WO2022225383A1 - A powder recoating system for additive manufacturing application - Google Patents

A powder recoating system for additive manufacturing application Download PDF

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Publication number
WO2022225383A1
WO2022225383A1 PCT/LV2022/050005 LV2022050005W WO2022225383A1 WO 2022225383 A1 WO2022225383 A1 WO 2022225383A1 LV 2022050005 W LV2022050005 W LV 2022050005W WO 2022225383 A1 WO2022225383 A1 WO 2022225383A1
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WO
WIPO (PCT)
Prior art keywords
powder
recoating
fabrication
arm
delivery assembly
Prior art date
Application number
PCT/LV2022/050005
Other languages
French (fr)
Inventor
Uldis KLAPERIS
Original Assignee
Klaperis Uldis
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 Klaperis Uldis filed Critical Klaperis Uldis
Priority to EP22717022.2A priority Critical patent/EP4326465A1/en
Publication of WO2022225383A1 publication Critical patent/WO2022225383A1/en

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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
    • 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
    • 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
    • B22F12/50—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
    • B22F12/60—Planarisation devices; Compression devices
    • 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
    • B29C64/205—Means for applying layers
    • B29C64/214—Doctor blades
    • 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
    • B33Y40/00—Auxiliary operations or equipment, e.g. for material handling
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
    • Y02P—CLIMATE CHANGE MITIGATION TECHNOLOGIES IN THE PRODUCTION OR PROCESSING OF GOODS
    • Y02P10/00—Technologies related to metal processing
    • Y02P10/25—Process efficiency

Definitions

  • the present invention relates to powder recoating systems or recoaters for additive manufacturing (AM) applications, for example a selective laser melting (SLM), a selective laser sintering (SLS) or the like.
  • AM additive manufacturing
  • SLM selective laser melting
  • SLS selective laser sintering
  • AM is the construction of a three-dimensional object from a Computer Aided Design (CAD) model or a digital three-dimensional (3D) model.
  • CAD Computer Aided Design
  • 3D digital three-dimensional
  • U.S. patent publication No. 4,863,538 and U.S. patent publication No. 5,460,758 describe conventional laser sintering techniques.
  • Typical recoating techniques are disclosed in the international patent application publication No. WO2018/156264 and U.S. patent application publications Nos. US2020/2386131 and US2018/0370213.
  • Prior-art recoating technique involves a linear movement of a recoating arm along a powder delivery assembly to collect a powder and transfer it to a fabrication powder bed recoating thereof. After recoating the recoating arm is linearly moved back along the safe trajectory. In order not to disturb already recoated layer on the fabrication powder bed, the bed is repositioned. The same repositioning takes place also in the powder delivery assembly.
  • Aforementioned reposition requires complicated control of the process as well as reposition itself brings certain repositioning inaccuracies in the process.
  • International application publication No. WO 2020/075122 discloses an apparatus for powder deposition mechanism in an additive manufacturing process.
  • the apparatus comprises at least two belt driven cyclic arms which are configured to travel only in forward direction.
  • a Programmable Logic Controller (PLC) controls the movement of the arm.
  • a vertical loop is configured to translate recoating arms in the vertical plane and horizontal plane. This recoating system takes considerable amount of build space and hence increases the overall dimensions of the additive manufacturing apparatus.
  • Aim of the invention is to design a powder recoating system or a recoater for the AM without aforementioned drawbacks.
  • the aim is reached by design of a new powder recoating system for additive manufacturing application utilizing a powder material.
  • the typical 3D printer comprising a laser, a powder delivery assembly or a powder bunker and a fabrication powder bed or a printing platform, and a powder recoating system.
  • the laser is configured to generate a laser beam for selective laser sintering or melting of a powder in the fabrication powder bed.
  • the printing of the object is performed in the fabrication powder bed.
  • the new powder recoating system comprises an endless chain conveyor arranged above a powder delivery assembly and a fabrication powder bed.
