WO2022140208A1 - Ensemble d'alimentation en matériau à commande précise pour la fabrication additive - Google Patents

Ensemble d'alimentation en matériau à commande précise pour la fabrication additive Download PDF

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Publication number
WO2022140208A1
WO2022140208A1 PCT/US2021/064250 US2021064250W WO2022140208A1 WO 2022140208 A1 WO2022140208 A1 WO 2022140208A1 US 2021064250 W US2021064250 W US 2021064250W WO 2022140208 A1 WO2022140208 A1 WO 2022140208A1
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WO
WIPO (PCT)
Prior art keywords
assembly
build platform
supply outlet
flow control
processing machine
Prior art date
Application number
PCT/US2021/064250
Other languages
English (en)
Inventor
Yoon Jung JEONG
Joseph P. Rossi
Johnathan Agustin MARQUEZ
Original Assignee
Nikon Corporation
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 Nikon Corporation filed Critical Nikon Corporation
Publication of WO2022140208A1 publication Critical patent/WO2022140208A1/fr

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Classifications

    • 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
    • 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]
    • 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
    • B22F12/22—Driving means
    • 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
    • B22F12/30—Platforms or substrates
    • B22F12/37—Rotatable
    • 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
    • B22F12/50—Means for feeding of material, e.g. heads
    • B22F12/52—Hoppers
    • 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
    • B22F12/50—Means for feeding of material, e.g. heads
    • B22F12/57—Metering means
    • 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
    • B29C64/205—Means for applying layers
    • 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
    • B29C64/30—Auxiliary operations or equipment
    • B29C64/307—Handling of material to be used in additive manufacturing
    • B29C64/343—Metering
    • 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
    • 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
    • B22F2999/00—Aspects linked to processes or compositions used in powder metallurgy
    • 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

  • Three-dimensional printing systems are used to print three-dimensional objects.
  • Existing three-dimensional printing systems are relatively slow, have a low throughput, are expensive to operate, and/or generate excessive waste.
  • the present implementation is directed to a processing machine for building three-dimensional objects from material.
  • the processing machine can include a build platform; a material supply assembly that deposits the material onto the build platform to form a material layer; and an energy system that directs an energy beam at a portion of the material on the build platform to form a portion of the object.
  • the material supply assembly includes (i) a material container that retains the material; and (ii) a flow control assembly that selectively controls a flow characteristic of the material deposited onto the build platform.
  • the material supply assembly includes a supply outlet positioned above the build platform.
  • the flow control assembly selectively controls an effective area of the supply outlet.
  • the flow control assembly can selectively control an effective width of the supply outlet.
  • the flow control assembly selectively controls the effective shape and/or effective size of the supply outlet to correspond to a shape of the build platform.
  • the flow control assembly selectively controls the effective shape and/or effective size of the supply outlet to correspond to a shape of the built object.
  • the flow control assembly can include a first shutter and a first shutter mover that selectively moves the first shutter relative to the material container to selectively control the effective shape of the supply outlet. Additionally, the flow control assembly can include a second shutter and a second shutter mover that selectively moves the second shutter relative to the first shutter to selectively control the effective shape of the supply outlet.
  • the flow control assembly can selectively control the flow characteristic to correspond to a shape of the build platform. Alternatively, the flow control assembly can selectively control the flow characteristic to correspond to a shape of the object.
  • a mover assembly moves the build platform relative to the material supply assembly.
  • the mover assembly can rotate the build platform relative to the material supply assembly.
  • the flow control assembly can selectively control an effective radial width of the supply outlet. Additionally or alternatively, the flow control assembly can selectively control an effective central axis of the supply outlet based on a position of the build platform relative to the supply outlet. The flow control assembly can selectively control the effective central axis of the supply outlet based on a design of the object.
  • a method for building a three-dimensional object from a material comprises: providing a build platform; depositing the material onto the build platform with a material supply assembly that includes (i) a material container that retains the material, and (ii) a flow control assembly that selectively controls a flow characteristic of the material deposited onto the build platform; and directing an energy beam at a portion of the material on the build platform to form a portion of the object.
  • depositing can include one or more of (i) selectively controlling an effective shape of a supply outlet that is positioned over the build platform; (ii) selectively controlling an effective width of the supply outlet; (iii) selectively controlling the effective shape of the supply outlet to correspond to a shape of the build platform; and/or (iv) selectively controlling the effective shape of the supply outlet to correspond to a shape of the object.
  • a first shutter and/or a second shutter can be moved relative to the material container to selectively control the effective shape of the supply outlet.
  • a processing machine for building a three- dimensional object from a powder material includes (i) a build platform; (ii) a material supply assembly that deposits the powder material to a selected area on the build platform; and (iii) an energy system that directs an energy beam at a portion of the powder material on the build platform to form a portion of the object.
  • the material supply assembly can include a material container that retains the powder material having a supply outlet through which the powder material being supplied onto the build platform.
  • the material supply assembly includes a flow control assembly that controls an effective area of the supply outlet to deposit the powder material onto the selected area on the build platform.
  • the build platform and the material supply assembly can be configured to move relative to each other in a first direction.
  • the supply outlet can have a rectangular shape having a long side intersecting to the first direction.
  • the flow control assembly can be configured to control an effective width which is an opening size in the long side of the supply outlet.
  • the flow control assembly can be configured to control an effective width which is an opening size in the short side of the supply outlet.
  • the flow control assembly can include a shutter assembly provided at the supply outlet configured to change of the effective width of the supply outlet.
  • the flow control assembly can change the effective width according to the relative movement of the build platform and the material supply assembly.
  • the flow control assembly can change the effective width according to position of the build platform relative to the material supply assembly.
  • the flow control assembly can be configured to control the size of the supply outlet to correspond to a shape of the build platform.
  • the flow control assembly can be configured to control the supply outlet to correspond to a shape of the object.
  • the flow control assembly can include an activation system which activates the material supply assembly to start depositing the powder material.
  • the activation system can include at least one vibration generator provided at the material container.
  • the flow control assembly can control the depositing of the powder material onto the selected area of the build platform by cooperating the supply outlet and the activation system.
  • the activation system includes plurality of vibration generators, and the flow control assembly can activate at least part of vibrators selectively in cooperation with the supply outlet.
  • a method for building a three-dimensional object from a material includes: (i) providing a build platform; (ii) depositing the powder material to a selected area on the build platform with a material supply assembly; and (iii) directing an energy beam at a portion of the powder material on the build platform with an energy system to form a portion of the object.
