JP6503375B2 - 選択的焼結による3d印刷のための方法及び装置 - Google Patents
選択的焼結による3d印刷のための方法及び装置 Download PDFInfo
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Description
することを含む付加製造工程によって物体が形成される。この工程は、一般に、物体が形成されるまで各層について繰り返される。本発明者は、圧縮成形ステップを層ごとに追加することにより、製造工程の効率を改善することができ、最終製品の品質をも改善することができることを見出した。
任意選択で、ダイ圧縮成形ステーションは、層と界接するダイの表面を暖めるための加熱要素を含む。
任意選択で、ダイ圧縮成形ステーションは、構築トレイをダイに向かって持ち上げるためのリフティング・システムを含む。
任意選択で、システムは、焼結後、層を冷却するための冷却ステーションを含む。
任意選択で、デジタル印刷システムは、液体担体内に懸濁するフリットを含むインクを分配するように動作可能である。
任意選択で、焼結ステーションは、層を焼結するための高サーマル・マス・ローラを含む。
任意選択で、高サーマル・マス・ローラは、ローラ長の1cm当たり20〜180ニュートン(N/cm)程度の大きさの圧力を加える。
任意選択で、焼結ステーションは、予熱及び/又は焼結するために層の上で掃引した垂直共振器面発光レーザ(VCSEL)のアレイを含む。
任意選択で、粉末は、アルミニウム粉末及び/又はアルミニウム合金である。
本発明のいくつかの実施形態の一態様によれば、3次元物体を構築するための方法であって、粉末の層を構築トレイ上に延展する工程と、マスク・パターンを層上に印刷する工程であって、マスク・パターンは、焼結されることになる層の一部分のネガを画定し、前記部分は露出され、層のためのマスク・パターンは、3次元物体の形状を画定するマスク・パターン・データによって定義される、工程と、露出されている層の部分を焼結する工程と、延展する工程、印刷する工程、及び焼結する工程を3次元物体が完成するまで繰り返す工程とを含む方法が提供される。
任意選択で、インクは、層のマスクされた部分上に断熱被覆を提供する。
任意選択で、この方法は、焼結する工程の前に、層ごとにダイ圧縮成形を実施する工程を含む。
任意選択で、圧縮成形中に層に加えられる圧力は、最大100MPaである。
任意選択で、ダイ圧縮成形は、層の印刷する工程後、層ごとに実施される。
任意選択で、焼結する工程は、構築トレイの長さにわたって熱源を通過させることによって実施され、熱源は、構築トレイの幅にわたって延びる細いストリップに沿って熱を提供する。
任意選択で、高サーマル・マス・ローラは、焼結する工程中、粉末の溶融温度より0℃〜30℃高く加熱される。
任意選択で、この方法は、焼結する工程中、構築トレイを冷却する工程を含む。
任意選択で、この方法は、構築される物体の1つ又は複数の前の層の厚さに応答して構築トレイの高さを調整する工程を含む。
工程と、提供する工程、ダイ圧縮成形、及び焼結する工程を3次元物体が完成するまで層ごとに繰り返す工程とを含む方法が提供される。
任意選択で、圧縮成形中に層に加えられる圧力は、最大100MPaである。
別段定義されない限り、本明細書で使用されるすべての技術用語及び/又は科学用語は、本発明が関連する技術における当業者によって一般的に理解されるものと同じ意味を有する。本明細書に記載のものと同様又は等価の方法及び材料を、本発明の実施形態を実施又はテストする際に使用することができるが、例示的な方法及び/又は材料が下記に記載されている。矛盾がある場合、定義を含めて本明細書が支配することになる。さらに、材料、方法、及び例は例示的なものにすぎず、必ずしも限定することは意図されていない。
本発明のいくつかの実施形態によれば、焼結された粉末の複数の層から物体を構築するための3D印刷システム及び方法が提供される。本発明のいくつかの実施形態によれば、このシステムは構築トレイを含み、その上に、粉末ディスペンサが層ごとに粉末状材料を加え、ローラが、粉末の各層を加えられた後で延展する。任意選択で、粉末分配及び粉末延展は、システムの粉末送達ステーション内で実施される。本発明のいくつかの実施形態によれば、粉末状材料が構築材料として使用される。いくつかの例示的な実施形態では、アルミニウム粉末が使用される。任意選択で、金属合金が使用され、たとえば、アルミニウム合金又は粉末金属の組合せが使用される。任意選択で、セラミック粉末が構築材料として使用され、及び/又は金属とセラミック粉末の組合せが使用される。
