US20220097174A1 - Variable beam geometry laser-based powder bed fusion - Google Patents
Variable beam geometry laser-based powder bed fusion Download PDFInfo
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- US20220097174A1 US20220097174A1 US17/547,064 US202117547064A US2022097174A1 US 20220097174 A1 US20220097174 A1 US 20220097174A1 US 202117547064 A US202117547064 A US 202117547064A US 2022097174 A1 US2022097174 A1 US 2022097174A1
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
- B23K—SOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
- B23K26/00—Working by laser beam, e.g. welding, cutting or boring
- B23K26/34—Laser welding for purposes other than joining
- B23K26/342—Build-up welding
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B22—CASTING; POWDER METALLURGY
- B22F—WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
- B22F12/00—Apparatus or devices specially adapted for additive manufacturing; Auxiliary means for additive manufacturing; Combinations of additive manufacturing apparatus or devices with other processing apparatus or devices
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B22—CASTING; POWDER METALLURGY
- B22F—WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
- B22F10/00—Additive manufacturing of workpieces or articles from metallic powder
- B22F10/20—Direct sintering or melting
- B22F10/28—Powder bed fusion, e.g. selective laser melting [SLM] or electron beam melting [EBM]
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B22—CASTING; POWDER METALLURGY
- B22F—WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
- B22F10/00—Additive manufacturing of workpieces or articles from metallic powder
- B22F10/30—Process control
- B22F10/36—Process control of energy beam parameters
- B22F10/362—Process control of energy beam parameters for preheating
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B22—CASTING; POWDER METALLURGY
- B22F—WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
- B22F10/00—Additive manufacturing of workpieces or articles from metallic powder
- B22F10/30—Process control
- B22F10/36—Process control of energy beam parameters
- B22F10/364—Process control of energy beam parameters for post-heating, e.g. remelting
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B22—CASTING; POWDER METALLURGY
- B22F—WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
- B22F10/00—Additive manufacturing of workpieces or articles from metallic powder
- B22F10/30—Process control
- B22F10/36—Process control of energy beam parameters
- B22F10/368—Temperature or temperature gradient, e.g. temperature of the melt pool
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B22—CASTING; POWDER METALLURGY
- B22F—WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
- B22F10/00—Additive manufacturing of workpieces or articles from metallic powder
- B22F10/80—Data acquisition or data processing
- B22F10/85—Data acquisition or data processing for controlling or regulating additive manufacturing processes
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B22—CASTING; POWDER METALLURGY
- B22F—WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
- B22F12/00—Apparatus or devices specially adapted for additive manufacturing; Auxiliary means for additive manufacturing; Combinations of additive manufacturing apparatus or devices with other processing apparatus or devices
- B22F12/10—Auxiliary heating means
- B22F12/13—Auxiliary heating means to preheat the material
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B22—CASTING; POWDER METALLURGY
- B22F—WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
- B22F12/00—Apparatus or devices specially adapted for additive manufacturing; Auxiliary means for additive manufacturing; Combinations of additive manufacturing apparatus or devices with other processing apparatus or devices
- B22F12/40—Radiation means
- B22F12/41—Radiation means characterised by the type, e.g. laser or electron beam
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B22—CASTING; POWDER METALLURGY
- B22F—WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
- B22F12/00—Apparatus or devices specially adapted for additive manufacturing; Auxiliary means for additive manufacturing; Combinations of additive manufacturing apparatus or devices with other processing apparatus or devices
- B22F12/40—Radiation means
- B22F12/44—Radiation means characterised by the configuration of the radiation means
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B22—CASTING; POWDER METALLURGY
- B22F—WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
- B22F12/00—Apparatus or devices specially adapted for additive manufacturing; Auxiliary means for additive manufacturing; Combinations of additive manufacturing apparatus or devices with other processing apparatus or devices
- B22F12/40—Radiation means
- B22F12/49—Scanners
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
- B23K—SOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
- B23K26/00—Working by laser beam, e.g. welding, cutting or boring
- B23K26/02—Positioning or observing the workpiece, e.g. with respect to the point of impact; Aligning, aiming or focusing the laser beam
- B23K26/03—Observing, e.g. monitoring, the workpiece
- B23K26/034—Observing the temperature of the workpiece
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
- B23K—SOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
- B23K26/00—Working by laser beam, e.g. welding, cutting or boring
- B23K26/02—Positioning or observing the workpiece, e.g. with respect to the point of impact; Aligning, aiming or focusing the laser beam
- B23K26/06—Shaping the laser beam, e.g. by masks or multi-focusing
- B23K26/062—Shaping the laser beam, e.g. by masks or multi-focusing by direct control of the laser beam
- B23K26/0626—Energy control of the laser beam
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
- B23K—SOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
- B23K26/00—Working by laser beam, e.g. welding, cutting or boring
- B23K26/02—Positioning or observing the workpiece, e.g. with respect to the point of impact; Aligning, aiming or focusing the laser beam
- B23K26/06—Shaping the laser beam, e.g. by masks or multi-focusing
- B23K26/064—Shaping the laser beam, e.g. by masks or multi-focusing by means of optical elements, e.g. lenses, mirrors or prisms
- B23K26/0648—Shaping the laser beam, e.g. by masks or multi-focusing by means of optical elements, e.g. lenses, mirrors or prisms comprising lenses
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
- B23K—SOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
- B23K26/00—Working by laser beam, e.g. welding, cutting or boring
- B23K26/02—Positioning or observing the workpiece, e.g. with respect to the point of impact; Aligning, aiming or focusing the laser beam
- B23K26/06—Shaping the laser beam, e.g. by masks or multi-focusing
- B23K26/073—Shaping the laser spot
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
- B23K—SOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
- B23K26/00—Working by laser beam, e.g. welding, cutting or boring
- B23K26/08—Devices involving relative movement between laser beam and workpiece
- B23K26/0869—Devices involving movement of the laser head in at least one axial direction
- B23K26/0876—Devices involving movement of the laser head in at least one axial direction in at least two axial directions
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B33—ADDITIVE MANUFACTURING TECHNOLOGY
- B33Y—ADDITIVE MANUFACTURING, i.e. MANUFACTURING OF THREE-DIMENSIONAL [3-D] OBJECTS BY ADDITIVE DEPOSITION, ADDITIVE AGGLOMERATION OR ADDITIVE LAYERING, e.g. BY 3-D PRINTING, STEREOLITHOGRAPHY OR SELECTIVE LASER SINTERING
- B33Y10/00—Processes of additive manufacturing
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B33—ADDITIVE MANUFACTURING TECHNOLOGY
- B33Y—ADDITIVE MANUFACTURING, i.e. MANUFACTURING OF THREE-DIMENSIONAL [3-D] OBJECTS BY ADDITIVE DEPOSITION, ADDITIVE AGGLOMERATION OR ADDITIVE LAYERING, e.g. BY 3-D PRINTING, STEREOLITHOGRAPHY OR SELECTIVE LASER SINTERING
- B33Y30/00—Apparatus for additive manufacturing; Details thereof or accessories therefor
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B33—ADDITIVE MANUFACTURING TECHNOLOGY
- B33Y—ADDITIVE MANUFACTURING, i.e. MANUFACTURING OF THREE-DIMENSIONAL [3-D] OBJECTS BY ADDITIVE DEPOSITION, ADDITIVE AGGLOMERATION OR ADDITIVE LAYERING, e.g. BY 3-D PRINTING, STEREOLITHOGRAPHY OR SELECTIVE LASER SINTERING
- B33Y50/00—Data acquisition or data processing for additive manufacturing
- B33Y50/02—Data acquisition or data processing for additive manufacturing for controlling or regulating additive manufacturing processes
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B22—CASTING; POWDER METALLURGY
- B22F—WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
- B22F10/00—Additive manufacturing of workpieces or articles from metallic powder
- B22F10/30—Process control
- B22F10/36—Process control of energy beam parameters
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B22—CASTING; POWDER METALLURGY
- B22F—WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
- B22F12/00—Apparatus or devices specially adapted for additive manufacturing; Auxiliary means for additive manufacturing; Combinations of additive manufacturing apparatus or devices with other processing apparatus or devices
- B22F12/90—Means for process control, e.g. cameras or sensors
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- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
- Y02P—CLIMATE CHANGE MITIGATION TECHNOLOGIES IN THE PRODUCTION OR PROCESSING OF GOODS
- Y02P10/00—Technologies related to metal processing
- Y02P10/25—Process efficiency
Definitions
- the present disclosure relates generally to additive manufacturing, and more particularly, to variable beam geometry laser-based powder bed fusion.