  • Figure 1 A is a simplified side illustration of an implementation of a processing machine having features of the present embodiment
  • Figure 1 B is a simplified top illustration of a material bed assembly from Figure 1 A;
  • Figure 2A is a simplified perspective view of a portion of a material bed assembly and a material supply assembly
  • Figure 2B is a cut-away view taken on line 2B-2B in Figure 2A;
  • Figure 2C is a cut-away view taken on line 2C-2C in Figure 2A;
  • Figure 2D is a cut-away view of the material supply assembly of Figure 2C at a different time
  • Figures 2E-2L are alternative, simplified top views of the build platform, the supply outlet, and the shutters at different times;
  • Figure 2M is a simplified top view of a flow restrictor
  • Figure 3 is a simplified top view of the supply outlet, and another implementation of the shutter assembly
  • Figures 4A and 4B illustrate a simplified top view of the supply outlet, and yet another implementation of the shutter assembly
  • Figures 5A and 5B are cut-away views of another implementation of the material supply assembly
  • Figure 6A is a perspective view of yet another implementation of the material supply assembly.
  • Figures 6B and 6C are alternative cut-away views of the material supply assembly of Figure 6A and a portion of a build platform.
  • FIG. 1 A is a simplified schematic side illustration of a processing machine 10 that may be used to manufacture one or more three-dimensional object(s) 11 (only one is illustrated in phantom).
  • the processing machine 10 can be an additive manufacturing system, e.g. a three-dimensional printer, in which a portion of a material 12 (illustrated as small circles) in a series of material layers 13 (only one layer is illustrated with small circles in phantom) are sequentially joined, melted, solidified, and/or fused together to manufacture one or more three-dimensional object(s) 11 .
  • the type of three-dimensional object(s) 11 manufactured with the processing machine 10 may be almost any shape or geometry.
  • the three-dimensional object 11 may be a metal part, or another type of part, for example, a resin (plastic) part or a ceramic part, etc.
  • the type of material 12 joined and/or fused together may be varied to suit the desired properties of the object(s) 11.
  • the material 12 may include metal powder grains (e.g., including one or more of titanium, aluminum, vanadium, chromium, copper, stainless steel, or other suitable metals) or alloys for metal three-dimensional printing.
  • the material 12 may be non-metal material, a plastic, polymer, glass, ceramic material, organic material, an inorganic material, or any other material known to people skilled in the art.
  • the material 12 may also be referred to as “powder” or “powder particles”.
  • Particle sizes of the material 12 can be varied.
  • a common particle size is approximately fifty microns.
  • the particle size can be approximately twenty microns, thirty microns, forty microns, sixty microns, seventy microns, eighty microns, ninety microns, one hundred microns, or other sizes.
  • the processing machine 10 includes (i) a material bed assembly 14; (ii) a pre-heat device 16; (iii) a material supply assembly 18 (illustrated as a box); (iii) a measurement device 20 (illustrated as a box); (iv) an energy system 22 (illustrated as a box); (v) a control system 24 (illustrated as a box); and (vi) a mover assembly 25 that causes relative motion between the material bed assembly 14 and the material supply assembly 18.
  • the design of each of these components may be varied pursuant to the teachings provided herein.
  • the positions of the components of the processing machine 10 may be different than that illustrated in Figure 1 A.
  • the processing machine 10 can include more components or fewer components than illustrated in Figure 1 A.
  • the processing machine 10 can include a cooling device (not shown in Figure 1A) that uses radiation, conduction, and/or convection to cool the material 12.
  • the processing machine 10 can be designed without the pre-heat device 16 and/or the measurement device 20.
  • these material supply assembly 18 is uniquely designed to quickly and accurately control the distribution of the material 12 onto the material bed assembly 14. Stated in another fashion, the material supply assembly 18 is uniquely designed to accurately adjust one or more flow characteristics (e.g. shape and/or amount) of the material 12 that is distributed onto the material bed assembly 14. Because the material 12 is distributed more accurately, the resulting object 11 will be more accurate, and less amount of material 12 will be wasted.
  • flow characteristics e.g. shape and/or amount
  • each material layer 13 can be varied to suit the manufacturing requirements.
  • one or more (e.g. all) of the material layers 13 can have a layer thickness (along the Z axis) of approximately twenty microns, thirty microns, forty microns, fifty microns, sixty microns, seventy microns, eighty microns, ninety microns, one hundred microns, or thicker.
  • layer thickness (along the Z axis) of approximately twenty microns, thirty microns, forty microns, fifty microns, sixty microns, seventy microns, eighty microns, ninety microns, one hundred microns, or thicker.
  • layer thicknesses are possible.
  • a number of Figures include an orientation system that illustrates an X axis, a Y axis that is orthogonal to the X axis, and a Z axis that is orthogonal to the X and Y axes. It should be noted that any of these axes can also be referred to as the first, second, and/or third axes. Further, as used herein, movement with six degrees of freedom shall mean along and about the X, Y, and Z axes.
  • the processing machine 10 may be operated in a controlled environment, e.g. such as a vacuum, using an environmental chamber 23 (illustrated in Figure 1 A as a box).
  • a controlled environment e.g. such as a vacuum
  • an environmental chamber 23 illustrated in Figure 1 A as a box.
  • one or more of the components of the processing machine 10 can be positioned entirely or partly within the environmental chamber 23.
  • at least a portion of one or more of the components of the processing machine 10 may be positioned outside the environmental chamber 23.
  • the processing machine 10 may be operated in non-vacuum environment such as inert gas (e.g., nitrogen gas or argon gas) environment.
  • inert gas e.g., nitrogen gas or argon gas
  • the material bed assembly 14 supports the material 12 while the object(s) 11 is being built.
  • the material bed assembly 14 includes a support platform 26 and one or more build platform assemblies 28 (only one is illustrated in phantom in Figure 1 A) that support the material 12 and the object 11 while being formed.
  • the material bed assembly 14 is discussed in more detail below.
  • the pre-heat device 16 selectively preheats the material 12.
  • the number of the pre-heat devices 16 may be one or plural.
  • the design of the pre-heat device 16 and the desired preheated temperature may be varied.
  • the preheat device 16 may include one or more pre-heat energy source(s) that direct one or more pre-heat beam(s) (not shown) at the material 12.
  • Each pre-heat beam may be steered as necessary.
  • each pre-heat device 16 may be an electron beam system, a mercury lamp, an infrared laser, a supply of heated air, thermal radiation system, a visual wavelength optical system, a microwave optical system, or other suitable system.
  • the desired preheated temperature may be five, ten, twenty, thirty, fifty, seventy-five, ninety, or ninety-five percent of the melting temperature of the material 12 used in the printing.
  • the desired preheated temperature may be one hundred, three hundred, five hundred, seven hundred, nine hundred, or one thousand degrees Celsius.
  • Energy input may also vary dependent on melt duty of previous layers, specific regions on a layer, or progress though the build.
  • the material supply assembly 18 deposits the material 12 onto the build platform assembly 28.
  • the number of the material supply assemblies 18 may be one or plural. With the present design, the material supply assembly 18 accurately deposits the material 12 onto the material bed assembly 14 to sequentially form each material layer 13. Once a portion of the material layer 13 has been melted with the energy system 22, the material supply assembly 18 can be controlled to accurately deposit another (subsequent) material layer 13.