  • the system further comprises a recoating arm or blade attached to the endless chain conveyor so that the recoating arm is movable in a forward direction along the powder delivery assembly and the fabrication powder bed to move a powder from the powder delivery assembly to the fabrication powder bed for recoating thereof.
  • the endless chain conveyor has a lower run and an upper run arranged so that the recoating arm moving along the lower ran of the endless chain conveyor conveys the powder from the powder delivery assembly to the fabrication powder bed recoating thereof and moving along the upper run of the endless chain conveyor repositions for the next convey or transfer of the powder from the powder delivery assembly to the fabrication powder bed. Utilization of the chain as the endless conveyor allowed to provide more stable transfer of the recoating arm compared to belt. Hence, less support mechanisms or features has to be used compared to belt conveyors allowing to design more compact powder recoating system.
  • the endless chain conveyor is arranged on two sprockets. Moreover, the endless chain conveyor is arranged on each sprocket so that it bends around the sprocket by at least 180 degrees. When the recoating arm runs around this 180-degree bend, a travel speed and a centrifugal force of the recoating arm increases. Int was surprisingly found out that this increase of travel speed and centrifugal force facilitated a cleaning of said recoating arm. [009] A diameter of the sprocket is in a range of 30 to 90 mm, preferably 45 to 65 mm, more preferably 50 mm. Aforementioned diameter of the sprocket is outer diameter of the sprocket.
  • the recoating arm or blade travels in continuous motion only in one or forward direction.
  • the recoating arm guiding mechanism may be driven by an electric motor or any other driving mechanism.
  • the recoating arm grabs powder from the powder delivery assembly, or powder bunker or other extruder and transfer the powder to the fabrication powder bed.
  • proposed continuous recoating system does not scrape previously applied powder layer because it travels back in inverted position, i.e., well above the powder delivery assembly and the fabrication powder bed.
  • the laser beam can start to melt or sinter previously applied powder layer.
  • the powder recoating system further comprises an auxiliary recoating arm attached to the endless chain conveyor mechanism.
  • the auxiliary recoating arm is positioned at the endless chain conveyor so that the distance of the auxiliary recoating arm from and to the recoating arm is generally equal.
  • the system may comprise more than two recoating arms.
  • the powder recoating system may further comprise a cleaning unit positioned in the upper run or on a side of the endless chain conveyor and configured to clean the recoating arm from the residual powder.
  • a cleaning unit positioned in the upper run or on a side of the endless chain conveyor and configured to clean the recoating arm from the residual powder.
  • the new powder recoating system implements a new method for recoating of the fabrication powder bed or the printing platform.
  • the method comprising: a) feeding of a powder in the powder delivery assembly so that the powder can be transferred by a recoating arm; b) moving the recoating arm along the powder delivery assembly to the fabrication powder bed so that the powder present in the powder delivery assembly is transferred to the fabrication powder bed providing a recoated layer of the powder therein; c) irradiating by means of a laser at least a portion of the recoated layer of the powder to form a fused region; d) moving down a fabrication piston of the fabrication powder bed to prepare a fabrication powder bed for providing the next recoated layer of the powder; and e) repeating steps a) and d) until a fabricated object is made.
  • the fabrication piston downwards movement is a movement away from the recoating arm guiding mechanism.
  • the method is characterized in that the recoating arm moves only in a direction from the powder delivery assembly to the fabrication powder bed.
  • the powder delivery piston moves only upwards providing the powder for recoating until the fabricated object is made.
  • the powder delivery piston upwards movement is a movement towards the recoating arm guiding mechanism.
  • the method comprises the following steps: a) moving up a powder delivery piston of the powder delivery assembly so that powder is arranged above a level where the recoating arm can move the powder; b) moving the recoating arm along the powder delivery assembly to the fabrication powder bed so that the powder present above the level in the powder delivery assembly is transferred to the fabrication powder bed providing a recoated layer of the powder therein; c) irradiating by means of a laser at least a portion of the recoated layer of the powder to form a fused region; and d) moving down a fabrication piston of the fabrication powder bed to prepare a fabrication powder bed for providing the next recoated layer.
