施方式,上述修改以及其它实施方式意图包括在所附权利要求书的范围内。只要对本发明的修改和改变落入所附权利要求书及其等同例的范围内,本发明就意图涵盖这些修改和改变。虽然本文使用了特定术语,但它们仅作为一般性和描述性意义使用,而非限制目的。
在描述本发明的上下文中(尤其在所附权利要求书的上下文中),术语“一”、“一个”、“该”以及相似参考措词的使用,应理解为涵盖单数和复数形式,除非本文另有说明或明显与上下文相矛盾。术语“包括”、“具有”、“包含”以及“含有”应理解为开放式术语(意即“包括但不限于”),除非另有说明。本文中记载的数值范围仅意图用于作为各个参照落入该范围内的各单独值的简略表达方法,除非本文另有说明,且各单独值就像在本文中各个记载一样被结合进说明书中。在本文中描述的所有方法可以任何合适顺序执行,除非本文另有说明或明显与上下文相矛盾。本文中提供的任何和所有示例、或者示例性语言(例如“诸如”)的使用,仅意图用于更好地阐明本发明,而非对本发明范围施加限制,除非另有要求保护。说明书中的语言不应理解为指示了任何非要求保护的元件对实践本发明是重要的。
Claims (19)
1.一种用于基于设计数据且由可烧结粉末制造三维物体的激光烧结系统,所述激光烧结系统包括:
进料斗,所述进料斗用于将所述可烧结粉末供应至所述激光烧结系统的构建室;
粉末分配装置,所述粉末分配装置用于将所述可烧结粉末分配在部件床上的层中;以及
返回粉末装置,所述返回粉末装置位于所述部件床的与所述进料斗相对置处,其中,所述返回粉末装置能选择性地移动以能够使粉末的一部分从所述粉末分配装置的一侧移送到另一侧,以便使得所述可烧结粉末分配在所述部件床上来形成第一层可烧结粉末,并且使得所述可烧结粉末的返回部分从所述部件床的与所述粉末分配装置相对置处重新定位到所述部件床和所述粉末分配装置之间且被随后分配到所述部件床上,以进一步形成所述第一层可烧结粉末。
2.如权利要求1所述的激光烧结系统,所述激光烧结系统还包括在所述进料斗和所述粉末分配装置之间使所述可烧结粉末通过的滑道。
3.如权利要求2所述的激光烧结系统,所述激光烧结系统还包括用于预加热所述滑道内的可烧结粉末的滑道加热器。
4.如权利要求2所述的激光烧结系统,其中,所述滑道是可旋转的。
5.如权利要求1所述的激光烧结系统,其中,所述粉末分配装置包括反向旋转辊子。
6.如权利要求5所述的激光烧结系统,所述激光烧结系统还包括用于加热所述辊子表面的辊子加热器。
7.如权利要求1所述的激光烧结系统,其中,所述返回粉末装置包括返回粉末活塞,所述返回粉末活塞选择性地抬升和下降。
8.如权利要求1所述的激光烧结系统,所述激光烧结系统还包括激光功率测量装置,所述激光功率测量装置能够测量所述构建室内的激光束功率。
9.如权利要求1所述的激光烧结系统,所述激光烧结系统还包括洗涤器和用于支撑至少一个加热器的加热器支架,其中,来自所述洗涤器的排出空气穿过所述加热器支架供应至所述构建室。
10.一种用于对基于设计数据且由可烧结粉末形成的三维物体进行激光烧结的方法,所述方法包括:
将可烧结粉末沉积在粉末分配装置和部件床之间;
将所述可烧结粉末分配在所述部件床上以形成第一层可烧结粉末;
使所述可烧结粉末的返回部分从所述部件床的与所述粉末分配装置相对置处重新定位到所述部件床和所述粉末分配装置之间;以及
将所述可烧结粉末的所述返回部分分配到所述部件床上,以进一步形成所述第一层可烧结粉末,
其中,两个分配步骤是在所述层的可烧结粉末基本上被激光烧结与第二层可烧结粉末被分配之前执行的。
11.如权利要求10所述的方法,其中,使所述可烧结粉末的返回部分重新定位包括:在所述粉末分配装置已移动经过返回粉末装置上方之后,抬升所述返回粉末装置。
12.如权利要求10所述的方法,其中,将可烧结粉末沉积包括通过滑道供应所述可烧结粉末。
13.如权利要求12所述的方法,其中,通过滑道供应所述可烧结粉末还包括:预加热所述滑道内的所述可烧结粉末。
14.如权利要求12所述的方法,其中,通过滑道供应所述可烧结粉末还包括:预加热定位在接近所述滑道处的辊子。
15.如权利要求10所述的方法,所述方法还包括测量构建室内部的激光束功率,所述可烧结粉末被供应至所述构建室。
16.一种用于基于设计数据且由可烧结粉末制造三维物体的激光烧结系统,所述激光烧结系统包括:
构建室,所述构建室包括部件床、粉末分配装置、以及至少一个加热器,所述粉末分配装置用于将所述可烧结粉末分配在所述部件床上的层中;
进料斗,所述进料斗用于将所述可烧结粉末供应至所述构建室;
返回粉末装置,所述返回粉末装置位于所述部件床的与所述进料斗相对置处,其中,所述返回粉末装置能选择性地移动以能够使粉末的一部分从所述粉末分配装置的一侧移送到另一侧,以便使得所述可烧结粉末分配在所述部件床上来形成第一层可烧结粉末,并且使得所述可烧结粉末的返回部分从所述部件床的与所述粉末分配装置相对置处重新定位到所述部件床和所述粉末分配装置之间且被随后分配到所述部件床上,以进一步形成所述第一层可烧结粉末;以及
激光功率测量装置,所述激光功率测量装置能够在构建工艺过程中测量所述构建室内的激光束功率。
17.如权利要求16所述的激光烧结系统,其中,所述激光功率测量装置能选择性地移动。
18.如权利要求16所述的激光烧结系统,其中,所述激光功率测量装置定位在所述至少一个加热器的上方与激光窗的下方。
19.如权利要求16所述的激光烧结系统,其中,所述激光功率测量装置包括伸缩管和用于将激光束反射到传感器的镜件。
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2014
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US20220324173A1 (en) | 2022-10-13 |
JP2016519009A (ja) | 2016-06-30 |
EP2969486A2 (en) | 2016-01-20 |
CN105163930A (zh) | 2015-12-16 |
US9931785B2 (en) | 2018-04-03 |
CN105163930B (zh) | 2017-12-12 |
EP3556493B1 (en) | 2022-05-18 |
JP2016518264A (ja) | 2016-06-23 |
JP6178491B2 (ja) | 2017-08-09 |
JP6178492B2 (ja) | 2017-08-09 |
EP2969486B1 (en) | 2018-05-09 |
EP2969485B1 (en) | 2019-06-05 |
WO2014165310A2 (en) | 2014-10-09 |
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