  • the three-dimensional object 1 1 is formed through consecutive fusions of consecutively formed cross sections of material 12 in one or more material layers 13. For simplicity, the example of Figure 1A illustrates only the top material layer 13. However, it should be noted that depending upon the design of the object 11 , the building process will require numerous material layers 13.
  • the material supply assembly 18 is an overhead material supply that supplies the material 12 onto the top of the material bed assembly 14.
  • the measurement device 20 inspects and monitors the melted (fused) layers of the object 11 as that are being built, and/or the deposition of the material 12.
  • the number of the measurement devices 20 may be one or plural.
  • the measurement device 20 can measure both before and after the material 12 is distributed.
  • the measurement device 20 may include one or more optical elements such as a uniform illumination device, fringe illumination device (structured illumination device), cameras that function at one or more wavelengths, lens, interferometer, or photodetector, or a non-optical measurement device such as an ultrasonic, eddy current, or capacitive sensor.
  • the energy system 22 selectively heats and melts the material 12 to sequentially form each of the layers of the object 11 .
  • the energy system 22 can selectively melt the material 12 at least based on a data regarding to the object 1 1 to be built.
  • the data may be corresponding to a computer-aided design (CAD) model data.
  • the number of the energy systems 22 may be one or plural.
  • the design of the energy system 22 can be varied.
  • the energy system 22 can direct one or more irradiation (energy) beam(s) (not shown) at the material 12.
  • the one or more energy systems 22 can be controlled to steer the energy beam(s) to melt the material 12.
  • each of the energy system 22 can be designed to include one or more of the following: (i) an electron beam generator that generates a charged particle electron beam; (ii) an irradiation system that generates an irradiation beam; (iii) an infrared laser that generates an infrared beam; (iv) a mercury lamp; (v) a thermal radiation system; (vi) a visual wavelength system; (vii) a microwave wavelength system; or (viii) an ion beam system.
  • the desired melting temperature may be at least five hundred, one thousand, fourteen hundred, seventeen hundred, two thousand, or more degrees Celsius.
  • the control system 24 controls the components of the processing machine 10 to build the three-dimensional object 11 from the computer-aided design (CAD) model by successively melting portions of one or more of the material layers 13.
  • the control system 24 can control (i) the material bed assembly 14; (ii) the pre-heat device 16; (iii) the material supply assembly 18; (iii) the measurement device 20; (iv) the energy system 22; and/or (v) the mover assembly 25.
  • the control system 24 can be a centralized or a distributed system.
  • the control system 24 may include, for example, a CPU (Central Processing Unit) 24A, a GPU (Graphics Processing Unit) 24B, and electronic memory 24C.
  • the control system 24 functions as a device that controls the operation of the processing machine 10 by the CPU executing the computer program.
  • This computer program is a computer program for causing the control system 24 (for example, a CPU) to perform an operation to be described later to be performed by the control system 24 (that is, to execute it). That is, this computer program is a computer program for making the control system 24 function so that the processing machine 10 will perform the operation to be described later.
  • a computer program executed by the CPU may be recorded in a memory (that is, a recording medium) included in the control system 24, or an arbitrary storage medium built in the control system 24 or externally attachable to the control system 24, for example, a hard disk or a semiconductor memory.
  • the CPU may download a computer program to be executed from a device external to the control system 24 via the network interface.
  • the control system 24 may not be disposed inside the processing machine 10, and may be arranged as a server or the like outside the processing machine 10, for example. In this case, the control system 24 and the processing machine 10 may be connected via a communication line such as a wired communications line (cable communications), a wireless communications line, or a network.
  • control system 24 may be capable of transmitting information such as commands and control parameters to the processing machine 10 via the communication line and the network.
  • the processing machine 10 may include a receiving device (receiver) that receives information such as commands and control parameters from the control system 24 via the communication line or the network.
  • a recording medium for recording the computer program executed by the CPU As a recording medium for recording the computer program executed by the CPU, a CD-ROM, a CD-R, a CD-RW, a flexible disk, an MO, a DVD-ROM, a DVD-RAM, a DVD-R, a DVD + R, a DVD-RW, a magnetic medium such as a magnetic disk and a magnetic tape such as DVD + RW and Blu-ray (registered trademark), a semiconductor memory such as an optical disk, a magnetooptical disk, a USB memory, or the like, and a medium capable of storing other programs.
  • the program includes a form distributed by downloading through a network line such as the Internet.
  • the recording medium includes a device capable of recording a program, for example, a general-purpose or dedicated device mounted in a state in which the program can be executed in the form of software, firmware or the like.
  • each processing and function included in the program may be executed by program software that can be executed by a computer, or processing of each part may be executed by hardware such as a predetermined gate array (FPGA, ASIC) or program software, and a partial hardware module that realizes a part of hardware elements may be implemented in a mixed form.
  • FPGA predetermined gate array
  • ASIC application specific integrated circuit
  • multiple operations may be performed at the same time (simultaneously) to improve the throughput of the processing machine 10.
  • one or more of (i) pre-heating with the pre-heat device 16, (ii) measuring with the measurement device 20, (iii) depositing material 12 with the material supply assembly 18, and (iv) melting the material with the energy system 22 may be partly or fully overlapping in time on different parts of the material bed assembly 14 to improve the throughput of the processing machine 10.
  • the mover assembly 25 is controlled to cause relative motion between the material bed assembly 14 and the material supply assembly 18.
  • the design of the mover assembly 25 can be varied to achieve the movement requirements of the processing machine 10.
  • the mover assembly 25 rotates the material bed assembly 14 about a rotational axis 25A (e.g. parallel to the Z axis) relative to the material supply assembly 18, the pre-heat device 16, the measurement device 20, and the energy system 22.
  • the mover assembly 25 can move the support platform 26 at a substantially constant or variable angular velocity about the rotational axis 25A.
  • the mover assembly 25 can be designed to move the material bed assembly 14 linearly, e.g. along the X axis and/or along the Y axis relative to the material supply assembly 18. Still alternatively, or additionally, the mover assembly 25 can be designed to move the material supply assembly 18 (e.g. rotate and/or move linearly) relative to the material bed assembly 14.
  • the mover assembly 25 can include one or more actuators (e.g. linear or rotary).
  • the processing machine 10 can include a component housing 30 that retains the pre-heat device 16, the material depositor 18, the measurement device 20, and the energy system 22. Collectively these components may be referred to as the top assembly. Further, the processing machine 10 can include a housing mover 32 that can be controlled to selectively move the top assembly.
  • the housing mover 32 can include one or more actuators (e.g. linear or rotary).
  • one or more of the pre-heat device 16, the material depositor 18, the measurement device 20, and the energy system 22 can be moved relative to the component housing 30.
  • Figure 1 B is a simplified top view, illustration of one, non-exclusive implementation of the material bed assembly 14 of Figure 1 A.
  • the material bed assembly 14 is generally circular shaped, and can be used to make multiple objects 11 (not shown in Figure 1 B) substantially simultaneously.
  • the material bed assembly 14 can have a different shape or configuration than is illustrated in Figure 1 B.