  • the steps a) to d) are sequentially repeated until a fabricated object is made.
  • the method is characterized in that the recoating arm moves only in a direction from the powder delivery assembly to the fabrication powder bed. Moreover, the powder delivery piston of the powder delivery assembly moves only upwards and the fabrication piston of the fabrication powder bed moves only downwards until the fabricated object is made. [016]
  • the powder delivery piston of the powder delivery assembly and the fabrication piston of the fabrication powder bed moves only in one direction without repositioning during 3D printing process, which increase layer thickness stability. No need to compensate for backlash. Saves time for travel moves in both directions - back and forth.
  • FIG. 1 is a schematic view of a powder bed additive manufacturing process using a recoating arm (1) to distribute powder over a fabrication powder bed (4).
  • the powder is fed by means of the powder delivery assembly (3) which is in the form of a powder delivery hopper (32).
  • FIG. 2 is a schematic view of a powder bed additive manufacturing process using a recoating arm (1) to distribute powder over a fabrication powder bed (4).
  • FIG. 3 is an illustration of one embodiment of the invention where a powder recoating system comprising one recoating arm (1).
  • FIG. 4 is an illustration of a powder recoating system comprising two recoating arms (1; 11).
  • a powder recoating system for additive manufacturing application utilizing a powder material as seen in Fig. 1 comprising an endless chain conveyor (2) having an endless chain (23).
  • the endless chain conveyor (2) is arranged above a powder delivery assembly (3) and a fabrication powder bed (4), but below a laser (5).
  • the endless chain conveyor (2) comprising a recoating arm (1) and an auxiliary recoating arm (11). Both arms (1, 11) attached to the endless chain conveyor (2) so that each recoating arm (1; 11) is movable along the powder delivery assembly (3) and the fabrication powder bed (4) to transfer a powder (P) from the powder delivery assembly (3) to the fabrication powder bed (4) for recoating thereof.
  • the powder delivery assembly (3) comprises a powder delivery hopper (32) configured to feed the powder (P) onto a surface along which the recoating arms (1, 11) move and can grab the fed powder (P) .
  • the endless chain conveyor (2) has a lower run (21 ) and an upper run (22) arranged so that the recoating arm ( 1 ; 11) moving along the lower run (21 ) of the endles s chain conveyor (2) conveys the powder (P) from the powder delivery assembly (3) to the fabrication powder bed (4) recoating thereof.
  • the recoating arm (1, 11) moves along the upper run (22) of the endless chain conveyor (2) repositioning itself for the next convey of the powder (P) from the powder delivery assembly (3) to the fabrication powder bed (4).
  • the endless chain conveyor (2) is arranged on two sprockets (7), wherein the endless chain (23) of the endless chain conveyor (2) bends around each sprocket (7) by at least 180 degrees.
  • a diameter of the sprocket (7) is 50 mm.
  • the endless chain conveyor (2) is so compact that it does not require any additional re-design of the powder delivery assembly (3), the fabrication powder bed (4) and the laser (5).
  • Fig. 2 is a schematic view of a powder bed additive manufacturing device or 3D printer and a process utilizing a powder recoating system as seen in Fig. 4.
  • the 3D printer comprises a laser (5) configured to generate a laser beam (55).
  • the 3D printer further comprises a powder delivery assembly (3) and a fabrication powder bed (4).
  • the powder delivery assembly (3) comprises a powder delivery piston (31) configured to move a powder (P) up for its transfer to the fabrication powder bed (4).
  • the fabrication powder bed (4) comprises a fabrication piston (41) configured to move down as the powder (P) is added to said bed, selective laser sintering or melting is performed and a fabricated model (6) is made.
