WO2021221601A1 - Fusion partielle dans la fabrication additive - Google Patents

Fusion partielle dans la fabrication additive Download PDF

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Publication number
WO2021221601A1
WO2021221601A1 PCT/US2020/030066 US2020030066W WO2021221601A1 WO 2021221601 A1 WO2021221601 A1 WO 2021221601A1 US 2020030066 W US2020030066 W US 2020030066W WO 2021221601 A1 WO2021221601 A1 WO 2021221601A1
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WO
WIPO (PCT)
Prior art keywords
light
build material
examples
build
selectable
Prior art date
Application number
PCT/US2020/030066
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English (en)
Inventor
Seongsik Chang
Original Assignee
Hewlett-Packard Development Company, L.P.
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by Hewlett-Packard Development Company, L.P. filed Critical Hewlett-Packard Development Company, L.P.
Priority to PCT/US2020/030066 priority Critical patent/WO2021221601A1/fr
Publication of WO2021221601A1 publication Critical patent/WO2021221601A1/fr

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Classifications

    • 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
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C64/00—Additive manufacturing, i.e. manufacturing of three-dimensional [3D] objects by additive deposition, additive agglomeration or additive layering, e.g. by 3D printing, stereolithography or selective laser sintering
    • B29C64/10—Processes of additive manufacturing
    • B29C64/141—Processes of additive manufacturing using only solid materials
    • B29C64/153—Processes of additive manufacturing using only solid materials using layers of powder being selectively joined, e.g. by selective laser sintering or melting
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C64/00—Additive manufacturing, i.e. manufacturing of three-dimensional [3D] objects by additive deposition, additive agglomeration or additive layering, e.g. by 3D printing, stereolithography or selective laser sintering
    • B29C64/20—Apparatus for additive manufacturing; Details thereof or accessories therefor
    • B29C64/264—Arrangements for irradiation
    • B29C64/277—Arrangements for irradiation using multiple radiation means, e.g. micromirrors or multiple light-emitting diodes [LED]
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C64/00—Additive manufacturing, i.e. manufacturing of three-dimensional [3D] objects by additive deposition, additive agglomeration or additive layering, e.g. by 3D printing, stereolithography or selective laser sintering
    • B29C64/20—Apparatus for additive manufacturing; Details thereof or accessories therefor
    • B29C64/264—Arrangements for irradiation
    • B29C64/286—Optical filters, e.g. masks
    • 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
    • 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

Definitions

  • Additive manufacturing may revolutionize design and manufacturing in producing three-dimensional (3D) objects.
  • Some forms of additive manufacturing may sometimes be referred to as 3D printing, and may produce 3D objects using a variety of different materials, some of which may comprise metal.
  • FIG. 1 is a block diagram and an isometric view schematically representing an example device and/or example method to additively manufacture a 3D object.
  • FIG. 2 is a diagram including a side view schematically representing a light modulating unit including a laser diode and a grating light valve (GLV).
  • FIGS. 3, 4A, and 4B are each a top view of an example two-dimensional array of light modulating units.
  • FIG. 5A is a block diagram schematically representing an example object formation engine.
  • FIG. 5B is a block diagram schematically representing an example control portion.
  • FIG. 5C is a block diagram schematically representing an example user interface.
  • FIG. 6 is a flow diagram schematically representing an example method of additively manufacturing a 3D object.
  • At least some examples of the present disclosure provide for additively manufacturing a 3D object via partial melting of selectable voxel locations of deposited build material followed by oven sintering to complete solidification of the formed 3D object.
  • the partial melting may be implemented via light modulating units, which comprise a diode laser element and a grating light valve (GLV), including an array of valve elements, to project the light (emitted by the laser diode) onto the selectable voxel locations of the build material.
  • light modulating units comprise a diode laser element and a grating light valve (GLV), including an array of valve elements
  • the diode laser element provides an economical source of light at high intensity while the grating light valve (GLV) provides light transmission selectivity in an arrangement capable of withstanding the high intensities of light for causing partial melting of powder build materials, such as but not limited to metal powder build materials.
  • causing a desired degree of partial melting of some metal powder build materials sufficient to cause neck-to-neck fusion may involve a fluence light of about 30 Joules/cm 2 , and intensities of about 1 kW/cm 2 to about 100 kW/cm 2 , depending on the size and type of particles of build material.