  • the material bed assembly 14 includes the support platform 26, a support hub 34, and a plurality of separate, spaced apart, build platform assemblies 28 that are integrated into and supported by the support platform 26.
  • the number of separate build platform assemblies 28 can be varied.
  • the material bed assembly 14 includes three separate build platform assemblies 28. With this design, one or more objects (not shown) can be made on each build platform assembly 28.
  • the material bed assembly 14 can include more than three or fewer than three separate build platform assemblies 28.
  • the support platform 26 is annular disk shaped and is rotated (with the build platform assemblies 28) about the rotational axis 25A (illustrated with a “+”) in a frame rotational direction 25B (e.g. counter-clockwise in this example) by the mover assembly 25 (illustrated in Figure 1 A) relative to the support hub 34.
  • the support platform 26 with the build platform assemblies 28 are rotated like a turntable during printing of the objects in the frame rotational direction 25B.
  • each build platform assembly 28 defines a separate build platform 28A that is selectively lowered like an elevator relative to a tubular shaped platform sidewall 28B with a platform mover assembly 28C (illustrated in phantom with a box) into the support platform 26 during the manufacturing process.
  • each build platform 28A is generally disk shaped.
  • Fabrication can begin with each the build platform 28A placed near the top of the support platform 26.
  • the material supply assembly 18 (illustrated in Figure 1 A) deposits the thin layer of material onto each build platform 28A as it is moved (e.g. rotated) below the material supply assembly 18.
  • each build platform 28A is stepped down one layer thickness with the platform mover assembly 28C so the next layer of material may be distributed properly.
  • each build platform 28A can be moved in steps that are smaller than the material layer or moved in a continuous fashion, rather than in discrete steps.
  • each build platform 28A defines a circular shaped build area that receives the material.
  • each build platform 28A can have a different configuration, e.g. rectangular or polygonal shaped.
  • one or more platform mover assemblies 28C can be used to move (e.g. rotate) one or more of the build platform 28A relative to the support platform 26 and each other about a platform rotational axis 28D (illustrated with a “+”, e.g. along the Z axis) in a platform rotational direction 28E (e.g. the clockwise direction).
  • a platform rotational axis 28D illustrated with a “+”, e.g. along the Z axis
  • a platform rotational direction 28E e.g. the clockwise direction
  • the support platform 26 can be rotated (e.g., at a substantially constant rate) in the frame rotational direction 25B (e.g. counterclockwise), and one or more of the build platforms 28A can be moved (e.g. rotated) relative to the support platform 26 in the opposite, platform rotational direction 28E (e.g. clockwise) during the printing process.
  • the rotational speed of the support platform 26 about the frame rotational direction 25B can be approximately the same or different from the rotational speed of each build platform 28E relative to the support platform 26.
  • the support platform 26 and one or more of the build platforms 28A can be rotated in the same rotational direction during the three dimensional printing operation.
  • FIG. 1A a separate platform mover assembly 28C is used for each build platform assembly 28.
  • one or more of the platform mover assemblies 28C can be designed to concurrently move more than one build platform assembly 28.
  • Figure 2A is a perspective view of a portion of a material bed assembly 214 and a material supply assembly 218 that can be integrated into the processing machine 10 of Figure 1A.
  • the material bed assembly 214 includes the support platform 226, the support hub 234, and one build platform assembly 228 that are similar to the corresponding components described above.
  • the support platform 226 and the build platform assembly 228 rotate relative to the material supply assembly 218; and the build platform 228A rotates relative to the support platform 226 and the material supply assembly 218.
  • the material supply assembly 218 is secured to the support hub 234, and cantilevers and extends radially over the support platform 226 to selectively deposit the material 212 (illustrated with small circles) onto the build platform 228A.
  • the material supply assembly 218 could be designed to be moved (e.g. linearly or rotationally) relative to the build platform 228A.
  • the material supply assembly 218 can be retained in another fashion than via the support hub 234.
  • the material supply assembly 218 can be coupled to the upper component housing 30 illustrated in Figure 1 A.
  • Figure 2B is a cut-away view of the material supply assembly 218 taken on line 2B-2B in Figure 2A.
  • the material supply assembly 218 is a top-down, gravity driven system that deposits the material 212 onto the build platform 228A.
  • the material supply assembly 218 includes a supply frame assembly 238, a material container assembly 240, and a flow control assembly 242 that is controlled by the control system 24 (illustrated in Figure 1A) to selectively and accurately deposit the material 212 onto the build platform(s) 228A.
  • the design of each of these components can be varied.
  • the flow control assembly 242 is closed and the material supply assembly 218 is not releasing the material 212 towards the build platform 228A.
  • the supply frame assembly 238 supports and couples the material container assembly 240 and the flow control assembly 242 to the support hub 234.
  • the supply frame assembly 238 includes (i) a riser frame 238A that is fixedly coupled to and extends upwardly along the Z axis from the support hub 234; and (ii) a transverse frame 238B that is fixedly coupled to and cantilevers radially away from the riser frame 238A.
  • the riser frame 238A, or the transverse frame 238B can be referred to as a first frame or a second frame.
  • the riser frame 238A is rigid and includes (i) a riser proximal end 238C that is secured to the support hub 234, and (ii) a riser distal end 238D that is positioned above the support hub 234.
  • the transverse frame 238B is rigid and includes (i) a transverse proximal end 238E that is secured to the riser distal end 238D, and (ii) a transverse distal end 238F that extends over an outer perimeter of the build platform 228A.
  • the riser frame 238A is right cylindrical shaped (e.g. hollow or solid), and the transverse frame 238B is rectangular beam shaped. However, other shapes and configurations can be utilized.
  • the transverse frame 238B can include a frame passageway 238G that allows the material 212 from the flow control assembly 242 to flow therethrough.
  • the frame passageway 238G can be rectangular shaped or another shape.
  • the frame passageway 238G can define the supply outlet 239 of the material 212 from the material supply assembly 218.
  • the supply outlet 239 is in fluid communication with the material container assembly 240 and the flow control assembly 242.
  • the size and shape of the supply outlet 239 can be varied.
  • the supply outlet 239 is generally rectangular shaped. However other shapes are possible.
  • the flow control assembly 242 can be controlled to selectively adjust an effective size, width, location, and/or shape of the supply outlet 239 to selectively control the distribution of the material 212 onto the build platform 228A.
  • the supply outlet 239 is positioned above and spaced apart a separation distance from the build platform(s) 228A or uppermost material layer on the build platform 228A.
  • the size of the separation distance can vary depending on the environment around the material supply assembly 218.
  • the separation distance can be larger if operated in a vacuum environment.
  • the separation distance can be as small as the largest material particle size.
  • the separation distance can be between approximately zero to fifty millimeters.
  • the material supply assembly 218 can be designed so that the supply outlet 239 is directly adjacent to and/or against the build platform(s) 228A or uppermost material layer on the build platform 228A.
  • the material container assembly 240 retains the material 212 prior to being deposited onto the build platform(s) 228A.