- Powder-bed fusion (PBF) systems can produce metal structures (referred to as build pieces) with geometrically complex shapes, including some shapes that are difficult or impossible to create with conventional manufacturing processes.
- PBF systems include additive manufacturing (AM) techniques to create build pieces layer-by-layer.
- AM additive manufacturing
- Each layer or slice can be formed by a process of depositing a layer of metal powder and then fusing (e.g., melting and cooling) areas of the metal powder layer that coincide with the cross-section of the build piece in the layer. The process may be repeated to form the next slice of the build piece, and so on until the build piece is complete. Because each layer is deposited on top of the previous layer, PBF may be likened to forming a structure slice-by-slice from the ground up.
- Laser-based PBF may be useful for manufacturing complex geometries and with reduced cost of customization.
- manufacturing using laser-based PBF systems can be a slow process compared to what may be needed for high-capacity production.
- Application of high-power laser systems in current PBF systems may lead to vaporization of materials during the printing process, thereby increasing manufacturing costs.
- variable beam geometry laser-based PBF and systems and methods for manufacturing therewith will be described more fully hereinafter.
- an apparatus for laser-based powder-bed fusion includes a depositor that deposits a plurality of layers of a powder material.
- the apparatus also includes a laser beam source that generates a laser beam having a variable beam geometry.
- the apparatus further includes a laser application component (e.g., a deflector) that applies the laser beam in one of a plurality of beam geometries to fuse the powder material.
- a method of laser-based powder-bed fusion includes adapting a laser beam geometry to form an adapted laser beam comprising a line or a two dimensional shape. The method further includes applying the adapted laser beam to at least a portion of a powder material to scan at least a portion of the defined build piece.
- FIGS. 1A-D illustrate respective side views of an exemplary PBF system during different stages of operation.
- FIGS. 2A and 2B are diagrams illustrating an exemplary beam shaping component operated to change the geometry of a laser beam in accordance with aspects of the present disclosure.
- FIG. 3 is a diagram illustrating an exemplary L-PBF system for scanning a build piece in accordance with aspects of the present disclosure.
- FIG. 4 illustrates an exemplary adaptation of a laser beam during a scan in accordance with aspects of the present disclosure.
- FIG. 5 is a diagram illustrating exemplary energy flux level configurations of a laser beam adapted for 2-D scanning in accordance with aspects of the present disclosure.
- FIG. 6 is a flowchart of an exemplary method of configuring a laser beam to scan a build piece in a L-PBF apparatus.
- L-PBF laser-based PBF
- the L-PBF process may include, among others, the following printing techniques: Direct metal laser sintering (DMLS), Selective laser melting (SLM) and Selective laser sintering (SLS).
- DMLS Direct metal laser sintering
- SLM Selective laser melting
- SLS Selective laser sintering
- Still other PBF processes to which the principles of this disclosure are pertinent include those that are currently contemplated or under commercial development. While the specific details of each such process are omitted to avoid unduly obscuring key concepts of the disclosure, it will be appreciated that the claims are intended to encompass such techniques and related structures.
- L-PBF systems can produce metal and polymer structures (referred to as build pieces) with geometrically complex shapes, including some shapes that are difficult or impossible to create using conventional manufacturing processes.
- L-PBF systems create build pieces layer-by-layer, i.e., slice-by-slice. Each slice may be formed by a process of depositing a layer of metal powder and fusing (e.g., melting and cooling) areas of the metal powder layer that coincide with the cross-section of the build piece in the slice. The process may be repeated to form the next slice of the build piece, and so on, until all the layers are deposited and the build piece is complete.
- fusing e.g., melting and cooling
- aspects of the present disclosure are directed to laser spot geometries for laser-based PBF (L-PBF) systems which may increase build rate and provide additional control and flexibility of the manufacturing process.
- a laser spot is the area of a surface illuminated by a laser.
- a laser beam may instead be configured to use variable beam or spot geometries.
- the beam geometry that is, the area of the surface of the print material illuminated by the laser—may be a line, a square, a rectangle, a triangle, an asymmetrical shape, or any other two-dimensional shape.
- the identified beam geometry can then be applied to the surface of the print material using two-dimensional scanning.
- the laser beam may be applied in a PBF print operation such that a larger contiguous area of the powder-bed may be processed at any given time.
- the beam geometry can be dynamically altered during a 3-D print operation.
- the L-PBF 3-D printer may fuse larger areas using a correspondingly large beam geometry, and subsequently or periodically, the 3-D printer may alter the beam geometry to a small line or an ordinary point-like shape to scan corner portions of the object and/or to fuse details of the build piece on a smaller scale.
- the laser beam geometry may be adapted based on the geometry of the object (build piece) to be produced.
- the laser beam geometry may be adapted at the beginning of a scan, on a slice-by slice basis, at a designated time within a slice, or dynamically on the fly. Further, the laser beam geometry may also be varied continuously as the laser scans across the powder-bed, whose variance is in accordance with the contemplated structure of the object as identified in a computer aided design (CAD) profile, for example.
- CAD computer aided design
- variable beam geometry may beneficially increase the throughput of the L-PBF process. Additionally, adapting the beam geometry as described herein may allow for application of laser power over a larger area to the powder bed, meaning that energy flux can be kept small to reduce vaporization of materials. Furthermore, given the two-dimensional nature of the adapted laser spot geometry, the energy profile of the spot geometry may be adjusted according to the scan vector (direction of scanning), to provide heating and cooling rate control. Controlling the cooling rate during the solidification process may allow reduction of thermal stresses and alterations of microstructure in the resultant component to achieve desired material properties.
- FIGS. 1A-D illustrate respective side views of an exemplary laser-based PBF (L-PBF) system 100 during different stages of operation.
- L-PBF laser-based PBF
- FIGS. 1A-D illustrate respective side views of an exemplary laser-based PBF (L-PBF) system 100 during different stages of operation.
- L-PBF laser-based PBF
- FIGS. 1A-D illustrate respective side views of an exemplary laser-based PBF (L-PBF) system 100 during different stages of operation.
- L-PBF laser-based PBF
- L-PBF system 100 may include a depositor 101 that may deposit each layer of powder material, a laser beam source 103 that may generate a laser beam, a beam shaping component 104 that may shape the laser beam according to a selected beam geometry, a deflector 105 that may apply the laser beam in the form of the selected beam geometry to fuse the powder material, and a build plate 107 that may support one or more build pieces, such as a build piece 109 .
- the L-PBF system 100 may also include a build floor 111 positioned within a powder bed receptacle.
- the walls of the powder bed receptacle 112 may generally define the boundaries of the powder bed receptacle, which is defined between the walls 112 from the side and a portion of the build floor 112 below.
- the build floor 111 may progressively lower build plate 107 such that depositor 101 may deposit a next layer of powder material.
- the L-PBF system 100 may additionally include a chamber 113 that may enclose the other components of L-PBF system 100 (e.g., laser beam source 103 , beam shaping component 104 and deflector 105 ), thereby protecting such other components, enabling atmospheric and temperature regulation and mitigating contamination risks.
- the L-PBF system 100 may include a temperature sensor 122 to monitor the atmospheric temperature, the temperature of the powder material 117 and/or components of the L-PBF system 100 .
- Depositor 101 may include a hopper 115 that contains a powder 117 , such as a metal powder, for example.