  • the grating light valve (GLV) can withstand such intensities, whereas some other types of light transmission selectivity devices (e.g. digital micro-mirror devices (DMD)) may not be able to withstand such high intensities of light.
  • DMD digital micro-mirror devices
  • the example diode laser element 205 and grating light valves (GLV) 207 can provide such intensities (to achieve the desired partial melting) at a cost substantially lower than using other expensive, high power light sources which are typically used to create complete melting, for example, in selective laser melting (SLM) method.
  • the substantially lower cost comprises a cost of at least one order of magnitude lower.
  • completion of the solidification of the 3D object may be implemented via oven sintering which increases densification and which may relax stresses induced during the partial melting.
  • FIG. 1 is a diagram 101 schematically representing an example device 100 (and/or example method) to additively manufacture a 3D object 180.
  • the device 100 comprises a material distributor 150 and a light source 200.
  • the light source 200 may sometimes be referred to as a radiation source.
  • the material distributor 150 is arranged to dispense a build material layer-by-layer onto a build platform 142 to additively form the 3D object 180. Once formed, the 3D object 180 may be separated from the build platform 142. It will be understood that a 3D object of any shape and any size can be manufactured, and the cube-shaped object 180 depicted in FIG. 1 provides just one example shape and size of a 3D object.
  • device 100 may sometimes be referred to as a 3D printer.
  • the build platform 142 may sometimes be referred to as a build pad, print bed, or a receiving surface.
  • a finally formed 3D object 180 may comprise just selectable portions of a total amount of material initially distributed onto the build platform 142, with the selectable portions corresponding to deposited build material which has been fused, solidified, etc. to form the 3D object, and the remaining non-fused material being separated and discarded.
  • the material distributor 150 may be implemented via a variety of electromechanical or mechanical mechanisms, such as doctor blades, rollers, slot dies, extruders, and/or other structures suitable to spread, deposit, and/or otherwise form a coating of the build material in a generally uniform layer relative to the build platform 142 or relative to a previously deposited layer of build material.
  • the material distributor 150 has a length (L1) at least generally matching an entire length (L1) of the build platform 142, such that the material distributor 150 is capable of coating the entire build platform 142 with a layer 182 of build material in a single pass as the material distributor 150 travels the width (W1) of the build platform 142.
  • the material distributor 150 can selectively deposit layers of material in lengths and patterns less than a full length of the material distributor 150. In some examples, the material distributor 150 may coat the build platform 142 with a layer 182 of build material(s) using multiple passes instead of a single pass.
  • a 3D object additively formed via device 100 may have a width and/or a length less than a width (W1) and/or length (L1) of the build platform 142.
  • the material distributor 150 moves in a first orientation (represented by directional arrow F) while the light source 200 moves in a second orientation (represented by directional arrow S) generally perpendicular to the first orientation.
  • the material distributor 150 can deposit material in each pass of a back-and-forth travel path along the first orientation while the light source 200 can transmit light selectively in each pass of a back-and-forth travel path along the second orientation.
  • one pass is completed by the material distributor 150, followed by a pass of the light source 200 before a second pass of the material distributor 150 is initiated, and so on. Further details regarding the light source 200 are provided below.
  • the material distributor 150 and the light source unit 200 can be arranged to move in the same orientation, either the first orientation (F) or the second orientation (S). In some such examples, the material distributor 150 and the light source 200 may be supported and moved via a single carriage while in some such examples, the material distributor 150 and light source 200 may be supported and moved via separate, independent carriages. In some examples, the movement of the material distributor 150, light source 200, and/or their carriage(s) relative to the build platform 142 may sometimes be referred to as scanning.
  • the build material used to generally form the 3D object comprises a metal material, such as a metal powder. At least some example materials may comprise aluminum alloys, steel, titanium alloys, and the like. In some examples, the build material may comprise a ceramic material, while in some examples the build material may comprise a crystal material. Some such example materials may comprise quartz, alumina, glass, and the like.
  • the build material may comprise a polymer material, and in some such examples, the polymer material comprises a polyamide material.
  • the polymer material comprises a polyamide material.
  • a broad range of polymer materials may be employed as the build material.
  • some example polymer materials may comprise nylon, thermoplastic materials, resin, carbon-fiber enhanced resin, polyetheretherketone (PEEK), and the like.