  • a powder recoating system comprises the endless chain conveyor (2) in the form of conveyor chain (23) arranged above a powder delivery assembly (3) and a fabrication powder bed (4).
  • the system further comprises a recoating arm (1) attached to the conveyor chain (23) so that the recoating arm (1) is movable along the powder delivery assembly (3) and the fabrication powder bed (4) to move or transfer the powder (P) from the powder delivery assembly (3) to the fabrication powder bed (4) for recoating thereof.
  • the conveyor chain (23) has a lower run (21) and an upper run (22) arranged so that the recoating arm (1) moving along the lower run (21) of the conveyor chain (23) conveys the powder (P) from the powder delivery assembly (3) to the fabrication powder bed (4) recoating thereof and moving along the upper run (22) of the conveyor chain (23) repositions for the next convey of the powder (P) from the powder delivery assembly (3) to the fabrication powder bed (4).
  • FIG. 4 is an illustration of a powder recoating system comprising the recoating arm (1) and an auxiliary recoating arm (11). Both arms (1; 11) are attached to the endless chain conveyor (2).
  • the auxiliary recoating arm (11) is positioned at the endless chain conveyor (2) so that the distance of the auxiliary recoating arm (11) from and to the recoating arm (1) is generally equal.

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  • Chemical & Material Sciences (AREA)
  • Materials Engineering (AREA)
  • Manufacturing & Machinery (AREA)
  • Physics & Mathematics (AREA)
  • Mechanical Engineering (AREA)
  • Optics & Photonics (AREA)
  • Plasma & Fusion (AREA)
  • Processing And Handling Of Plastics And Other Materials For Molding In General (AREA)
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  • Agricultural Chemicals And Associated Chemicals (AREA)
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Abstract

The present invention relates to powder recoating systems or recoaters for additive manufacturing applications. A powder recoating system comprises a recoating an endless chain conveyor (2) and a recoating arm (1) attached thereto. The endless chain conveyor (2) is arranged so that the recoating arm (1) is able to move a powder (P) from the powder delivery assembly (3) to the fabrication powder bed (4) recoating thereof. The endless chain conveyor (2) having lower run (21) and upper run (22) arranged so that the recoating arm (1) moving along the lower run (21) conveys the powder (P) from the powder delivery assembly (3) to the fabrication powder bed (4) recoating thereof and moving along the upper run (22) repositions for the next transfer of the powder (P) from the powder delivery assembly (3) to the fabrication powder bed (4).

Description

A POWDER RECOATING SYSTEM FOR ADDITIVE MANUFACTURING
APPLICATION
DESCRIPTION
Field of the Invention
[001] The present invention relates to powder recoating systems or recoaters for additive manufacturing (AM) applications, for example a selective laser melting (SLM), a selective laser sintering (SLS) or the like.
Background of the Invention
[002] AM is the construction of a three-dimensional object from a Computer Aided Design (CAD) model or a digital three-dimensional (3D) model. AM refers to producing 3D objects by using laser beam to sinter or melt a fine powder in a layer by layer.
[003] For example, U.S. patent publication No. 4,863,538 and U.S. patent publication No. 5,460,758 describe conventional laser sintering techniques. Typical recoating techniques are disclosed in the international patent application publication No. WO2018/156264 and U.S. patent application publications Nos. US2020/2386131 and US2018/0370213. Prior-art recoating technique involves a linear movement of a recoating arm along a powder delivery assembly to collect a powder and transfer it to a fabrication powder bed recoating thereof. After recoating the recoating arm is linearly moved back along the safe trajectory. In order not to disturb already recoated layer on the fabrication powder bed, the bed is repositioned. The same repositioning takes place also in the powder delivery assembly. Aforementioned reposition requires complicated control of the process as well as reposition itself brings certain repositioning inaccuracies in the process.