- the depositor 101 may also include a leveler 119 that may level the top of each layer of deposited powder (see e.g., powder layer 125 of FIG. 1C ) by displacing deposited powder 117 above a predefined layer height (e.g., corresponding to powder layer thickness 123 of FIG. 1B ).
- FIG. 1A shows L-PBF system 100 after a slice of build piece 109 has been fused, but before the next layer of powder 117 has been deposited.
- FIG. 1A illustrates a time at which L-PBF system 100 has already deposited and fused slices in multiple layers, e.g., 150 layers, to form the current state of build piece 109 , e.g., formed of 150 slices.
- the multiple layers already deposited have created a powder bed 121 , which includes powder that was deposited but not fused.
- FIG. 1B shows L-PBF system 100 at a stage in which build floor 111 may lower by a powder layer thickness 123 .
- the lowering of build floor 111 causes build piece 109 and powder bed 121 to drop by powder layer thickness 123 , so that the top of the build piece and powder bed are lower than the top of powder bed receptacle wall 112 by an amount equal to the powder layer thickness.
- a space with a consistent thickness equal to powder layer thickness 123 can be created over the tops of build piece 109 and powder bed 121 .
- FIG. 1C shows L-PBF system 100 at a stage in which depositor 101 is positioned to deposit powder 117 in a space created over the top surfaces of build piece 109 and powder bed 121 and bounded by powder bed receptacle walls 112 .
- depositor 101 progressively moves over the defined space while releasing powder 117 from hopper 115 .
- Leveler 119 can level the released powder to form a powder layer 125 that has a thickness of substantially equal to the powder layer thickness 123 (see FIG. 1B ).
- the powder 117 in L-PBF system 100 may be supported by a powder material support structure, which may include, for example, a build plate 107 , a build floor 111 , a build piece 109 , walls 112 , and the like.
- a powder material support structure which may include, for example, a build plate 107 , a build floor 111 , a build piece 109 , walls 112 , and the like.
- the illustrated thickness of powder layer 125 e.g., powder layer thickness 123 of FIG. 1B
- FIG. 1D illustrates the L-PBF system 100 generating a next slice in build piece 109 following the deposition of powder layer 125 ( FIG. 1C ).
- the laser beam source 103 may generate a laser beam.
- the beam shaping component 104 may be used to vary the geometric shape of the laser beam to be in the form of a line, a square, a rectangle, or other two-dimensional shape.
- the beam shaping component 104 may shape the laser beam through phase plates and free spacing propagation.
- the beam shaping component 104 may include multiple diffracting, reflecting and refracting apparatus, such as diffractive beam splitters, diffractive diffusers, phase plates, lenses, mirrors or other optical elements.
- Changes in the size and geometry of the laser beam 127 may, for example, be achieved by motorized displacement of the optical elements of beam shaping component 104 as discussed further below with reference to FIGS. 2A-B .
- the geometry of the beam shape may be set according to the build piece 109 .
- the geometry of the beam shape may be modified on a slice-by slice basis based on the geometry of the build piece to reduce scan time for a particular layer.
- the geometry of the beam shape may also be modified mid-layer or even continuously throughout the scanning of the build piece 109 .
- Deflector 105 may apply the laser beam 127 in the selected geometric shape to fuse the next slice in build piece 109 .
- the deflector 105 may include one or more gimbals and actuators that can rotate and/or translate the laser beam source 103 and/or beam shaping component 104 to position the laser beam 127 .
- laser beam source 103 , beam shaping component 104 and/or deflector 105 can modulate the laser beam, e.g., turn the laser beam on and off as the deflector scans such that the laser beam is applied only in the appropriate areas of the powder layer.
- the laser beam can be modulated by a digital signal processor (DSP).
- DSP digital signal processor
- FIGS. 2A and 2B are diagrams illustrating an exemplary beam shaping component operated at two exemplary points in time to change the geometry of a laser beam in accordance with aspects of the present disclosure.
- the beam shaping component 200 may include fixed optical elements 202 A, 202 B and one or more motorized optical elements 204 A, 204 B.
- the optical elements 202 A, 202 b may have a fixed position such that optical elements 202 A, 202 B may not be displaced.
- Motorized optical elements 204 A, 204 B may each include an optical element (e.g., a lens) with a motor component (not shown) to adjust the position of the optical element of the motorized optical element (e.g., 204 A) as a function of time.
- the exemplary beam shaping component 200 includes two motorized optical elements and two fixed optical elements, any number of such optical elements may be used to generate desired beam shape. Also, while for convenience and clarity the optical elements 202 A,B and 204 A,B are shown as circular symbols, these elements can take on any necessary or suitable physical form. Beam shaping may be achieved through phase plates and free spacing propagation. As such, beam shaping component 200 may include multiple diffracting, reflecting and refracting apparatus, such as diffractive beam splitters, diffractive diffusers, phase plates, lenses and mirrors. Of course, still other mechanisms may be used additionally or alternatively to achieve the desired beam geometry. For purposes of FIGS.
- the propagating light from the laser sources is represented generally by the lines originating at a laser beam sources 210 at the left, moving through the various optical elements in one or both directions (depending, for example, on whether the light or portions thereof is being reflected), and terminating in a desired pattern on the surface of the printed object (omitted for clarity) at the right of the figure.
- a ray from a laser beam source 210 may be applied to the fixed optical element 202 A.
- the laser beam may thereafter be alternately reflected and refracted via the fixed optical elements (e.g., 202 A, 202 B) and the presently stationary motorized optical elements ( 204 A, 204 B) to thereby produce a first laser spot 206 .
- the motorized optical elements 204 A, 204 B may be thereafter repositioned such that the geometric shape of the laser beam produced may be changed to a line 208 .
- the size and geometry of the laser beam may be adjusted by displacement of the motorized optical elements. That is, the motorized or otherwise automated mechanism that may be included in each of the motorized optical elements 204 A, 204 B may be used to control the propagation space between optical elements such that the resultant beam size and shape may be modified to the desired form.
- FIG. 3 is a diagram illustrating an exemplary L-BPF system for scanning a build piece in accordance with aspects of the present disclosure.
- a laser beam source 302 may supply a laser beam to a beam shaping component 304 .
- beam shaping component 304 may be configured similarly to beam shaping component 200 ( FIG. 2A ). However, other mechanisms may additionally or alternatively be used to adapt the geometrical shape of the laser beam.
- the beam shaping component 304 may modify the laser beam supplied by laser beam source 302 to generate a laser spot in the form of a line 306 .
- the modified laser beam source 302 may be directed at deflector 305 , which applies the modified laser beam 306 to the powder surface.
- the modified laser beam 306 may be configured in the form of a line that is 10 mm in length, 0.2 mm in width.
- the laser beam 306 may be applied to a powder bed 308 supported by a substrate plate 310 .
- the laser beam 306 may scan across an area of the powder bed in a direction perpendicular to line 306 to fuse powder material in the powder bed 308 to form a slice or layer of a build piece according to a design profile, for example.
- the build rate may be increased and the production time may be reduced.
- the L-BPF process may have a build rate of 2,000 cm 3 /h at a layer thickness of 0.05 mm.
- the shape of the laser beam may be adapted based on the geometry of a desired part to be built.
- the shape of a laser beam may be adapted such that the resultant laser spot is a line.
- the length of the laser spot line (e.g., 402 A, 402 B, and 402 C) may be continuously modified (e.g., under the control of beam shaping component 104 ) based on the geometrical boundaries of the part to be built (e.g., build piece).
- the length of the laser spot line 402 A may be at a maximum L max .
- the length of the laser spot may be adapted such that the powder outside of the geometrical boundary is not be processed. Accordingly, as shown in FIG. 4 , length of the laser beam may be continuously modified (e.g., progressively reduced) to follow the geometrical boundary of the part as the laser beam continues to scan the powder material in a direction perpendicular to its length until a second portion is reached. At the second portion, the laser beam 402 B may be a length L 1 which is less than L max . As the scan continues, the length of the laser beam may be further adapted (e.g., progressively increased) until a third portion of the build piece is reached. At the third portion, the length of laser beam 402 C may be increased to length L 2 . In some aspects, the power (P) of the laser may also be adjusted such that a laser power to length ratio may be maintained such that the overall energy flux remains constant during the scan.