  • the build material may take the form of a powder.
  • the build material are suitable for spreading, depositing, extruding, flowing, etc. in a form to produce layers (via material distributor 150) additively relative to build platform 142 and/or relative to previously formed first layers of the build material.
  • the light source 200 comprises, and is to selectively transmit light via, an array of light modulating units 202 arranged in a side-by- side relationship (e.g. a linear array) as shown in FIG.1.
  • each respective light modulating unit 202 may sometimes be referred to as a radiation unit.
  • each light modulating unit 202 includes a diode laser element 205 and a grating light valve (GLV) 207.
  • the diode laser element 205 emits light which selectively passes through grating light valve 207 to be projected onto a respective layer of build material on build platform 142.
  • each light modulating unit 202, the diode laser element 205 emits light E toward and into a grating light valve (GLV) 207.
  • each grating light valve (GLV) 207 comprises a linear array of valve elements 272, which are individually controllable to either dissipate light (e.g. to prevent its passage) or to permit passage and projection of light (as represented by arrows G) onto a respective layer of build material on the build platform 142.
  • each valve element 272 of the GLV 207 may comprise a ribbon structure which is configurable into a first state and a second state, and which operates on the principle of optical reflectance and optical interference.
  • the ribbon structure (defining the valve element 272) is configured to cause superposition of reflected radiation which constructively interferes such that light (e.g. radiation from the diode laser element 205) is permitted to pass through the respective valve element 272 onto a respective layer 182 of the build material.
  • the valve element 272 may sometimes be referred to as being “on”, an on pixel, or as a pixel in an “on” state.
  • the ribbon structure (defining the valve element 272) is configured to cause superposition of the reflected radiation to destructively interfere, such that the light (e.g. radiation from the diode laser element) is dissipated isotropically (e.g. at an 180 degree angle) and therefore not projected from the valve element.
  • valve element 272 in the second state the valve element 272 may sometimes be referred to as being “off”, an off pixel, or a pixel in an “off” state. Accordingly, via this arrangement each valve element 272 of a GLV 207 (and therefore of a light modulating unit 202) is individually controllable to modulate light to permit its projection or to prevent its projection on the build material.
  • the grating light valve (GLV) 207 may comprise one example implementation of, or sometimes be referred to as, a spatial light modulator (SLM), which comprises an array of optical elements (e.g. 272) in which each optical element acts independently as an optical "valve" to modulate light intensity, such as in the above-described example implementation.
  • SLM spatial light modulator
  • the diode laser element 205 comprises solely a diode laser (i.e. laser diode).
  • the diode laser element 205 may comprise a diode-pumped solid state (DPSS) laser, which includes a diode laser as part of its construction along with additional optical elements.
  • DPSS diode-pumped solid state
  • the example DPSS laser also provides a relatively inexpensive way to generate light, at desired intensity levels to cause partial melting and neck-to-neck fusion, as compared to much higher cost, high power laser sources typically used for selective laser sintering (SLS), selective laser melting (SLM), and the like.
  • SLS selective laser sintering
  • SLM selective laser melting
  • the light modulating units 202 of light source 200 selectively transmit light on a voxel-by- voxel basis.
  • a voxel may be understood as a unit of volume in a three-dimensional space.
  • an X-Y dimension of a voxel corresponds to the area of light projected onto the build material from each individually controllable valve element 272 of a respective grating light valve (GLV) 207.
  • one such voxel corresponds to a voxel location 174 illustrated in FIG. 1
  • several such voxels correspond to one of the voxel locations 174 in FIG. 1.
  • an at least partially formed 3D object 180 on build platform 142 comprises at least first portion 171 and an exterior side surface 188.
  • the light source 200 is employed to transmit light at some selectable voxel locations 174 of at least some respective layers 182 to at least partially define at least the first portion 171 of the 3D object. It will be understood that a group 172 of selectable voxel locations 174, or multiple different groups 172 of selectable voxel locations 174 may be selected in any position, any size, any shape, and/or combination of shapes.
  • the at least some selectable voxel locations 174 may correspond to an entire layer 182 of a 3D object or just a portion of a layer 182. In some examples, each selectable voxel location 174 corresponds to a single voxel.