  • the material container assembly 240 can be positioned above and coupled to the transverse frame 238B of the supply frame assembly 238.
  • the material container assembly 240 is open at the top and the bottom, and can include a material container 240A that retains the material 212, and a container base 240B that couples the material container 240A to the transverse frame 238B with the flow control assembly 242 positioned at least partly therebetween.
  • the material container 240A and the container base 240B can be integrally formed or secured together during assembly.
  • the opening at the top of the material container assembly 240 is larger than the opening at its bottom.
  • the size and shape of the material container 240A can be varied to suit the material 212 supply requirements for the system.
  • the material container 240A is tapered, rectangular tube shaped (V shaped cross-section) and includes (i) a bottom, container proximal end 240C that is coupled to the container base 240B, and that has an open, rectangular shape; (ii) a top, container distal end 240D that is an open, rectangular tube shaped and positioned above the proximal end 240C; (iii) a front side 240E; (iv) a back side 240F; (v) a left side 240G; and (vi) a right side 240H. Any of these sides can be referred to as a first, second, third, etc side.
  • the material container 240A can function as a funnel that uses gravity to urge the material 212 against the flow control assembly 242.
  • the left side 240G and the right side 240H extend substantially parallel to each other; while the front side 240E and a back side 240F taper towards each other moving from the container distal end 240D to the container proximal end 240C.
  • the sides 240E, 240F can be steep (near vertical).
  • the angle of taper relative to normal (vertical) can be at approximately 0, 0.5, 1 , 2, 4, 6, 8, 10, 20, 30 degrees or other angles.
  • the angle of taper can be determined based upon the characteristics (e.g. size) of the material particles, the material of the material particles, the amount of material to be retained in the material container 240A and other factors.
  • the material container 240A comprises two slopes (walls 240E, 240F) getting closer to each other from one end (top 240D) to the other end (bottom 240C) on which the flow controller 242A.
  • the container base 240B can be rectangular tube shaped to allow the material 212 to flow therethrough.
  • the material container 240A can have a tapering, oval tube shape, or another suitable shape.
  • the control system 24 controls the flow control assembly 242 to selectively and accurately control the flow of the material 212 from the supply outlet 239 onto the build platform(s) 226A, and the shape of each material layer deposited on the build platform(s) 226A.
  • the flow control assembly 242 includes (i) a shutter assembly 244; (ii) a flow restrictor 246; and (iii) an activation system 248 that are controlled by the control system 24 to precisely control the flow of the material 212 to the build platform 228A.
  • the flow control assembly 242 can be designed without the flow restrictor 246 and/or the activation system 248. Further, the design of each of these components can be varied to achieve the desired flow control.
  • the design and location of the shutter assembly 244 can be varied.
  • the shutter assembly 244 is located below the material container 240A and above the flow restrictor 246 and the transverse frame 238B.
  • the shutter assembly 244 can be located below the flow restrictor 246, below the transverse frame 238B, and/or another location.
  • the shutter assembly 244 is controlled to selectively control one or more flow characteristics of the material 212 from the supply outlet 239 that is being deposited onto the build platform 228A to selectively control the shape of each material layer deposited onto the build platform 228A.
  • the one or more flow characteristics can include a flow area, a flow width, a flow shape, a flow location, and/or a flow rate.
  • the shutter assembly 244 can be controlled to selectively adjust an effective area, an effective size, an effective width, an effective shape, and/or an effective location of the supply outlet 239 to selectively control the distribution of the material 212 onto the build platform 228A.
  • the shutter assembly 244 can be controlled by the control system 24 to selectively block a portion or all of the supply outlet 239.
  • the shutter assembly 244 can be controlled to selectively control the depositing (distribution) area of the material 212 and selectively control how the material 212 is being deposited across the build platform(s) 228A.
  • the shutter assembly 244 can include
  • the first shutter subassembly 250 can include a first shutter 250A, and a first shutter mover 250B;
  • the second shutter subassembly 252 can include a second shutter 252A, and a second shutter mover 252B.
  • each shutter 250A, 252A can be a plate coupled with a guide (e.g. a linear guide) to the material container 240A, and each mover 250B, 252B can be an actuator (e.g. a linear motor) that is controlled by the control system 24.
  • the first mover 250B can selectively move (e.g. slide) the first shutter 250A relative to the material container 240A along the Y axis; and/or (ii) the second mover 252B can selectively move (e.g. slide) the second shutter 252A relative to the material container 240A along the Y axis to selective control the flow supply outlet 239.
  • the position of the first shutter 250A can be independently controlled to selectively control flow of the material 212 to the build platform 228A; and (ii) the position of the second shutter 252A can be independently controlled to selectively control flow of the material 212 to the build platform 228A.
  • the shutters 250A, 252A can be controlled to manipulate (and restrict) the area of the supply outlet 239 in which material 212 can flow through, and ultimately how and what area the material 212 is distributed onto the build platform 228A during movement of the build platform 228A.
  • the shutter assembly 244 can selectively adjust the radial distribution of the material 212 along the Y axis across each build platform 228A.
  • the shutter assembly 244 can be designed to move along the X axis to adjust the axial distribution of the material 212.
  • one or each shutter 250A, 252A can be flexible plate that is deflected (or rotated) with the respective mover 250B, 252B to adjust the effective size of the supply outlet 239 instead of or in addition to linear actuation.
  • the flow restrictor 246 restricts flow from the material container 240A.
  • the flow restrictor 246 includes one or more mesh screen(s) or other porous structure through which the material 212 flows.
  • the activation system 248 can include one or more vibration generators 248A that are controlled by the control system 24 to selectively vibrate the material container 240A.
  • Each vibration generator 248A can be a vibration motor.
  • the number and location of the vibration generator(s) 248A can be varied.
  • the activation system 248 includes (i) five spaced apart vibration generators 248A that are secured to the front side 240E near the top, container distal end 240D; and (ii) five spaced apart vibration generators 248A (only one is visible in Figure 2B) that are secured to the back side 240F near the container distal end 240D.
  • the activation system 248 can include more than ten or fewer than ten vibration generators 248A, and/or one or more of the vibration generators 248A located at different positions than illustrated in Figures 2A and 2B.
  • the activation system 248 and the flow restrictor 246 can control start and stop of the powder material 212 distribution. For example, when the vibration generator 248A is not vibrating (i.e. the activation system 248 is not activated), the powder material 212 is kept at the flow restrictor 246 due to an effect of friction. Once the vibration generator 248A vibrates the material container 240A (i.e. the activation system 248 is activated), the powder material 212 goes through the flow restrictor 246 and distributed onto the build platform 228A.
  • the volume of deposited powder material 212 can also be controlled by vibration strength of each vibration generator 248A, number of activated vibration generator 248A, and other parameter of the activation system 248.
  • the control system 24 may control the vibration generators 248A and the shutter assembly 244 based on feedback results from the measurement device 20 (illustrated in Figure 1 A). For example, with feedback from the measurement device 20, the vibration generators 248A and the shutter assembly 244 are controlled to adjust the amount and location of material 212 deposited on the build platform(s) 228A.