- FIG. 5 is a diagram illustrating exemplary energy flux level configurations of a laser beam adapted for 2-D scanning.
- a laser beam may be transformed to have an essentially one dimensional (1-D) shape (approximated by a line) or a two-dimensional (2-D) shape.
- the beam shape in 2-D scanning may take on any 2-D shape, including, but not limited to rectangles, triangles, or other polygonal or geometric shapes.
- Lower energy levels may be applied to portions of the 1-D or 2-D shape.
- applying a laser beam with different energy levels for different portions of the 2-D shape may be used to provide preheating of the powder material and/or to provide cooling rate control based on the laser beam's relative direction to the region of peak energy flux.
- each portion 504 A, 504 B, etc. may represent a discretely adapted geometric beam shape applied with a particular power.
- an energy profile may be configured such that the energy levels may be adjusted along the width of the rectangle.
- the energy flux level may be increased to a level sufficient for melting the powder material (e.g., peak energy flux).
- the energy flux level is successively reduced in each region.
- the rectangular beam shape 502 A may provide localized preheating of the powder material. That is, as rectangular beam shape 502 A scans powder material in a powder bed, proceeding horizontally in a direction from left to right, the 2-D scan may progressively heat the powder in an area of a powder bed first applying 504 D with the lowest energy flux level.
- the energy flux level (e.g., laser beam intensity) may be increased and in turn, the temperature of the powder material may be increased.
- the energy profile for the laser beam may be configured to preheat the powder material before heating the powders to melting, thermal fluctuation and resultant thermal stresses may be reduced.
- rectangular laser beam shape 502 B four regions having different energy flux levels are shown.
- the energy flux level applied to the powder may be progressively reduced.
- region 506 D may be applied to the region of the powder bed 510 to melt the powder material in the area.
- a progressively lower energy flux level may be applied as regions 506 C, 506 B and 506 A are applied to sequentially scan the material in the area.
- a laser beam may be configured with an energy profile to provide localized heating of powder material and cooling rate control after the powder material has been melted.
- rectangular laser beam 502 C includes seven regions.
- regions 508 G, 508 F, 508 E progressively heat the powder material in the area prior to melting when region 508 D scans the area.
- regions 508 C, 508 B, and 508 A may be sequentially applied to progressively lower the applied energy flux level thereby controlling the cooling rate of the melted material.
- the energy flux level of the laser beam (e.g., 502 A, 502 B, or 502 C) may be adjusted according to the material being processed to reduce thermal stresses commonly observed in parts fabricated by L-PBF processes.
- FIG. 6 is a flowchart of an exemplary method of configuring a laser beam to scan a build piece in a L-PBF apparatus.
- a L-PBF apparatus may optionally determine a geometry of a defined build piece ( 602 ).
- the L-PBF apparatus may adapt a geometry of a laser beam to form an adapted laser beam comprising a line or a 2-D shape ( 604 ).
- the beam shaping component 200 may receive a laser beam from a laser beam source.
- the beam shaping component 200 may be configured with fixed optical elements ( 202 A, 202 B) and motorized optical elements ( 204 A, 204 B).
- the motorized optical elements ( 204 A, 204 B) may be moved or repositioned relative to the fixed optical elements ( 202 A, 202 B) to control the propagation space between optical elements (e.g., motorized and fixed optical elements) such that the resultant laser beam size and shape may be modified.
- Alternative techniques for adapting the desired laser beam shape may also be possible.
- the geometry of the laser beam may be varied during application of the laser beam.
- a laser beam adapted to be in the form of a line (e.g., 402 A, 402 B, and 402 C) may be continuously modified as the laser beam scans the powder material to generate a build piece.
- the length of the laser spot line was modified as the scan progressed across the powder bed.
- the shape of the beam may also be adapted as the scan progresses. That is, the laser beam may be formed as a rectangle during one portion of a scan and may later be changed to a triangle shape at another portion of the scan.
- the laser beam may be adapted based on the geometry of the defined build piece ( 610 ).
- the geometry of the desired build piece may be analyzed to determine the geometrical shape that may most efficiently (e.g., such that the completion time may be reduced or optimized) be used to scan the desired build piece.
- the length of the laser spot line is adjusted based on a boundary specified for the part being built.
- the laser beam geometry may be adapted based on an energy profile associated with the part being built ( 608 ).
- the melting point may vary based on the type of powder material (e.g., different metals) used for the desired build piece.
- the adapted laser beam geometry may be divided into regions.
- An energy profile may specify a different energy flux level to be applied via each of the different regions of the adapted laser beam.
- a rectangular laser beam 502 A may be configured with four regions. In each of the regions 504 B, 504 C, and 504 D, the energy flux level applied is successively reduced. Accordingly, when applied to powder (in reverse order), rectangular beam 502 A progressively heats the powder.
- the energy flux level e.g., laser beam intensity
- the temperature of the powder material may be increased.
- the laser beam may be configured to preheat the powder material before heating the powder to melting (via region 504 A). Accordingly, thermal fluctuation and resultant thermal stresses in the resulting build piece may be reduced.
- the energy profile may be used to adapt the laser beam in order to provide cooling control after the powder material has been melted.
- a rectangular laser beam 502 B may be adapted and configured to include four regions having different energy flux levels. As the rectangular laser beam 502 B scans powder material in a region of the powder bed, the energy flux level applied in each region of the laser beam to the powder may be progressively reduced. By controlling the cooling rate, thermal stresses in the resulting build piece may be further reduced.
- the L-PBF apparatus may apply the adapted laser beam to at least a portion of a powder material to scan at least a portion of the defined build piece ( 606 ).
- a laser beam adapted to be in the form of a line ( 306 ) is applied to the powder material in powder bed 308 thereby melting the powder material to define a portion of the build piece.
- the adapted laser beam may be applied in a direction perpendicular to its length (e.g., a line) or its width. In this way, the adapted laser beam may be applied to a greater area during a scan thereby reducing production time.
- the geometry of the laser beam may be adapted based on a temperature profile ( 612 ).
- the temperature profile may include the temperature at which the powder material to be used for the build piece melts, as well as other thresholds (e.g., temperature at which the powder material evaporates).
- a temperature sensor such as temperature sensor 122 A of FIG. 1A may monitor the temperature of the powder material in the powder bed. When the temperature reaches a critical point, the laser beam may be adapted (e.g., to reduce the energy flux of the laser beam).
- the 2-D shapes may be amorphous, asymmetrical, and need not be in the form of a known shape.
- the CAD software or applications working in conjunction with the CAD software may determine an optimal sequence of varying shapes as a function of time for use in a 3-D print job.
- the software may take into account, among other variables, some or all of the factors described above, including temperature profiles, areas where pre-heating and/or pre-cooling are favorable, geometrical shape of the build object, desire to minimize vaporization effects, etc.
- the beam shaping component 104 ( FIG. 1 ) may be built using various hardware elements referenced herein and implemented in the 3-D printer to adapt the geometrical shape of the beam.
- the beam shaping component 104 may be configured to change the beam shape over time, such as a continuous change of a length of a beam shape in the form of a line. Continuously moving motorized lens and other optical elements, in conjunction with fixed elements, may assist in providing the capability to change the beam shape with the progression of time.
- the CAD software and/or application software associated therewith may be used as a data model for providing instructions to the 3-D printer to operate the beam shaping component 104 and the power profile of the laser beam source 103 in a manner that will render the desired results for a given build piece.
- the laser beam source 103 and the beam shaping component 104 have been generally identified as separate components, in some exemplary embodiments the functionality of both components may be included as part of a single integrated structure without departing from the scope of the disclosure.