ことによって、焼結中の結合を促進する。任意選択で、圧縮成形は、粉末層の熱伝導率を高め、より均一な焼結を可能にする。任意選択で、圧縮成形は、層間の結合を改善し、焼結後に起こり得る層分離を防止する。本発明のいくつかの実施形態によれば、層ごとのダイ圧縮成形は、3D物体を構築するための知られているSLM及びSLS工程に適用される。
おいて、これらの構成要素の構造及び構成、ならびに/あるいは以下の説明に示される及び/又は図面及び/もしくは例に示されている方法の詳細に必ずしも限定されないことを理解されたい。本発明は、他の実施形態が可能であり、様々な方法で実践又は実施することが可能である。
体積は、システム100及び/又はコントローラ300からのフィードバックに基づいて構築工程の間に調整される。いくつかの例示的な実施形態では、圧縮成形後の層の厚さが監視され、粉末分配ステーション10によって分配される定義された体積は、圧縮成形された層の厚さに応答して調整される。任意選択で、粉末55は、トレイ200が動いている間に分配され、その結果、粉末55は、トレイ200の長さにわたって延展される。いくつかの例示的な実施形態では、粉末分配ステーション10は、粉末アルミニウムを送達するように適合される。他の例示的な実施形態では、他の金属及び/又は合金が粉末分配ステーション10によって貯蔵及び送達される。任意選択で、容器12は、混合される複数の構成要素を含む。任意選択で、容器12は、貯蔵された内容物を混合するための機構を含む。
む。典型的には、液体担体は、油又は油性である。本発明のいくつかの実施形態によれば、ガラス及び/又はケイ素粒子及び/又はフリットは、1μm未満、たとえば500〜600nmである平均直径を有する。いくつかの例示的な実施形態では、インク溶液内のガラス・フリットの濃度は、最大50%である。典型的には、粒子は、液体担体が粉末層を貫通する間、断熱表面を提供する断熱材料から形成される。典型的には、インク32によって提供される断熱は、マスクされた部分の温度の上昇を遅らせるだけである。典型的には、ガラス・フリットは、粉末粒子より著しく小さく、たとえば、粉末粒子は、約40μmの直径を有し、一方、ガラス・フリットは、約500〜600nmの直径を有する。
する。任意選択で、圧縮成形は、約50%だけ層の厚さを減少させる。
回避することを見出した。
酸化物の殻を破ることを可能にする。典型的には、粉末状金属の層を通じた熱伝導は、酸化物の殻を破った後、より均一になる。本発明のいくつかの実施形態によれば、焼結(ブロック825)が圧縮成形後の層上で実施される。任意選択で、焼結は、焼結ローラで実施される。本発明のいくつかの実施形態によれば、層は、焼結後、直ちに冷却される(ブロック830)。典型的には、冷却は、焼結中に蓄積される熱が層のマスクされたエリア内に広がるのを防止する。本発明のいくつかの実施形態によれば、ブロック805〜830に記載の方法は、印刷される各層ごとに繰り返される。一般に、すべての層が印刷された後、最終的な物体を粉末ベッドから除去することができる。一般に、追加の仕上げ後手順は必要とされない。
「consisting essentially of」という用語は、組成、方法、又は構造が、追加の成分、ステップ、及び/又は部分を含み得るが、それは、それらの追加の成分、ステップ、及び/又は部分が、特許請求されている組成、方法、又は構造の基本的特徴及び新規の特徴を実質的に変えない場合だけであることを意味する。
Claims (25)
- 3次元物体を構築するためのシステムにおいて、
粉末材料の層を構築トレイ上に加えるための粉末送達ステーションと、
マスク・パターンを前記層上に印刷するためのデジタル印刷ステーションであって、前記マスク・パターンは、焼結されることになる前記層の一部分のネガを画定する、デジタル印刷ステーションと、
焼結されることになる前記マスクによって画定される前記層の前記部分を選択的に焼結するための焼結ステーションであって、前記焼結ステーションは前記層を焼結するための高サーマル・マス・ローラを備える、焼結ステーションと、
共に前記3次元物体を形成する複数の層を構築するために、前記構築トレイを前記粉末送達ステーション、デジタル印刷ステーション、及び焼結ステーションのそれぞれに繰り返し進めるステージと
からなるシステム。 - 前記粉末材料の層に圧縮成形するためのダイ圧縮成形ステーションをさらに備え、前記圧縮成形ステーションは、前記層を受け取るためのダイを有する、請求項1に記載のシステム。
- 前記ダイ圧縮成形ステーションは、前記層と界接する前記ダイの表面を暖めるための加熱要素を備える、請求項2に記載のシステム。
- 前記ダイ圧縮成形ステーションは、最大100MPaの圧力を前記層に対して加えるように動作可能であり、前記ダイ圧縮成形ステーションは、前記構築トレイを前記ダイに向かって持ち上げるためのリフティング・システムを備える、請求項2に記載のシステム。