  • a thin, accurate, even layer of material 212 can be supplied to the build platform(s) 228A without having to spread the material 212 (e.g. with a rake) using the flow control assembly 242.
  • the material supply assembly 218 include a material distributer (not shown in Figures 2A and 2B) such as a rake, roller, wiper, squeegee, and/or a brush to further improve the flat material surface.
  • Figure 2C is a cut-away view of the material supply assembly 218 taken on line 2C-2C in Figure 2A, including a portion of the supply frame assembly 238, the material container assembly 240, and the flow control assembly 242 including the shutter assembly 244 and the flow restrictor 246. It should be noted that only a portion of the material 212 is shown in Figure 2C for clarity.
  • the first shutter mover 250B has moved the first shutter 250A to a closed position.
  • the second shutter mover 252B has moved the second shutter 252A to a closed position.
  • the first shutter 250A is adjacent to the second shutter 252A, the shutters 250A, 252A completely cover the supply outlet 239, and there is no material flow from the supply outlet 239.
  • Figure 2D is a cut-away view of the material supply assembly 218 including a portion of the supply frame assembly 238, the material container assembly 240, and the flow control assembly 242 from Figure 2C.
  • the first shutter mover 250B has moved the first shutter 250A to a partly open position.
  • the second shutter mover 252B has moved the second shutter 252A to a partly open position.
  • the first shutter 250A and the second shutter 252A are spaced apart, the shutters 250A, 252A only partly cover the supply outlet 239, and there is flow of the material 212 from the supply outlet 239.
  • the first shutter mover 250B can selectively move the first shutter 250A
  • the second shutter mover 252B can selectively move the second shutter 252A to selectively control the effective size, shape and location of the supply outlet 239.
  • one or both of the shutters 250A, 250B can be moved along the Y axis to control an effective shape (including an effective width 254) of the supply outlet 239.
  • one or both of the shutters 250A, 250B can be moved to selectively control a location along the Y axis of an effective central axis 254A of the supply outlet 239.
  • the effective central axis 254A is parallel to the Z axis, and intersects with the center position of the effective width 254.
  • the first shutter 250A is moved farther left along the Y axis, the effective central axis 254A will move left.
  • the effective central axis 254A will move right.
  • the location of material distribution can be shifted.
  • the material supply assembly 218 extends radially over the build platform 228A.
  • the one or both of the shutters 250A, 250B can be moved along the Y axis to control an effective radial width 254 (and effective radial shape) of the supply outlet 239; and/or (ii) one or both of the shutters 250A, 250B can be moved to selectively control a location of an effective radial central axis 254A (along the Y axis) of the supply outlet 239.
  • the shutter assembly 244 can selectively adjust the radial distribution of the material 212 along the Y axis across each build platform 228A.
  • Figure 2E is a simplified top view of one of the build platforms 228A, and the shutters 250A, 252A positioned over the supply outlet 239 (illustrated in phantom).
  • the supply outlet 239 is generally rectangular shaped.
  • the build platform 228A is being moved towards the supply outlet 239.
  • the shutters 250A, 252A have been controlled to be closed so that no material 212 (illustrated in Figure 2A) falls down onto the build platform 228A.
  • FIG. 2F is another simplified top view of the shutters 250A, 252A positioned over the supply outlet 239 (illustrated partly in phantom), and one of the build platforms 228A.
  • the build platform 228A is now partly under the supply outlet 239.
  • the shutters 250A, 252A have been moved apart (along the Y axis) so that the supply outlet 239 has an effective width 254 and an effective central axis (illustrated with a plus) that matches (corresponds to) a width (or desired deposit area) of the build platform 228A at that location.
  • the material container assembly 240 (illustrated in Figure 2A) will deposit the material 212 (illustrated in Figure 2A) without dropping too much material 212 on the support platform 226 (illustrated in Figure 2A).
  • the shutters 250A, 252A are controlled so that the effective width 254 and the effective central axis 254A of the supply outlet 239 corresponds and matches the width (and/or desired deposition area) of the build platform 228A under the supply outlet 239.
  • FIG. 2G is still another simplified top view of the shutters 250A, 252A positioned over the supply outlet 239 (illustrated partly in phantom), and one of the build platforms 228A. At this time, the build platform 228A is still under the supply outlet 239. Further, at this time, the shutters 250A, 252A have been moved apart (along the Y axis) so that the effective central axis 254A and the effective width 254 of the supply outlet 239 again matches a width of the build platform 228A at that location.
  • the material container assembly 240 (illustrated in Figure 2A) will deposit the material 212 (illustrated in Figure 2A) without dropping too much material 212 on the support platform 226 (illustrated in Figure 2A).
  • the shutters 250A, 252A are controlled so that the effective central axis 254A and the effective width 254 of the supply outlet 239 corresponds and matches the build platform 228A under the supply outlet 239.
  • Figure 2H is yet another simplified top view of the shutters 250A, 252A positioned over the supply outlet 239 (illustrated partly in phantom), and one of the build platforms 228A. At this time, the build platform 228A is still under the supply outlet 239. Further, at this time the shutters 250A, 252A have been moved apart (along the Y axis) so that the effective central axis 254A and the effective width 254 of the supply outlet 239 again matches a width of the build platform 228A at that location.
  • the material container assembly 240 (illustrated in Figure 2A) will deposit the material 212 (illustrated in Figure 2A) without dropping too much material 212 on the support platform 226 (illustrated in Figure 2A).
  • the shutters 250A, 252A are controlled so that the effective central axis 254A and the effective width 254 of the supply outlet 239 corresponds and matches the width of the build platform 228A under the supply outlet 239.
  • Figures 2E-2H illustrate the build platform 228A at different times while being moved upward on the page relative to the supply outlet 239. These Figures also illustrate how the effective width 254 of the supply outlet 239 can be selectively adjusted (via the shutters 250A, 252A) to match the width of the build platform 228A directly below the supply outlet 239. It should be noted that the Figures 2E-2H merely illustrate the effective width 254 at four different moments in time. However, in certain implementations, the effective width 254 can be dynamically adjusted as necessary so that the effective width 254 of the supply outlet 239 corresponds to match the width of the moving build platform 228A (and/or the desired deposit area) directly below the supply outlet 239. With this design, the effective width 254 is controlled so that a relatively even layer of material 212 is deposited over the entire build platform 228A, without depositing too much material 212 on the support platform 226.
  • the build platform 228A is moved substantially linearly between the positions in Figures 2E-2H.
  • the shutters 250A, 252A are moved symmetrically relatively to each other.
  • the build platform 228A is moved in a curved fashion.
  • the shutter 250A, 250B can be moved in an asymmetric fashion relative to each other during depositing of the material.
  • the build platform 228A can be rotated about two different axes (as described above in reference to Figure 1 B), and the shutter 250A, 250B are radial shutters that adjust the radial distribution of the material. In this design, it is necessary to control the radial shutter 250A, 250B in accordance with a trajectory of the rotating build platform 228A.