- Various exemplary embodiments disclosed herein are directed to novel configurations of a laser with variable bean geometry in a L-PBF system.
Abstract
Systems and methods of adapting the geometrical shape of a laser beam in laser-based powder-bed fusion (PBF) are provided. An apparatus for laser-based powder-bed fusion includes a depositor that deposits a plurality of layers of a powder material. The apparatus further includes a laser beam source that generates a laser beam having a variable beam geometry. A laser application component applies the laser beam in one of a plurality of beam geometries to fuse the powder material to construct a build piece.
Description
- The present disclosure relates generally to additive manufacturing, and more particularly, to variable beam geometry laser-based powder bed fusion.
- Powder-bed fusion (PBF) systems can produce metal structures (referred to as build pieces) with geometrically complex shapes, including some shapes that are difficult or impossible to create with conventional manufacturing processes. PBF systems include additive manufacturing (AM) techniques to create build pieces layer-by-layer. Each layer or slice can be formed by a process of depositing a layer of metal powder and then fusing (e.g., melting and cooling) areas of the metal powder layer that coincide with the cross-section of the build piece in the layer. The process may be repeated to form the next slice of the build piece, and so on until the build piece is complete. Because each layer is deposited on top of the previous layer, PBF may be likened to forming a structure slice-by-slice from the ground up.
- Laser-based PBF may be useful for manufacturing complex geometries and with reduced cost of customization. Unfortunately, manufacturing using laser-based PBF systems can be a slow process compared to what may be needed for high-capacity production. Application of high-power laser systems in current PBF systems may lead to vaporization of materials during the printing process, thereby increasing manufacturing costs.
- Several aspects of a variable beam geometry laser-based PBF and systems and methods for manufacturing therewith will be described more fully hereinafter.
- In an aspect of the present disclosure, an apparatus for laser-based powder-bed fusion is presented. The apparatus includes a depositor that deposits a plurality of layers of a powder material. The apparatus also includes a laser beam source that generates a laser beam having a variable beam geometry. The apparatus further includes a laser application component (e.g., a deflector) that applies the laser beam in one of a plurality of beam geometries to fuse the powder material.
- In another aspect of the present disclosure, a method of laser-based powder-bed fusion is presented. The method includes adapting a laser beam geometry to form an adapted laser beam comprising a line or a two dimensional shape. The method further includes applying the adapted laser beam to at least a portion of a powder material to scan at least a portion of the defined build piece.
- Other aspects will become readily apparent to those skilled in the art from the following detailed description, wherein is shown and described only several exemplary embodiments by way of illustration. As will be realized by those skilled in the art, concepts described herein are capable of other and different embodiments, and several details are capable of modification in various other respects, all without departing from the present disclosure. Accordingly, the drawings and detailed description are to be regarded as illustrative in nature and not as restrictive.
- Various aspects of the concepts described herein will now be presented in the detailed description by way of example, and not by way of limitation, in the accompanying drawings, wherein:
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FIGS. 1A-D illustrate respective side views of an exemplary PBF system during different stages of operation. -
FIGS. 2A and 2B are diagrams illustrating an exemplary beam shaping component operated to change the geometry of a laser beam in accordance with aspects of the present disclosure. -
FIG. 3 is a diagram illustrating an exemplary L-PBF system for scanning a build piece in accordance with aspects of the present disclosure. -
FIG. 4 illustrates an exemplary adaptation of a laser beam during a scan in accordance with aspects of the present disclosure. -
FIG. 5 is a diagram illustrating exemplary energy flux level configurations of a laser beam adapted for 2-D scanning in accordance with aspects of the present disclosure. -
FIG. 6 is a flowchart of an exemplary method of configuring a laser beam to scan a build piece in a L-PBF apparatus. - The detailed description set forth below in connection with the appended drawings is intended to provide a description of various exemplary embodiments of the concepts disclosed herein and is not intended to represent the only embodiments in which the disclosure may be practiced. The term “exemplary” used in this disclosure means “serving as an example, instance, or illustration,” and should not necessarily be construed as preferred or advantageous over other embodiments presented in this disclosure. The detailed description includes specific details for the purpose of providing a thorough and complete disclosure that fully conveys the scope of the concepts to those skilled in the art. However, the disclosure may be practiced without these specific details. In some instances, well-known structures and components may be shown in block diagram form, or omitted entirely, in order to avoid obscuring the various concepts presented throughout this disclosure.
- While this disclosure is generally directed to laser-based PBF (L-PBF) systems, it will be appreciated that such L-PBF systems may encompass a wide variety of AM techniques. Thus, the L-PBF process may include, among others, the following printing techniques: Direct metal laser sintering (DMLS), Selective laser melting (SLM) and Selective laser sintering (SLS). Still other PBF processes to which the principles of this disclosure are pertinent include those that are currently contemplated or under commercial development. While the specific details of each such process are omitted to avoid unduly obscuring key concepts of the disclosure, it will be appreciated that the claims are intended to encompass such techniques and related structures.
- L-PBF systems can produce metal and polymer structures (referred to as build pieces) with geometrically complex shapes, including some shapes that are difficult or impossible to create using conventional manufacturing processes. L-PBF systems create build pieces layer-by-layer, i.e., slice-by-slice. Each slice may be formed by a process of depositing a layer of metal powder and fusing (e.g., melting and cooling) areas of the metal powder layer that coincide with the cross-section of the build piece in the slice. The process may be repeated to form the next slice of the build piece, and so on, until all the layers are deposited and the build piece is complete.
- Aspects of the present disclosure are directed to laser spot geometries for laser-based PBF (L-PBF) systems which may increase build rate and provide additional control and flexibility of the manufacturing process. A laser spot is the area of a surface illuminated by a laser. Rather than use a laser beam configured as terminating in a tiny, almost point-like spot with a small radius that remains constant over time, a laser beam may instead be configured to use variable beam or spot geometries. For example, the beam geometry—that is, the area of the surface of the print material illuminated by the laser—may be a line, a square, a rectangle, a triangle, an asymmetrical shape, or any other two-dimensional shape. The identified beam geometry can then be applied to the surface of the print material using two-dimensional scanning. In so doing, the laser beam may be applied in a PBF print operation such that a larger contiguous area of the powder-bed may be processed at any given time. In an embodiment, the beam geometry can be dynamically altered during a 3-D print operation. Thus, for example, the L-PBF 3-D printer may fuse larger areas using a correspondingly large beam geometry, and subsequently or periodically, the 3-D printer may alter the beam geometry to a small line or an ordinary point-like shape to scan corner portions of the object and/or to fuse details of the build piece on a smaller scale.
- In accordance with aspects of the present disclosure, the laser beam geometry may be adapted based on the geometry of the object (build piece) to be produced. The laser beam geometry may be adapted at the beginning of a scan, on a slice-by slice basis, at a designated time within a slice, or dynamically on the fly. Further, the laser beam geometry may also be varied continuously as the laser scans across the powder-bed, whose variance is in accordance with the contemplated structure of the object as identified in a computer aided design (CAD) profile, for example.
- Employing the variable beam geometry may beneficially increase the throughput of the L-PBF process. Additionally, adapting the beam geometry as described herein may allow for application of laser power over a larger area to the powder bed, meaning that energy flux can be kept small to reduce vaporization of materials. Furthermore, given the two-dimensional nature of the adapted laser spot geometry, the energy profile of the spot geometry may be adjusted according to the scan vector (direction of scanning), to provide heating and cooling rate control. Controlling the cooling rate during the solidification process may allow reduction of thermal stresses and alterations of microstructure in the resultant component to achieve desired material properties.