- 前記ダイ圧縮成形ステーションは、剥がれ防止機構を備え、前記剥がれ防止機構は、前記構築トレイと前記ダイとの間に配置された箔を有し、前記箔は、2つの反対側の縁部によって支持され、前記構築トレイと前記ダイの間の分離中、前記箔の弓反りを可能にする、請求項2〜4のいずれか1項に記載のシステム。
- 後続の層における前記構築トレイの高さを、圧縮成形後、前記層の厚さに応答して調整するためのコントローラをさらに備える、請求項2〜4のいずれか1項に記載のシステム。
- 焼結後、前記層を冷却するための冷却ステーションをさらに備え、前記冷却ステーションは、ガスのジェット噴流を提供するためのエア・ナイフを有する、請求項1〜4のいずれか1項に記載のシステム。
- 前記デジタル印刷システムは、液体担体内に懸濁するフリットを含んでなるインクを分配すべく動作可能であり、前記フリットは、500nmから1μmの直径を有する粒子から形成される、請求項1〜4のいずれか1項に記載のシステム。
- 前記高サーマル・マス・ローラは、前記粉末の前記溶融温度より0℃〜80℃高く加熱される、請求項1〜4のいずれか1項に記載のシステム。
- 前記高サーマル・マス・ローラは、ローラ長の1cm当たり20〜180ニュートン(N/cm)程度の大きさの圧力を加える、請求項1〜4のいずれか1項に記載のシステム。
- 前記焼結ステーションは、剥がれ防止機構を備え、前記剥がれ防止機構は、前記高サーマル・マス・ローラと前記層との間に配置された箔を有する、請求項1〜4のいずれか1項に記載のシステム。
- 前記焼結ステーションは、予熱又は焼結のうちの少なくとも一方を行うために前記層の上で掃引した垂直共振器面発光レーザ(VCSEL)のアレイを含んでなる、請求項1〜4のいずれか1項に記載のシステム。
- 前記構築トレイは、前記層が配置される前記トレイの表面に対して実質的に平行に走る少なくとも1つのチャネルを有し、前記チャネルを通じて前記構築トレイを冷却するための流体が導入される、請求項1〜4のいずれか1項に記載のシステム。
- 前記粉末は、アルミニウム又はアルミニウム合金のうちの少なくとも一方からなる粉末である、請求項4に記載のシステム。
- 3次元物体を構築するための方法において、
粉末の層を構築トレイ上に延展する工程と、
マスク・パターンを前記層上に印刷する工程であって、前記マスク・パターンは、焼結されることになる前記層の一部分のネガを画定し、前記層のための前記マスク・パターンは、前記3次元物体の形状を画定するマスク・パターン・データによって定義される、マスク・パターンを前記層上に印刷する工程と、
焼結されることになる前記マスクによって画定される前記層の前記部分を焼結する工程であって、前記焼結する工程は、前記層の上で転動する高サーマル・マス・ローラによって実施される、前記焼結する工程と、
前記延展する工程、前記印刷する工程、及び前記焼結する工程を前記3次元物体が完成するまで繰り返す工程と
からなる方法。 - 前記マスク・パターンは、インクを分配するデジタル・プリンタで印刷され、前記インクは、前記層のマスクされた部分上に断熱被覆を与える、請求項15に記載の方法。
- 前記インクは、前記粉末の溶融温度より低い蒸発温度を有するように選択された液体担体を含む、請求項16に記載の方法。
- 前記焼結する工程の前、かつ前記層の印刷する工程の後で、前記層の上にダイ圧縮成形を実施する工程をさらに備え、前記ダイ圧縮成形中に前記層に加えられる圧力は、最大100MPaである、請求項15のいずれか1項に記載の方法。
- 温間ダイ圧縮成形を実施する工程をさらに備え、前記ダイ圧縮成形中に前記層に加えられる圧力は、最大100MPaであり、前記温間ダイ圧縮成型は前記印刷する工程後、層ごとに実施される、請求項18に記載の方法。
- 前記ダイ圧縮成形中に前記構築トレイを冷却する工程を備える、請求項18に記載の方法。
- 前記高サーマル・マス・ローラは、前記焼結する工程中、前記粉末の溶融温度より0℃〜30℃高く加熱される、請求項15〜19のいずれか1項に記載の方法。
- 前記高サーマル・マス・ローラは、ローラ長の1cm当たり10ニュートン(N/cm)程度の大きさの圧力で前記層に押し付けられる、請求項15〜19のいずれか1項に記載の方法。
- 焼結する工程中、前記構築トレイを冷却する工程を備える、請求項15〜19のいずれか1項に記載の方法。
- 前記焼結する工程の直後に前記層を冷却する工程をさらに備え、前記冷却する工程は、ガスのジェット噴流で実施される、請求項15〜19のいずれか1項に記載の方法。
- 構築される前記物体の1つ又は複数の前の層の厚さに応答して前記構築トレイの高さを調整する工程をさらに備える、請求項15〜19のいずれか1項に記載の方法。
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