  • 182a voxel may correspond to an about 30 micron (X) by about 30 micron (Y) area in the x-y plane, and each valve element 272 of a grating light valve (GLV) 207 (e.g. FIG. 2) may correspond to a single voxel.
  • GLV grating light valve
  • light may be transmitted from light source 200 at a resolution of 1000 voxels per 30 micron (X) by 3 centimeter (Y) area in the X-Y plane (e.g. per each GLV 207).
  • the size of the voxel may comprise other dimensions, such as 20 micrometers (X) by about 20 micrometers, about 25 micrometers (X) by about 25 micrometers (Y), 35 micrometers (X) by about 35 micrometers (Y), and the like.
  • each grating light valve (GLV) 207 comprises a total light projection area of 30 micrometers by 3 centimeters, where the 3 centimeters extends in an orientation across a width (W1 in FIG. 1) of the build platform 142 (e.g. scanning area) and 30 micrometers extends along a length (L1) of the build platform (e.g. scanning area).
  • W1 in FIG. 1 a width
  • L1 a length of the build platform
  • each grating light valve (GLV) 207 has the dimensions noted above (e.g. 30 micrometers by 3 centimeters).
  • the height (H2) of a voxel (Z dimension) is selectable in some examples, and may depend (at least in part) on the depth of penetration of partial melting caused by the light projected from the respective valve elements 272 (of each GLV 207 of the respective light units 202), wherein the thickness of build material deposited via the material distributor 150 may be selected to correspond to the expected depth of penetration of partial melting. Accordingly, in some examples, the height (H2) of the voxel may correspond to a thickness of one layer (e.g. 182) of the build material as distributed by material distributor 150. In some examples, a voxel may have a height H2 (or thickness) of about 100 microns.
  • a height of the voxel may fall between about 80 microns and about 100 microns. However, in some examples, a height of a voxel (H2) may fall outside the range of about 80 to about 100 microns.
  • FIG. 1 also illustrates that the finally formed 3D object 180, comprising multiple layers 182, as having a height H1.
  • the build material upon application of light (e.g. irradiating) by light source 200 onto the deposited build materials, the build material is heated to result in partial melting at selectable voxel locations 174 of the build material.
  • the partial melting may cause neck-to-neck fusion, which refers to the shape and manner by which separate particles of build material become connected as a neck grows between two separate particles.
  • necking which corresponds to deformation, caused by partial melting, in which contacts points develop between adjacent particles (e.g. powder particles) with the contact points gradually growing and/or forming “necks” between the adjacent particles.
  • the partial melting and/or neck-to-neck fusion may be implemented without any substantial increase in densification of the particles of the build material.
  • the light source 200 may control the projection of light (e.g. radiation) from each respective valve element 272 (of a respective GLV 207 of a respective light modulating unit 202) onto the build material (e.g. for a particular layer of build material), with a resulting degree of heating of the build material depending on an exposure time and intensity of the light on the selectable voxel locations (174 in FIG. 1).
  • a pulse shape of the emitted light also may affect the degree of partial melting exhibited as neck-to-neck fusion.
  • exposure time and intensity may depend on, and/or be implemented in association with speed and/or direction of the relative movement.
  • the exposure time and/or intensity of transmitted light will not depend speed and/or direction of movement because the two-dimensional array is static and is sized and shaped to cover entire build platform (or at least size/shape of 3D object to be formed).
  • the exposure time and/or intensity of light projected onto the selectable voxel locations also may be selected in accordance with the particular size and/or type of build material.
  • the light projected via a valve element (e.g. 272 in FIG. 2) of a grating light valve (GLV) 207 may comprise an intensity of about 1 kW/cm 2 to about 100 kW/cm 2 for a particle size of about 30 to about 50 micrometers, such as some commercially available metal powders with about half of the light being absorbed by the powder.
  • the intensity range may comprise about 5 kW/cm 2 to about 70 kW/cm 2 , while in some examples, the intensity range may comprise about 10 kW/cm 2 to about 50 kW/cm 2 .
  • the light projected via a valve element (e.g. 272) of a grating light valve may comprise an intensity of about 1 kW/cm 2 to about 10 kW/cm 2 for a particle size (of build material) about 10-15 micrometers, such as some commercially available particles, which may comprise a metal material.
  • these intensities may cause a desired degree of partial melting upon projection of light onto the selectable voxel locations 174 of the build material.