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FIGS. 1A-D illustrate respective side views of an exemplary laser-based PBF (L-PBF)system 100 during different stages of operation. As noted above, the particular embodiment illustrated inFIGS. 1A-D is one of many suitable examples of a L-PBF system employing principles of this disclosure. It should also be noted that elements ofFIGS. 1A-D and the other figures in this disclosure are not necessarily drawn to scale, but may be drawn larger or smaller for the purpose of better illustration of concepts described herein. L-PBF system 100 may include adepositor 101 that may deposit each layer of powder material, alaser beam source 103 that may generate a laser beam, abeam shaping component 104 that may shape the laser beam according to a selected beam geometry, adeflector 105 that may apply the laser beam in the form of the selected beam geometry to fuse the powder material, and abuild plate 107 that may support one or more build pieces, such as abuild piece 109. - The L-
PBF system 100 may also include abuild floor 111 positioned within a powder bed receptacle. The walls of thepowder bed receptacle 112 may generally define the boundaries of the powder bed receptacle, which is defined between thewalls 112 from the side and a portion of thebuild floor 112 below. Thebuild floor 111 may progressivelylower build plate 107 such thatdepositor 101 may deposit a next layer of powder material. The L-PBF system 100 may additionally include achamber 113 that may enclose the other components of L-PBF system 100 (e.g.,laser beam source 103,beam shaping component 104 and deflector 105), thereby protecting such other components, enabling atmospheric and temperature regulation and mitigating contamination risks. Further, the L-PBF system 100 may include atemperature sensor 122 to monitor the atmospheric temperature, the temperature of thepowder material 117 and/or components of the L-PBF system 100.Depositor 101 may include ahopper 115 that contains apowder 117, such as a metal powder, for example. Thedepositor 101 may also include aleveler 119 that may level the top of each layer of deposited powder (see e.g.,powder layer 125 ofFIG. 1C ) by displacing depositedpowder 117 above a predefined layer height (e.g., corresponding topowder layer thickness 123 ofFIG. 1B ). - Referring specifically to
FIG. 1A , this figure shows L-PBF system 100 after a slice ofbuild piece 109 has been fused, but before the next layer ofpowder 117 has been deposited. In fact,FIG. 1A illustrates a time at which L-PBF system 100 has already deposited and fused slices in multiple layers, e.g., 150 layers, to form the current state ofbuild piece 109, e.g., formed of 150 slices. The multiple layers already deposited have created apowder bed 121, which includes powder that was deposited but not fused. -
FIG. 1B shows L-PBF system 100 at a stage in which buildfloor 111 may lower by apowder layer thickness 123. The lowering ofbuild floor 111 causesbuild piece 109 andpowder bed 121 to drop bypowder layer thickness 123, so that the top of the build piece and powder bed are lower than the top of powderbed receptacle wall 112 by an amount equal to the powder layer thickness. In this way, for example, a space with a consistent thickness equal topowder layer thickness 123 can be created over the tops ofbuild piece 109 andpowder bed 121. -
FIG. 1C shows L-PBF system 100 at a stage in whichdepositor 101 is positioned to depositpowder 117 in a space created over the top surfaces ofbuild piece 109 andpowder bed 121 and bounded by powderbed receptacle walls 112. In this example,depositor 101 progressively moves over the defined space while releasingpowder 117 fromhopper 115.Leveler 119 can level the released powder to form apowder layer 125 that has a thickness of substantially equal to the powder layer thickness 123 (seeFIG. 1B ). Thus, thepowder 117 in L-PBF system 100 may be supported by a powder material support structure, which may include, for example, abuild plate 107, abuild floor 111, abuild piece 109,walls 112, and the like. It should be noted that the illustrated thickness of powder layer 125 (e.g.,powder layer thickness 123 ofFIG. 1B ) may be greater than an actual thickness used for the example involving 150 previously-deposited layers discussed above with reference toFIG. 1A . -
FIG. 1D illustrates the L-PBF system 100 generating a next slice inbuild piece 109 following the deposition of powder layer 125 (FIG. 1C ). Referring toFIG. 1D , thelaser beam source 103 may generate a laser beam. Thebeam shaping component 104 may be used to vary the geometric shape of the laser beam to be in the form of a line, a square, a rectangle, or other two-dimensional shape. In some aspects, thebeam shaping component 104 may shape the laser beam through phase plates and free spacing propagation. Thebeam shaping component 104 may include multiple diffracting, reflecting and refracting apparatus, such as diffractive beam splitters, diffractive diffusers, phase plates, lenses, mirrors or other optical elements. Changes in the size and geometry of thelaser beam 127 may, for example, be achieved by motorized displacement of the optical elements ofbeam shaping component 104 as discussed further below with reference toFIGS. 2A-B . In some aspects, the geometry of the beam shape may be set according to thebuild piece 109. The geometry of the beam shape may be modified on a slice-by slice basis based on the geometry of the build piece to reduce scan time for a particular layer. In some aspects, the geometry of the beam shape may also be modified mid-layer or even continuously throughout the scanning of thebuild piece 109. -
Deflector 105 may apply thelaser beam 127 in the selected geometric shape to fuse the next slice inbuild piece 109. In various embodiments, thedeflector 105 may include one or more gimbals and actuators that can rotate and/or translate thelaser beam source 103 and/orbeam shaping component 104 to position thelaser beam 127. In various embodiments,laser beam source 103,beam shaping component 104 and/ordeflector 105 can modulate the laser beam, e.g., turn the laser beam on and off as the deflector scans such that the laser beam is applied only in the appropriate areas of the powder layer. For example, in various embodiments, the laser beam can be modulated by a digital signal processor (DSP). - As shown in
FIG. 1D , much of the fusing ofpowder layer 125 occurs in areas of the powder layer that are on top of the previous slice, i.e., previously-fused powder. An example of such an area is the surface ofbuild piece 109. The fusing of the powder layer inFIG. 1D is occurring over the previously fused layers characterizing the substance ofbuild piece 109. -
FIGS. 2A and 2B are diagrams illustrating an exemplary beam shaping component operated at two exemplary points in time to change the geometry of a laser beam in accordance with aspects of the present disclosure. Referring toFIGS. 2A-2B , thebeam shaping component 200 may include fixedoptical elements optical elements optical elements 202A, 202 b may have a fixed position such thatoptical elements optical elements beam shaping component 200 includes two motorized optical elements and two fixed optical elements, any number of such optical elements may be used to generate desired beam shape. Also, while for convenience and clarity theoptical elements 202A,B and 204A,B are shown as circular symbols, these elements can take on any necessary or suitable physical form. Beam shaping may be achieved through phase plates and free spacing propagation. As such,beam shaping component 200 may include multiple diffracting, reflecting and refracting apparatus, such as diffractive beam splitters, diffractive diffusers, phase plates, lenses and mirrors. Of course, still other mechanisms may be used additionally or alternatively to achieve the desired beam geometry. For purposes ofFIGS. 2A-B , the propagating light from the laser sources is represented generally by the lines originating at alaser beam sources 210 at the left, moving through the various optical elements in one or both directions (depending, for example, on whether the light or portions thereof is being reflected), and terminating in a desired pattern on the surface of the printed object (omitted for clarity) at the right of the figure. - As shown in
FIG. 2A , a ray from alaser beam source 210 may be applied to the fixedoptical element 202A. When a laser beam is applied initially tooptical elements 202A, the laser beam may thereafter be alternately reflected and refracted via the fixed optical elements (e.g., 202A, 202B) and the presently stationary motorized optical elements (204A, 204B) to thereby produce afirst laser spot 206. InFIG. 2B , the motorizedoptical elements line 208. The size and geometry of the laser beam may be adjusted by displacement of the motorized optical elements. That is, the motorized or otherwise automated mechanism that may be included in each of the motorizedoptical elements -
FIG. 3 is a diagram illustrating an exemplary L-BPF system for scanning a build piece in accordance with aspects of the present disclosure. Referring toFIG. 3 , alaser beam source 302 may supply a laser beam to abeam shaping component 304. In this example,beam shaping component 304 may be configured similarly to beam shaping component 200 (FIG. 2A ). However, other mechanisms may additionally or alternatively be used to adapt the geometrical shape of the laser beam. Thebeam shaping component 304 may modify the laser beam supplied bylaser beam source 302 to generate a laser spot in the form of aline 306. The modifiedlaser beam source 302 may be directed atdeflector 305, which applies the modifiedlaser beam 306 to the powder surface. By way of example only, the modifiedlaser beam 306 may be configured in the form of a line that is 10 mm in length, 0.2 mm in width. Thelaser beam 306 may be applied to apowder bed 308 supported by asubstrate plate 310. Thelaser beam 306 may scan across an area of the powder bed in a direction perpendicular toline 306 to fuse powder material in thepowder bed 308 to form a slice or layer of a build piece according to a design profile, for example. Here, by adapting the geometry of thelaser beam 306 to be in form of line rather than a point, the build rate may be increased and the production time may be reduced. For instance, using the exemplary laser beam, moving perpendicular to its length at a speed of 1200 mm/s, the L-BPF process may have a build rate of 2,000 cm3/h at a layer thickness of 0.05 mm. - In some aspects, the shape of the laser beam may be adapted based on the geometry of a desired part to be built. Referring to