[004] International application publication No. WO 2020/075122 discloses an apparatus for powder deposition mechanism in an additive manufacturing process. The apparatus comprises at least two belt driven cyclic arms which are configured to travel only in forward direction. A Programmable Logic Controller (PLC) controls the movement of the arm. A vertical loop is configured to translate recoating arms in the vertical plane and horizontal plane. This recoating system takes considerable amount of build space and hence increases the overall dimensions of the additive manufacturing apparatus.
[005] Aim of the invention is to design a powder recoating system or a recoater for the AM without aforementioned drawbacks.
Summary of the Invention
[006] The aim is reached by design of a new powder recoating system for additive manufacturing application utilizing a powder material. The typical 3D printer comprising a laser, a powder delivery assembly or a powder bunker and a fabrication powder bed or a printing platform, and a powder recoating system. The laser is configured to generate a laser beam for selective laser sintering or melting of a powder in the fabrication powder bed. The printing of the object is performed in the fabrication powder bed.
[007] The new powder recoating system comprises an endless chain conveyor arranged above a powder delivery assembly and a fabrication powder bed. The system further comprises a recoating arm or blade attached to the endless chain conveyor so that the recoating arm is movable in a forward direction along the powder delivery assembly and the fabrication powder bed to move a powder from the powder delivery assembly to the fabrication powder bed for recoating thereof. The endless chain conveyor has a lower run and an upper run arranged so that the recoating arm moving along the lower ran of the endless chain conveyor conveys the powder from the powder delivery assembly to the fabrication powder bed recoating thereof and moving along the upper run of the endless chain conveyor repositions for the next convey or transfer of the powder from the powder delivery assembly to the fabrication powder bed. Utilization of the chain as the endless conveyor allowed to provide more stable transfer of the recoating arm compared to belt. Hence, less support mechanisms or features has to be used compared to belt conveyors allowing to design more compact powder recoating system.
[008] The endless chain conveyor is arranged on two sprockets. Moreover, the endless chain conveyor is arranged on each sprocket so that it bends around the sprocket by at least 180 degrees. When the recoating arm runs around this 180-degree bend, a travel speed and a centrifugal force of the recoating arm increases. Int was surprisingly found out that this increase of travel speed and centrifugal force facilitated a cleaning of said recoating arm. [009] A diameter of the sprocket is in a range of 30 to 90 mm, preferably 45 to 65 mm, more preferably 50 mm. Aforementioned diameter of the sprocket is outer diameter of the sprocket.
[010] The recoating arm or blade travels in continuous motion only in one or forward direction. The recoating arm guiding mechanism may be driven by an electric motor or any other driving mechanism. The recoating arm grabs powder from the powder delivery assembly, or powder bunker or other extruder and transfer the powder to the fabrication powder bed. Compared to other systems where both units - the powder delivery assembly and the fabrication powder bed - have to be lowered before the recoating arm can move back to a powder collection point, proposed continuous recoating system does not scrape previously applied powder layer because it travels back in inverted position, i.e., well above the powder delivery assembly and the fabrication powder bed. When the recoating arm in inverted position has traveled over a middle point between the powder delivery assembly and the fabrication powder bed then the laser beam can start to melt or sinter previously applied powder layer.
[Oil] In order to increase productivity, the powder recoating system further comprises an auxiliary recoating arm attached to the endless chain conveyor mechanism. In one embodiment of the invention the auxiliary recoating arm is positioned at the endless chain conveyor so that the distance of the auxiliary recoating arm from and to the recoating arm is generally equal. In other embodiments of the invention, the system may comprise more than two recoating arms.
[012] The powder recoating system may further comprise a cleaning unit positioned in the upper run or on a side of the endless chain conveyor and configured to clean the recoating arm from the residual powder. Aforementioned 180-degree bend of the chain around the sprocket already provides satisfactory cleaning, but for certain applications it may be combined with the cleaning unit known from the prior art.