  • the example diode laser element 205 and grating light valve (GLV) 207 can provide such intensities at a cost substantially lower (e.g.
  • DMD digital micro-mirror devices
  • causing a desired degree of partial melting of some ceramic or crystal materials sufficient to cause neck-to-neck fusion, while accounting for absorbency may comprise a fluence and intensities substantially the same as those described above for metals.
  • causing a desired degree of partial melting of some polymer powder build materials sufficient to cause neck-to-neck fusion may comprise a fluence on the order of about 0.1 to about 10 Joules/cm 2 , and intensities of about 0.01 kW/cm 2 to about 10 kW/cm 2 , depending on the size and type of particles of build material.
  • the example light source 200 (via the respective valve elements 272 of the GLVs 207 of the respective light modulating units 202) projects a targeted intensity of light onto a selectable voxel location as described above, it may take about 1 millisecond of exposure time to cause the desired partial melting for a given selectable voxel location.
  • exposure times greater than or less than 1 milliseconds are contemplated, depending on the type of build material, fluence, etc.
  • a respective layer 182 of build material is formed and additional layers 182 of build material may be formed in a similar manner as represented in FIG. 1.
  • the fully formed 3D object 180 may sometimes be referred to as a brown part to the extent that the formed 3D object omits binders and comprises neck-to-neck fusion.
  • the powder build material may exhibit about 60 percent to about 70 percent densification via the packing of the powder particles.
  • the entire 3D object 180 is placed into an oven 250 (or other enclosable heating unit) for sintering.
  • Oven sintering involves heating the 3D object at a temperature less than a melting temperature of the build material.
  • sintering temperatures may range between about 900 degrees Celsius to about 1700 degrees Celsius.
  • the 3D object is received in the oven 250, further heating is applied in the form of sintering by which the already partially melted build material is further solidified to increase its densification to at least about 95 percent densification, in some examples.
  • the level of densification upon sintering may comprise at least about 96 percent, 97 percent, 98 percent, 99 percent.
  • the finally formed 3D object may exhibit volume shrinkage in all three dimensions (x, y, z).
  • the finally formed 3D object may be removed from the oven 250.
  • the additive manufacturing device 100 forms a 3D object without the use of fusing agents, whether dry or liquid. In some examples, the additive manufacturing device 100 forms a 3D object without the use of binders.
  • device 100 may comprise a control portion to direct operations of device 200, with one such example control portion being implemented via at least some of substantially the same features and attributes as control portion 500, as later described in association with at least FIG. 5B.
  • operation via the control portion 500 also may comprise, and/or be implemented, via object formation engine 400 (FIG. 4A).
  • FIG. 3 is diagram schematically representing a top view of an example light source 320.
  • example light source 320 comprises a two-dimensional array 321 of light modulating units 202, which are arranged in rows 322.
  • each row 322 of light modulating units 202 in device 320 of FIG. 3 may comprise at least some of substantially the same features and attributes as the array 201 of light modulating units 202 in the light source 200 of FIG. 1.
  • each grating light valve (GLV) 207 shown in FIG. 3 comprises a linear array of valve elements (e.g. 272 in FIG. 2).
  • the diode laser elements e.g. 205 in FIGS.
  • the light modulating units 202 which emit light to the grating light valves (GLV) 207, are omitted from FIG. 3 for illustrative clarity.
  • the light source 320 can take the place of the light source 200 in the device 100 of FIG. 1.
  • the two-dimensional array 321 has a width (W2) and a length (L2).
  • the width (W2) and length (L2) of array 321 correspond to a width (W1) and a length (L1) of the build platform 142 such that the light source 320 may be moved into a stationary position over the build platform 142 and transmit light onto a particular layer 182 of build material, without movement of the array 321 , at any selectable voxel location (e.g. 174 in FIG. 1) over the layer 182 of build material to cause partial melting of those selectable voxel locations 174.
  • the width (W2) and length (L2) of array 321 of light modulating units 322 is less than a width (W1) and a length (L1) of the build platform 142.
  • the build area is divided into multiple target portions.
  • the light source 320 is then operated to cause just one (or a selectable number) of light modulating units 202 (which overlies a corresponding target portion of the build area) to project light (via individually controllable valve elements 272) onto the target portion of the build area.