FIG. 4 , the shape of a laser beam may be adapted such that the resultant laser spot is a line. The length of the laser spot line (e.g., 402A, 402B, and 402C) may be continuously modified (e.g., under the control of beam shaping component 104) based on the geometrical boundaries of the part to be built (e.g., build piece). At a first portion the length of thelaser spot line 402A may be at a maximum Lmax. Based on the geometry of the build piece as given by the designated geometrical boundary of the part, the length of the laser spot may be adapted such that the powder outside of the geometrical boundary is not be processed. Accordingly, as shown inFIG. 4 , length of the laser beam may be continuously modified (e.g., progressively reduced) to follow the geometrical boundary of the part as the laser beam continues to scan the powder material in a direction perpendicular to its length until a second portion is reached. At the second portion, thelaser beam 402B may be a length L1 which is less than Lmax. As the scan continues, the length of the laser beam may be further adapted (e.g., progressively increased) until a third portion of the build piece is reached. At the third portion, the length oflaser beam 402C may be increased to length L2. In some aspects, the power (P) of the laser may also be adjusted such that a laser power to length ratio may be maintained such that the overall energy flux remains constant during the scan. -
FIG. 5 is a diagram illustrating exemplary energy flux level configurations of a laser beam adapted for 2-D scanning. As discussed above, a laser beam may be transformed to have an essentially one dimensional (1-D) shape (approximated by a line) or a two-dimensional (2-D) shape. The beam shape in 2-D scanning may take on any 2-D shape, including, but not limited to rectangles, triangles, or other polygonal or geometric shapes. Lower energy levels may be applied to portions of the 1-D or 2-D shape. In one example, applying a laser beam with different energy levels for different portions of the 2-D shape may be used to provide preheating of the powder material and/or to provide cooling rate control based on the laser beam's relative direction to the region of peak energy flux. - Referring to
FIG. 5 , energy flux level configurations are provided for three exemplary rectangular laser beam shapes 502A, 502B, and 502C.Rectangular laser beam 502A is divided into four regions. Each of the regions may be configured to have different sizes with different energy flux levels. By way of example only, a rectangular laser spot may be configured to be 10 mm in length and 5 mm in width with varying energy levels across its width. Of course, the number and size of the regions are merely exemplary and any number and size of regions may be included in a laser beam shape. Similarly, although the beam shapes in the examples ofFIG. 5 are rectangles, any multi-dimensional shape may be used. In other embodiments, each portion 504A, 504B, etc. may represent a discretely adapted geometric beam shape applied with a particular power. - In shaping the laser beam, an energy profile may be configured such that the energy levels may be adjusted along the width of the rectangle. In region 504A, the energy flux level may be increased to a level sufficient for melting the powder material (e.g., peak energy flux). Thereafter, in
regions rectangular beam shape 502A may provide localized preheating of the powder material. That is, asrectangular beam shape 502A scans powder material in a powder bed, proceeding horizontally in a direction from left to right, the 2-D scan may progressively heat the powder in an area of a powder bed first applying 504D with the lowest energy flux level. As each successive region is applied to the same area of powder material, the energy flux level (e.g., laser beam intensity) may be increased and in turn, the temperature of the powder material may be increased. By configuring the energy profile for the laser beam to preheat the powder material before heating the powders to melting, thermal fluctuation and resultant thermal stresses may be reduced. - In rectangular
laser beam shape 502B, four regions having different energy flux levels are shown. As thelaser beam shape 502B scans powder material in a region of the powder bed, the energy flux level applied to the powder may be progressively reduced. For instance, region 506D may be applied to the region of thepowder bed 510 to melt the powder material in the area. As the laser beam continues in the direction perpendicular to the width oflaser beam 502B from left to right, a progressively lower energy flux level may be applied asregions laser beam shape 502B this way, a 2-D scan usinglaser beam shape 502B may provide control on the cooling rate of the solidified material. Controlling the cooling rate may reduce thermal stress and further enable production of the resultant microstructure of the build piece components to desired properties. - In some aspects, a laser beam may be configured with an energy profile to provide localized heating of powder material and cooling rate control after the powder material has been melted. As shown in
FIG. 5 ,rectangular laser beam 502C includes seven regions. When applied to powder material in an area ofpowder bed 510,regions 508G, 508F, 508E progressively heat the powder material in the area prior to melting when region 508D scans the area. After region 508D scans the designated area of thepowder bed 510,regions -
FIG. 6 is a flowchart of an exemplary method of configuring a laser beam to scan a build piece in a L-PBF apparatus. A L-PBF apparatus may optionally determine a geometry of a defined build piece (602). The L-PBF apparatus may adapt a geometry of a laser beam to form an adapted laser beam comprising a line or a 2-D shape (604). For example, referring toFIGS. 2A-2B , thebeam shaping component 200 may receive a laser beam from a laser beam source. Thebeam shaping component 200 may be configured with fixed optical elements (202A, 202B) and motorized optical elements (204A, 204B). The motorized optical elements (204A, 204B) may be moved or repositioned relative to the fixed optical elements (202A, 202B) to control the propagation space between optical elements (e.g., motorized and fixed optical elements) such that the resultant laser beam size and shape may be modified. Alternative techniques for adapting the desired laser beam shape may also be possible. - In some aspects, the geometry of the laser beam may be varied during application of the laser beam. For example, as shown in
FIG. 4 , a laser beam adapted to be in the form of a line (e.g., 402A, 402B, and 402C) may be continuously modified as the laser beam scans the powder material to generate a build piece. In the example ofFIG. 4 , the length of the laser spot line was modified as the scan progressed across the powder bed. However, the present disclosure is not so limiting and other modifications are contemplated. For example, the shape of the beam may also be adapted as the scan progresses. That is, the laser beam may be formed as a rectangle during one portion of a scan and may later be changed to a triangle shape at another portion of the scan. In some aspects, the laser beam may be adapted based on the geometry of the defined build piece (610). For example, the geometry of the desired build piece may be analyzed to determine the geometrical shape that may most efficiently (e.g., such that the completion time may be reduced or optimized) be used to scan the desired build piece. In another example, as shown inFIG. 4 , the length of the laser spot line is adjusted based on a boundary specified for the part being built. - In some aspects, the laser beam geometry may be adapted based on an energy profile associated with the part being built (608). For instance, the melting point may vary based on the type of powder material (e.g., different metals) used for the desired build piece. The adapted laser beam geometry may be divided into regions. An energy profile may specify a different energy flux level to be applied via each of the different regions of the adapted laser beam. For example, as shown in
FIG. 5 , arectangular laser beam 502A may be configured with four regions. In each of theregions rectangular beam 502A progressively heats the powder. As each successive region (e.g.,504 D→ 504C→504B→504A) is applied to the same area of powder material, the energy flux level (e.g., laser beam intensity) may be increased, and in turn, the temperature of the powder material may be increased. By adapting the laser beam with regions based on the energy profile, the laser beam may be configured to preheat the powder material before heating the powder to melting (via region 504A). Accordingly, thermal fluctuation and resultant thermal stresses in the resulting build piece may be reduced. - Furthermore, the energy profile may be used to adapt the laser beam in order to provide cooling control after the powder material has been melted. For example, as shown in