[013] The new powder recoating system implements a new method for recoating of the fabrication powder bed or the printing platform. The method comprising: a) feeding of a powder in the powder delivery assembly so that the powder can be transferred by a recoating arm; b) moving the recoating arm along the powder delivery assembly to the fabrication powder bed so that the powder present in the powder delivery assembly is transferred to the fabrication powder bed providing a recoated layer of the powder therein; c) irradiating by means of a laser at least a portion of the recoated layer of the powder to form a fused region; d) moving down a fabrication piston of the fabrication powder bed to prepare a fabrication powder bed for providing the next recoated layer of the powder; and e) repeating steps a) and d) until a fabricated object is made. The fabrication piston downwards movement is a movement away from the recoating arm guiding mechanism.
[014] The method is characterized in that the recoating arm moves only in a direction from the powder delivery assembly to the fabrication powder bed. In another embodiment of the invention with the powder delivery piston of the powder delivery assembly, the powder delivery piston moves only upwards providing the powder for recoating until the fabricated object is made. The powder delivery piston upwards movement is a movement towards the recoating arm guiding mechanism.
[015] In another embodiment of the invention, wherein the powder delivery assembly comprises the powder delivery piston configured to feed the powder, the method comprises the following steps: a) moving up a powder delivery piston of the powder delivery assembly so that powder is arranged above a level where the recoating arm can move the powder; b) moving the recoating arm along the powder delivery assembly to the fabrication powder bed so that the powder present above the level in the powder delivery assembly is transferred to the fabrication powder bed providing a recoated layer of the powder therein; c) irradiating by means of a laser at least a portion of the recoated layer of the powder to form a fused region; and d) moving down a fabrication piston of the fabrication powder bed to prepare a fabrication powder bed for providing the next recoated layer. The steps a) to d) are sequentially repeated until a fabricated object is made. The method is characterized in that the recoating arm moves only in a direction from the powder delivery assembly to the fabrication powder bed. Moreover, the powder delivery piston of the powder delivery assembly moves only upwards and the fabrication piston of the fabrication powder bed moves only downwards until the fabricated object is made. [016] The powder delivery piston of the powder delivery assembly and the fabrication piston of the fabrication powder bed moves only in one direction without repositioning during 3D printing process, which increase layer thickness stability. No need to compensate for backlash. Saves time for travel moves in both directions - back and forth.
Brief Description of the Drawings
[017] The drawings illustrate generally, by way of example, but not by way of limitation, various embodiments of the invention.
[018] Fig. 1 is a schematic view of a powder bed additive manufacturing process using a recoating arm (1) to distribute powder over a fabrication powder bed (4). The powder is fed by means of the powder delivery assembly (3) which is in the form of a powder delivery hopper (32).
[019] Fig. 2 is a schematic view of a powder bed additive manufacturing process using a recoating arm (1) to distribute powder over a fabrication powder bed (4).
[020] Fig. 3 is an illustration of one embodiment of the invention where a powder recoating system comprising one recoating arm (1).
[021] Fig. 4 is an illustration of a powder recoating system comprising two recoating arms (1; 11).
Detailed Description of the Embodiments
[022] Aspects and advantages of the invention will be set forth in part in the following description, or may be obvious from the description, or may be learned through practice of the invention.