  • shutters 250A, 252A can be controlled to provide a different material distribution than is illustrated in Figures 2E-2H.
  • the shutters 250A, 252A can be controlled so that the material distribution matches the shape of the partly formed object 21 1 .
  • Figure 2I is a simplified top view of the shutters 250A, 252A positioned over the supply outlet 239 (illustrated in phantom), and one of the build platforms 228A.
  • the build platform 228A is under the supply outlet 239, but the partly formed object 211 is not below the supply outlet 239.
  • the shutters 250A, 252A have been controlled to be closed so that no material 212 (illustrated in Figure 2A) flows from the supply outlet 239 onto the build platform 228A.
  • FIG. 2J is another simplified top view of the shutters 250A, 252A positioned over the supply outlet 239 (illustrated partly in phantom), and the build platform 228A.
  • the partly built object 211 is now partly under the supply outlet 239.
  • the shutters 250A, 252A have been moved apart (along the Y axis) so that the supply outlet 239 has an effective central axis 254A, and an effective width 254 that matches a width of the partly built object 211 at that location.
  • the material container assembly 240 illustrated in Figure 2A
  • the shutters 250A, 252A are controlled so that the effective central axis 254A and the effective width 254 of the supply outlet 239 corresponds and matches the width of the built object 211 under the supply outlet 239.
  • FIG. 2K is still another simplified top view of the shutters 250A, 252A positioned over the supply outlet 239 (illustrated partly in phantom), and the build platform 228A. At this time, the partly built object 211 is still under the supply outlet 239. Further, at this time the shutters 250A, 252A have been moved apart (along the Y axis) so that the supply outlet 239 has an effective central axis 254A and an effective width 254 that matches a width of the partly built object 211 at that location.
  • FIG. 2L is yet another simplified top view of the shutters 250A, 252A positioned over the supply outlet 239 (illustrated partly in phantom), and the build platform 228A. At this time, the partly built object 211 is still under the supply outlet 239. Further, at this time the shutters 250A, 252A have been moved apart (along the Y axis) so that the supply outlet 239 has an effective central axis 254A and an effective width 254 that matches a width of the partly built object 211 at that location.
  • Figures 2I-2L illustrate the effective width 254 at four different moments in time to match the profile of the partly built object 211 .
  • These Figures also illustrate how the effective width 254 and the effective central axis 254A can be dynamically adjusted (via the shutters 250A, 252A) as necessary so that the effective width 254 and the effective central axis 254A of the supply outlet 239 corresponds to match the moving object 211 being built below the supply outlet 239.
  • the effective width 254 can be adjusted to any size between fully open to fully closed as necessary to suit the deposit requirements for the material 212.
  • the shutter assembly 244 includes two shutter subassemblies 250, 252.
  • the shutter assembly 244 can include less than two or more than two shutter subassemblies 250, 252.
  • the object 211 to be build is a square cube, and the build platform 228 is being rotating about the two different axes (as describe above in reference to Figure 1 B), then the trajectory of the object 211 with respect to the fixed material supply assembly 218 (illustrated in Figure 2A) is a part of circle. Therefore, even though the object 211 is a square and a length between two opposite sides is constant, the shutters 250A and 252A should be controlled to move along the circle (trajectory).
  • Figure 2M is a top view of one, non-exclusive implementation of the flow restrictor 246 of Figure 2A.
  • the flow restrictor 246 includes a flow structure 246A, and a plurality of flow apertures 246B that extend through the flow structure 246A.
  • the flow structure 246A is rectangular plate shaped. However, other shapes are possible.
  • the flow apertures 246B can have a circular, oval, square, polygonal, or other suitable shape. Further, flow apertures 246B can follow a straight or curved path through the flow structure 246A. Moreover, in this implementation, one or more (typically all) of the flow apertures 246B have an aperture size that is larger than a nominal material particle size of each of the material particles. In alternative, nonexclusive examples, the aperture size is at least approximately 1 , 1 .25, 1 .5, 1 .7, 2, 2.5, 3 or 4 times the nominal material particle size.
  • the flow restrictor 246 can include one or more mesh screens.
  • FIG. 3 is a simplified top view of the supply outlet 339 (illustrated in phantom), and another implementation of the shutter assembly 344.
  • the shutter assembly 344 includes (i) a first shutter subassembly 350 having a first shutter 350A, and a first shutter mover 350B that selectively moves the first shutter 350A relative to the supply outlet 339; (ii) a second shutter subassembly 352 having a second shutter 352A, and a second shutter mover 352B that selectively moves the second shutter 352A relative to the supply outlet 339; (iii) a third shutter subassembly 356 having a third shutter 356A, and a third shutter mover 356B that selectively moves the third shutter 356A relative to the supply outlet 339; and (iv) a fourth shutter subassembly 358 having a fourth shutter 358A, and a fourth shutter mover 358B that selectively moves the fourth shutter 358A relative to the supply outlet 3
  • each shutter mover 350B, 352B, 356B, 358B can move the respective shutter 350A, 352A, 356A, 358A along the Y axis relative to the supply outlet 339 and the other shutters 350A, 352A, 356A, 358A. Additionally or alternatively, each shutter mover 350B, 352B, 356B, 358B can move the respective shutter 350A, 352A, 356A, 358A along the X axis relative to the supply outlet 339 and the other shutters 350A, 352A, 356A, 358A.
  • each shutter mover 350B, 352B, 356B, 358B can move the respective shutter 350A, 352A, 356A, 358A about the Z axis relative to the supply outlet 339 and the other shutters 350A, 352A, 356A, 358A. Still additionally, each shutter mover 350B, 352B, 356B, 358B can move the respective shutter 350A, 352A, 356A, 358A about the X and/or Y axis.
  • the position of each of the shutters 350A, 352A, 356A, 358A can be precisely controlled to precisely control the effective shape and location of the supply outlet 339 and the distribution of the material.
  • FIG. 4A is a simplified top view of the supply outlet 439 (illustrated in phantom), and another implementation of the shutter assembly 444.
  • the shutter assembly 444 includes ten, adjacent shutter subassemblies 450, with each shutter subassembly 450 including a shutter 450A, and a shutter mover 450B (illustrated as a box) that individually moves its corresponding shutter 450A relative to the supply outlet 439.
  • the shutter subassemblies 450 are labeled A-J for reference.
  • each shutter mover 450B can individually move its corresponding shutter 450A along the X axis relative to the supply outlet 339 and the other shutters 450A. Additionally or alternatively, each shutter mover 450B can move the respective shutter 450A along the Y axis relative to the supply outlet 339 and the other shutters 450A. Additionally or alternatively, each shutter mover 450B can move the respective shutter 450A about the Z axis relative to the supply outlet 439 and the other shutters 450A. Still additionally, each shutter mover 450B can move the respective shutter 450A about the X and/or Y axis, and/or along the Z axis.