  • the targeted portion may be implemented as selectable voxel locations 174 of a respective layer of build material. This process is repeated until light has been projected upon the voxel locations 174 in all of the target portions defining the build area for a particular 3D object.
  • FIG. 4A is a diagram including a top view of an example light source 350, which forms a two-dimensional array 351 of two rows 352A, 352B of light modulating units 202 (like elements 202 in FIG. 1). Similar to the view in FIG. 3, FIG. 4A omits the diode laser elements 205 (of each light modulating unit 202) for illustrative simplicity.
  • the light source 350 can take the place of the light source 200 in the device 100 of FIG. 1. In such an arrangement, the light source 350 can be moved over the build platform 132 in a first direction (arrow P1 in FIG.
  • the immediately following second row 352B of light modulating units 202 selectively projects light onto just the selectable voxel locations (e.g. 174 in FIG. 1) of the uniformly pre-heated voxel locations at which is it desired to cause partial melting. Because of the pre-heating via the first row 352B, a lower amount of light can be projected (e.g. transmitted) via the second row 352B while still achieving a targeted degree of partial melting of the build material.
  • This arrangement of the dual rows 352A, 352B may lower the power requirements and amount of light to be transmitted by the diode laser elements 205 and/or may enable faster completion of the partial melting of the build material (at selectable voxel locations 174).
  • FIG. 4B schematically depicts movement of the light source 350 in an opposite direction (as represented by directional array P2) in which the respective rows 352A, 352B (of light modulating units 202) reverse their roles.
  • row 352B transmits light in a uniform manner with all light modulating units 202 (including all their respective valve elements 272) being turned “on”, i.e. to project light so as to uniformly pre-heat the build material over which row 352B passes.
  • row 352A (of light modulating units 202) then selectively projects (e.g.
  • this arrangement may lower the power requirements of a light source (e.g. diode laser element 205) used to generate and emit the light and also may enable faster completion of the partial melting of the build material (at selectable voxel locations 174).
  • a light source e.g. diode laser element 205
  • FIG. 5A is a block diagram schematically representing an example object formation engine 400.
  • the object formation engine 400 may form part of a control portion 500, as later described in association with at least FIG. 5B, such as but not limited to comprising at least part of the instructions 511.
  • the object formation engine 400 may be used to implement at least some of the various example devices and/or example methods of the present disclosure as previously described in association with FIGS. 1-4B and/or as later described in association with FIGS. 5B-6.
  • the object formation engine 400 (FIG. 5A) and/or control portion 500 (FIG. 5B) may form part of, and/or be in communication with, an object formation device, such as the additive manufacturing device 100 in FIG. 1.
  • control portion 500 may comprise one example implementation of a control portion of example device 100 in FIG. 1 and/or the associated example implementations in FIGS. 2- 4B.
  • the object formation engine 400 may comprise a material distributor engine 402, a light modulating engine 406, and a sintering engine 408.
  • the material distributor engine 402 may be used to implement at least some of the various example devices and/or example methods of the present disclosure as previously described in association with FIGS. 1 -4B and/or as later described in association with FIGS. 5B-6. Accordingly, in some examples the material distributor engine 402 may track and/or control distribution of layers of build material relative to a build platform (e.g. 142 in FIG. 1) and/or relative to previously deposited layers of build material. In some examples, the material distributor engine 402 comprises a material parameter to specify which build material(s) and the quantity of such build material which can be used to additively form a body of the 3D object.
  • these materials are deposited via build material distributor 150 of device 100 (FIG. 1). It will be understood that such control by the material distributor engine 402 may comprise associated or cooperative control of a carriage supporting and providing movement of the material distributor 150.
  • the material controlled via the material distributor engine 402 may comprise metals, polymers, ceramics, etc. having sufficient strength, formability, toughness, resiliency, etc. for the intended use of the 3D object with at least some example materials being previously described in association with at least FIG. 1.
  • the light modulating engine 406 may be used to implement at least some of the various example devices and/or example methods of the present disclosure as previously described in association with FIGS. 1-4B and/or as later described in association with FIGS. 5B-6.
  • the light modulating engine 406 of object formation engine 400 is to control operations of at least one light source (e.g. 200 in FIG. 1), such as but not limited to the manner as previously described in association with FIGS. 1- 4B.