FIG. 5 , arectangular laser beam 502B may be adapted and configured to include four regions having different energy flux levels. As therectangular laser beam 502B scans powder material in a region of the powder bed, the energy flux level applied in each region of the laser beam to the powder may be progressively reduced. By controlling the cooling rate, thermal stresses in the resulting build piece may be further reduced. - The L-PBF apparatus may apply the adapted laser beam to at least a portion of a powder material to scan at least a portion of the defined build piece (606). For example, as shown in
FIG. 3 , a laser beam adapted to be in the form of a line (306) is applied to the powder material inpowder bed 308 thereby melting the powder material to define a portion of the build piece. The adapted laser beam may be applied in a direction perpendicular to its length (e.g., a line) or its width. In this way, the adapted laser beam may be applied to a greater area during a scan thereby reducing production time. - In some aspects, the geometry of the laser beam may be adapted based on a temperature profile (612). For example, the temperature profile may include the temperature at which the powder material to be used for the build piece melts, as well as other thresholds (e.g., temperature at which the powder material evaporates). A temperature sensor such as temperature sensor 122A of
FIG. 1A may monitor the temperature of the powder material in the powder bed. When the temperature reaches a critical point, the laser beam may be adapted (e.g., to reduce the energy flux of the laser beam). - In other embodiments, the 2-D shapes may be amorphous, asymmetrical, and need not be in the form of a known shape. In some embodiments, the CAD software or applications working in conjunction with the CAD software may determine an optimal sequence of varying shapes as a function of time for use in a 3-D print job. The software may take into account, among other variables, some or all of the factors described above, including temperature profiles, areas where pre-heating and/or pre-cooling are favorable, geometrical shape of the build object, desire to minimize vaporization effects, etc. The beam shaping component 104 (
FIG. 1 ) may be built using various hardware elements referenced herein and implemented in the 3-D printer to adapt the geometrical shape of the beam. Thebeam shaping component 104 may be configured to change the beam shape over time, such as a continuous change of a length of a beam shape in the form of a line. Continuously moving motorized lens and other optical elements, in conjunction with fixed elements, may assist in providing the capability to change the beam shape with the progression of time. The CAD software and/or application software associated therewith may be used as a data model for providing instructions to the 3-D printer to operate thebeam shaping component 104 and the power profile of thelaser beam source 103 in a manner that will render the desired results for a given build piece. - While the
laser beam source 103 and thebeam shaping component 104 have been generally identified as separate components, in some exemplary embodiments the functionality of both components may be included as part of a single integrated structure without departing from the scope of the disclosure. - Various exemplary embodiments disclosed herein are directed to novel configurations of a laser with variable bean geometry in a L-PBF system.
- The previous description is provided to enable any person skilled in the art to practice the various aspects described herein. Various modifications to these exemplary embodiments presented throughout this disclosure will be readily apparent to those skilled in the art, and the concepts disclosed herein may be applied to other support structures and systems and methods for removal of support structures. Thus, the claims are not intended to be limited to the exemplary embodiments presented throughout the disclosure, but are to be accorded the full scope consistent with the language claims. All structural and functional equivalents to the elements of the exemplary embodiments described throughout this disclosure that are known or later come to be known to those of ordinary skill in the art are intended to be encompassed by the claims. Moreover, nothing disclosed herein is intended to be dedicated to the public regardless of whether such disclosure is explicitly recited in the claims. No claim element is to be construed under the provisions of 35 U.S.C. § 112(f), or analogous law in applicable jurisdictions, unless the element is expressly recited using the phrase “means for” or, in the case of a method claim, the element is recited using the phrase “step for.”
Claims (28)
1. An apparatus for laser-based powder-bed fusion, comprising:
a depositor that deposits a plurality of layers of a powder material;
a laser beam source that generates a laser beam; and
a beam shaping component that shapes the laser beam into one of a plurality of beam geometries to fuse the powder material.
2. The apparatus of claim 1 , wherein the beam shaping component is configured to vary a beam geometry of the laser beam from the laser beam source during application of the laser beam.
3. The apparatus of claim 1 , wherein a laser beam geometry is varied based on a design profile for an object to be produced.
4. The apparatus of claim 1 , wherein a laser beam geometry is varied based on an energy profile for an object to be produced.
5. The apparatus of claim 1 , wherein a beam geometry of the laser beam comprises a two-dimensional shape.
6. The apparatus of claim 1 , wherein a beam geometry of the laser beam comprises a line.
7. The apparatus of claim 6 , wherein a length of the line is variable based on an energy profile of the laser beam.
8. The apparatus of claim 1 , wherein a beam geometry includes at least a first portion and a second portion and an energy profile of the first portion is different from an energy profile of the second portion.
9. The apparatus of claim 8 , wherein the energy profile of the first portion and the energy profile of the second portion are configured based at least in part on a temperature profile.
10. The apparatus of claim 8 , wherein the laser beam source is configured to provide a constant energy flux between the first portion and the second portion.
11. The apparatus of claim 8 , wherein the first portion is configured to preheat the powder material and the second portion is configured to fuse the powder material.
12. The apparatus of claim 8 , wherein the first portion is configured to fuse the powder material and the second portion is configured to reduce an energy flux to control cooling of the fused powder material.
13. The apparatus of claim 1 , further comprising a controller coupled to the laser beam source and configured to control a power density of a laser beam emitted from the laser beam source.
14. The apparatus of claim 1 , wherein a laser beam geometry is varied based on a temperature profile for an object to be produced.
15. The apparatus of claim 1 , wherein the beam shaping component comprises at least one of each of a fixed optical element and a movable optical element aligned to encompass the laser beam.
16. The apparatus of claim 15 , wherein at least one of the optical elements comprises a lens.
17. A method of laser-based powder-bed fusion, comprising:
adapting a geometry of a laser beam to form an adapted laser beam comprising a line or a two dimensional shape upon contacting a surface of a layer of powder material; and
applying the adapted laser beam to at least a portion of the layer of powder material to fuse at least a portion of a defined build piece.
18. The method of claim 17 , further comprising varying the geometry of the laser beam over time during application of the laser beam.
19. The method of claim 17 , further comprising varying the geometry of the laser beam based on an energy profile for an object to be produced.
20. The method of claim 17 , wherein a laser beam geometry of the adapted laser beam comprises a two-dimensional shape.
21. The method of claim 17 , wherein a laser beam geometry of the adapted laser beam comprises the line, the method further comprising applying the adapted laser beam in a direction perpendicular to a length of the line.
22. The method of claim 21 , further comprising varying a length of the line based on an energy profile of the adapted laser beam.
23. The method of claim 17 , wherein a laser beam geometry of the adapted laser beam includes at least a first portion and a second portion and an energy profile of the first portion is different than the energy profile of the second portion.
24. The method of claim 23 , wherein the energy profile of the first portion and the energy profile of the second portion are configured based at least in part on a temperature profile.
25. The method of claim 23 , wherein the energy profile of the first portion and the energy profile of the second portion are configured to provide a constant energy flux between the first portion and the second portion.
26. The method of claim 23 , wherein the first portion is configured to preheat the powder material and the second portion is configured to fuse the powder material.
27. The method of claim 23 , wherein the first portion is configured to fuse the powder material and the second portion is configured to reduce an energy flux to control cooling of the fused powder material.
28. The method of claim 17 , further comprising determining a geometry of the defined build piece, and wherein the geometry of the laser beam is adapted based on the geometry of the defined build piece.
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CN116117174A (en) | 2023-05-16 |
CN112118926A (en) | 2020-12-22 |
WO2019173363A1 (en) | 2019-09-12 |
CN112118926B (en) | 2023-03-28 |
US11224943B2 (en) | 2022-01-18 |
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