  • each shutter 450A can be precisely controlled to precisely control the effective shape and location of the supply outlet 439 and the distribution of the material.
  • the shutter assembly 444 can include more than ten, adjacent shutter subassembly 450 to allow for the fine tuning of the effective shape of the supply outlet 439 and the distribution of the material. This allows for the precise control of the material 212 (illustrated in Figure 2A) distribution to the build platform 228A (illustrated in Figure 2A). This also inhibits material 212 from being distributed off of the build platform 228A. With this design, the control system 24 may individually control the shutter subassemblies 450 based on feedback results from the measurement device 20 (illustrated in Figure 1 A) to create the desired material 212 coverage.
  • FIGS 5A and 5B are cut-away views of another implementation of the material supply assembly 518 for distributing the material 512.
  • the material supply assembly 518 includes a material container assembly 540 and a flow control assembly 542 having a shutter subassembly 550 that are somewhat similar to the corresponding components described above.
  • the shutter subassembly 550 selectively adjusts an effective length 560 (along the X axis) of the supply outlet 539.
  • the shutter subassembly 550 includes a shutter 550A and a shutter mover 550B that selectively moves the shutter 550A along the X axis.
  • the shutter 550A is moved to the open position and the material 512 is flowing from the supply outlet 539.
  • the shutter 550A was moved to the closed position and the material 512 is not flowing from the supply outlet 539.
  • the shutter 550A can be moved to any intermediate position between the open position of Figure 5A and the closed position of Figure 5B. Further, the single shutter subassembly 550 can be replaced with multiple shutter subassemblies positioned along the Y axis that adjust the effective axial length 560.
  • the material supply assembly 518 of Figures 5A and 5B can be used with the build platforms 28A of Figure 1 B.
  • the shutter subassembly 550 adjusts the effective axial length 560 of the supply outlet 539.
  • the build platform 28A can be rotated about two different axes (as described above in reference to Figure 1 B), and the shutter 550A is an axial shutter that adjusts the axial distribution of the material 512. In this design, it is necessary to control the axial shutter 550A in accordance with a trajectory of the rotating build platform 28A.
  • the axial shutter subassembly 550 of Figures 5A and 5B can be additionally implemented into the material supply assemblies 18, 218 described above.
  • Figure 6A is a perspective view of yet another implementation of the material supply assembly 618
  • Figures 6B and 6C are alternative cut-away views of the material supply assembly 618 of Figure 6A, and a portion of a build platform 628A.
  • the material supply assembly 618 includes a material container assembly 640 and a flow control assembly 642 having a shutter subassembly 650 that are somewhat similar to the corresponding components described above and illustrated in Figures 5A and 5B.
  • the shutter subassembly 650 again selectively adjusts an effective length 660 (along the X axis) of the supply outlet 639.
  • the shutter subassembly 650 includes a shutter 650A and a shutter mover 650B that selectively moves the shutter 650A to adjust the opening along the X axis.
  • the shutter 650A is moved to the closed position and the material 612 is not flowing from the supply outlet 639.
  • Figure 6C the shutter 650A was moved to the open position and the material 612 is flowing from the supply outlet 639.
  • the flow control assembly 642 includes a rigid frame 642A that retains the shutter mover 650B, and a linear guide 642B that guides the motion of the shutter 650A. Further, in this design, the shutter 650A is at an angle of approximately forty-five degrees relative to the build platform 628A. However, the angle of the shutter 650A can be varied.
  • the shutter 650A can be moved to any intermediate position between the open position of Figure 6C and the closed position of Figure 6B. Further, it should be noted that the single shutter subassembly 650 can be replaced with multiple shutter subassemblies (positioned along the Y axis) that adjust the effective axial length 660.
  • the material supply assembly 618 of Figures 6A-6C can be used with the build platforms 28A of Figure 1 B.
  • the shutter subassembly 650 adjusts the effective axial length 660 of the supply outlet 639.
  • the build platform 628A can be rotated about two different axes (as described above in reference to Figure 1 B), and the shutter 650A is an axial shutter that adjusts the axial distribution of the material 612.
  • the axial shutter 650A can be controlled in accordance with a trajectory of the rotating build platform 28A. For example, the axial shutter 650A can be opened when the build platform 628A is below the material supply assembly 618, and the axial shutter 650A can be closed when the build platform 628A is not below the material supply assembly 618.
  • the axial shutter subassembly 650 of Figures 6A-6C can be additionally implemented into the material supply assemblies 18, 218 described above.
  • the material supply assembly 618 can include a rake 662 (or other structure) that levels the material 612 on the build platform 628A.

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  • Engineering & Computer Science (AREA)
  • Chemical & Material Sciences (AREA)
  • Materials Engineering (AREA)
  • Manufacturing & Machinery (AREA)
  • Physics & Mathematics (AREA)
  • Mechanical Engineering (AREA)
  • Optics & Photonics (AREA)
  • Plasma & Fusion (AREA)

Abstract

Une machine de traitement (10) pour construire un objet (11) à partir de matériau (12), comprend une plateforme de construction (28A) ; un ensemble d'alimentation en matériau (18) qui dépose le matériau (12) sur la plateforme de construction (28A) ; et un système d'énergie (22) qui dirige un faisceau d'énergie (22A) au niveau d'une partie du matériau (12) sur la plateforme de construction (28A) pour former une partie de l'objet (11). L'ensemble d'alimentation en matériau (18) comprend un récipient de matériau (240) qui retient le matériau (12) ; et (ii) un ensemble de commande d'écoulement (242) qui commande sélectivement une caractéristique d'écoulement du matériau (12) déposé sur la plateforme de construction (28A).
PCT/US2021/064250 2020-12-23 2021-12-19 Ensemble d'alimentation en matériau à commande précise pour la fabrication additive WO2022140208A1 (fr)

Applications Claiming Priority (2)

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US202063130138P 2020-12-23 2020-12-23
US63/130,138 2020-12-23

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Citations (3)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US20180141126A1 (en) * 2015-07-20 2018-05-24 Velo3D, Inc. Transfer of particulate material
US20190070663A1 (en) * 2017-09-06 2019-03-07 General Electric Company Apparatus and method for additive manufacturing with real-time and in-situ adjustment of growth parameters
DE102018200802A1 (de) * 2018-01-18 2019-07-18 Eos Gmbh Electro Optical Systems Dosiervorrichtung, Vorrichtung und Verfahren zum generativen Herstellen eines dreidimensionalen Objekts

Patent Citations (3)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US20180141126A1 (en) * 2015-07-20 2018-05-24 Velo3D, Inc. Transfer of particulate material
US20190070663A1 (en) * 2017-09-06 2019-03-07 General Electric Company Apparatus and method for additive manufacturing with real-time and in-situ adjustment of growth parameters
DE102018200802A1 (de) * 2018-01-18 2019-07-18 Eos Gmbh Electro Optical Systems Dosiervorrichtung, Vorrichtung und Verfahren zum generativen Herstellen eines dreidimensionalen Objekts

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