  • At least some parameters controllable via light modulating engine 406 comprise selecting a timing, intensity, exposure time, etc. of the light emitted from a diode laser element (e.g. 205 in FIG. 1) and/or controlling a timing, duration, sequence, pattern, etc.
  • control by the light modulating engine 406 may comprise associated or cooperative control of a carriage supporting and providing movement of the light modulating unit(s).
  • the sintering engine 408 may be used to implement at least some of the various example devices and/or example methods of the present disclosure as previously described in association with FIGS. 1-4B and/or as later described in association with FIGS. 5B-6.
  • the sintering engine 408 is to track and/or control operation of sintering oven (e.g. 250 in FIG. 1), including initiation, management, and/or termination of the sintering process, which may comprise control to select and maintain the oven temperature at temperature less than a melting temperature of the build material.
  • the object formation engine 400 comprises a location parameter 430, a volume parameter 432, and/or a shape parameter 434.
  • these parameters are to track and/or control a location (430), a volume (432), and/or a shape (434) of the partial melting and/sintering of the selectable voxel locations (e.g. 174 in FIG. 1), and thereby track and/or control a location, volume, and/or shape of the 3D object being additively formed.
  • the object formation engine 400 may comprise a preheating parameter 450 which is to track and/or control preheating the build material prior to further selective heating at selectable voxel locations, such as described in association with at least FIGS. 4A-4B.
  • the preheating parameter 450 also may be implemented in association with preheating build material via heating the build platform 142 (FIG. 1).
  • FIG. 5B is a block diagram schematically representing an example control portion 500.
  • control portion 500 provides one example implementation of a control portion forming a part of, implementing, and/or generally managing the example additive manufacturing devices, as well as the particular portions, components, material distributors, light sources, light modulating units, sintering ovens, control portion, instructions, engines, functions, parameters, and/or methods, as described throughout examples of the present disclosure in association with FIGS. 1-5A and 5C-6.
  • control portion 500 includes a controller 502 and a memory 510.
  • controller 502 of control portion 500 comprises at least one processor 504 and associated memories.
  • the controller 502 is electrically couplable to, and in communication with, memory 510 to generate control signals to direct operation of at least some the object formation devices, various portions and elements of the example additive manufacturing devices, as well as the particular portions, components, material distributors, light sources, light modulating units, sintering ovens, control portion, instructions, engines, functions, parameters, and/or methods, as described throughout examples of the present disclosure.
  • these generated control signals include, but are not limited to, employing instructions 511 stored in memory 510 to at least direct and manage additive manufacturing of 3D objects in the manner described in at least some examples of the present disclosure.
  • controller 502 or control portion 500 may sometimes be referred to as being programmed to perform the above-identified actions, functions, etc.
  • the stored instructions 511 are implemented as a, or may be referred to as, a 3D print engine, an object formation engine, and the like, such as but not limited to the object formation engine 400 in FIG. 5A.
  • controller 502 In response to or based upon commands received via a user interface (e.g. user interface 520 in FIG. 5C) and/or via machine readable instructions, controller 502 generates control signals as described above in accordance with at least some of the examples of the present disclosure.
  • controller 502 is embodied in a general purpose computing device while in some examples, controller 502 is incorporated into or associated with at least some of the additive manufacturing devices, as well as the particular portions, components, material distributors, light sources, light modulating units, sintering ovens, control portion, instructions, engines, functions, parameters, and/or methods, etc. as described throughout examples of the present disclosure.
  • processor shall mean a presently developed or future developed processor (or processing resources) that executes machine readable instructions contained in a memory or that includes circuitry to perform computations.
  • execution of the machine readable instructions such as those provided via memory 510 of control portion 500 cause the processor to perform the above-identified actions, such as operating controller 502 to implement the formation of 3D objects via the various example implementations as generally described in (or consistent with) at least some examples of the present disclosure.
  • the machine readable instructions may be loaded in a random access memory (RAM) for execution by the processor from their stored location in a read only memory (ROM), a mass storage device, or some other persistent storage (e.g., non-transitory tangible medium or non volatile tangible medium), as represented by memory 510.
  • the machine readable instructions may include a sequence of instructions, a processor- executable machine learning model, or the like.
  • memory 510 comprises a computer readable tangible medium providing non-volatile storage of the machine readable instructions executable by a process of controller 502.
  • the computer readable tangible medium may sometimes be referred to as, and/or comprise at least a portion of, a computer program product.
  • controller 502 may be embodied as part of at least one application-specific integrated circuit (ASIC), at least one field- programmable gate array (FPGA), and/or the like. In at least some examples, the controller 502 is not limited to any specific combination of hardware circuitry and machine readable instructions, nor limited to any particular source for the machine readable instructions executed by the controller 502.
  • ASIC application-specific integrated circuit
  • FPGA field- programmable gate array
  • control portion 500 may be entirely implemented within or by a stand-alone device.
  • control portion 500 may be partially implemented in one of the object formation devices and partially implemented in a computing resource separate from, and independent of, the object formation devices but in communication with the object formation devices.
  • control portion 500 may be implemented via a server accessible via the cloud and/or other network pathways.
  • the control portion 500 may be distributed or apportioned among multiple devices or resources such as among a server, an object formation device, and/or a user interface.
  • control portion 500 includes, and/or is in communication with, a user interface 520 as shown in FIG. 5C.
  • user interface 520 comprises a user interface or other display that provides for the simultaneous display, activation, and/or operation of at least some of the additive manufacturing devices, as well as the particular portions, components, material distributors, light sources, light modulating units, sintering ovens, control portion, instructions, engines, functions, parameters, and/or methods, etc., as described in association with FIGS. 1-5B and 6.
  • GUI graphical user interface
  • FIG. 6 is a flow diagram of an example method 600.
  • method 600 may be performed via at least some of the devices, components, material distributors, light sources, light modulating units, sintering ovens, instructions, control portions, engines, functions, parameters, and/or methods, etc. as previously described in association with at least FIGS. 1-5C.
  • method 600 may be performed via at least some of the devices, components, material distributors, light sources, light modulating units, sintering ovens, instructions, control portions, engines, functions, parameters, and/or methods, etc. other than those previously described in association with at least FIGS. 1-5C.
  • method 600 comprises providing a light source comprising an array of light modulating units arranged in a side-by-side relationship, with each light modulating unit comprising a diode laser element to emit light and a grating light valve, including an array of valve elements, to selectively permit transmission of the emitted light.
  • method 600 comprises distributing a build material, layer-by-layer, on the build platform.
  • the build material may comprise a powder material, which in some examples, comprises at least one of a metal material, a ceramic material, or a crystal material.
  • the build material may comprise a powder material, which in some examples, comprises at least one of a metal material, a ceramic material, or a crystal material.
  • method 600 may further comprise selectively modulating light via the respective valve elements of the respective light modulating units onto selectable voxel locations of a respective layer of the build material to cause partial melting at the selectable voxel locations of the build material to at least partially form a 3D object.
  • method 600 comprises sintering in an enclosable heating unit, the entire at least partially formed 3D object 3D object to solidify the selectable voxel locations of the build material to complete formation of the 3D object.

Abstract

Une source de lumière destinée à être utilisée dans la fabrication additive comprend un premier élément de modulation de lumière comportant un élément laser à diode destiné à émettre de la lumière, et un modulateur de lumière à grille destiné à permettre sélectivement la projection de la lumière émise sur des emplacements de voxels sélectionnables d'une couche respective d'un matériau de construction.
PCT/US2020/030066 2020-04-27 2020-04-27 Fusion partielle dans la fabrication additive WO2021221601A1 (fr)

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Citations (3)

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Publication number Priority date Publication date Assignee Title
US20160067780A1 (en) * 2013-04-29 2016-03-10 Nuburu, Inc. Devices, systems and methods for three-dimensional printing
US20160214322A1 (en) * 2013-03-12 2016-07-28 Orange Maker LLC 3D Printing Using Spiral Buildup
US20190091988A1 (en) * 2008-05-05 2019-03-28 Georgia Tech Research Corporation Systems and methods for fabricating three-dimensional objects

Patent Citations (3)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US20190091988A1 (en) * 2008-05-05 2019-03-28 Georgia Tech Research Corporation Systems and methods for fabricating three-dimensional objects
US20160214322A1 (en) * 2013-03-12 2016-07-28 Orange Maker LLC 3D Printing Using Spiral Buildup
US20160067780A1 (en) * 2013-04-29 2016-03-10 Nuburu, Inc. Devices, systems and methods for three-dimensional printing

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