[023] A powder recoating system for additive manufacturing application utilizing a powder material as seen in Fig. 1 comprising an endless chain conveyor (2) having an endless chain (23). The endless chain conveyor (2) is arranged above a powder delivery assembly (3) and a fabrication powder bed (4), but below a laser (5). The endless chain conveyor (2) comprising a recoating arm (1) and an auxiliary recoating arm (11). Both arms (1, 11) attached to the endless chain conveyor (2) so that each recoating arm (1; 11) is movable along the powder delivery assembly (3) and the fabrication powder bed (4) to transfer a powder (P) from the powder delivery assembly (3) to the fabrication powder bed (4) for recoating thereof. The powder delivery assembly (3) comprises a powder delivery hopper (32) configured to feed the powder (P) onto a surface along which the recoating arms (1, 11) move and can grab the fed powder (P) . The endless chain conveyor (2) has a lower run (21 ) and an upper run (22) arranged so that the recoating arm ( 1 ; 11) moving along the lower run (21 ) of the endles s chain conveyor (2) conveys the powder (P) from the powder delivery assembly (3) to the fabrication powder bed (4) recoating thereof. The recoating arm (1, 11) moves along the upper run (22) of the endless chain conveyor (2) repositioning itself for the next convey of the powder (P) from the powder delivery assembly (3) to the fabrication powder bed (4). The endless chain conveyor (2) is arranged on two sprockets (7), wherein the endless chain (23) of the endless chain conveyor (2) bends around each sprocket (7) by at least 180 degrees. A diameter of the sprocket (7) is 50 mm. The endless chain conveyor (2) is so compact that it does not require any additional re-design of the powder delivery assembly (3), the fabrication powder bed (4) and the laser (5).
[024] Fig. 2 is a schematic view of a powder bed additive manufacturing device or 3D printer and a process utilizing a powder recoating system as seen in Fig. 4. The 3D printer comprises a laser (5) configured to generate a laser beam (55). The 3D printer further comprises a powder delivery assembly (3) and a fabrication powder bed (4). The powder delivery assembly (3) comprises a powder delivery piston (31) configured to move a powder (P) up for its transfer to the fabrication powder bed (4). The fabrication powder bed (4) comprises a fabrication piston (41) configured to move down as the powder (P) is added to said bed, selective laser sintering or melting is performed and a fabricated model (6) is made.
[025] As seen in Figs. 1 to 4, a powder recoating system comprises the endless chain conveyor (2) in the form of conveyor chain (23) arranged above a powder delivery assembly (3) and a fabrication powder bed (4). The system further comprises a recoating arm (1) attached to the conveyor chain (23) so that the recoating arm (1) is movable along the powder delivery assembly (3) and the fabrication powder bed (4) to move or transfer the powder (P) from the powder delivery assembly (3) to the fabrication powder bed (4) for recoating thereof. The conveyor chain (23) has a lower run (21) and an upper run (22) arranged so that the recoating arm (1) moving along the lower run (21) of the conveyor chain (23) conveys the powder (P) from the powder delivery assembly (3) to the fabrication powder bed (4) recoating thereof and moving along the upper run (22) of the conveyor chain (23) repositions for the next convey of the powder (P) from the powder delivery assembly (3) to the fabrication powder bed (4).
[026] Fig. 4 is an illustration of a powder recoating system comprising the recoating arm (1) and an auxiliary recoating arm (11). Both arms (1; 11) are attached to the endless chain conveyor (2). The auxiliary recoating arm (11) is positioned at the endless chain conveyor (2) so that the distance of the auxiliary recoating arm (11) from and to the recoating arm (1) is generally equal.
[027] While the invention may be susceptible to various modifications and alternative forms, specific embodiments of which have been shown by way of example in the figures and have been described in detail herein, it should be understood that the invention is not intended to be limited to the particular forms disclosed. Rather, the invention includes all modifications, equivalents, and alternatives falling within the scope of the invention as defined by the following claims.
[028] List of references:
1 - a recoating arm;
11 - an auxiliary recoating arm;
2 - an endless chain conveyor;
21 a lower run of an endless conveyor;
22 - an upper run of an endless conveyor;
23 - a conveyer chain;
3 a powder delivery assembly;
31 - a powder delivery piston;
32 - a powder delivery hopper;
4 - a fabrication powder bed;
41 - a fabrication piston;
5 - a laser;
51 - a laser beam;
6 - a fabricated object; and
7 - a sprocket.

Claims

1. A powder recoating system for additive manufacturing application utilizing a powder material comprising: a fabrication powder bed (4); a powder delivery assembly (3) configured to deliver a powder (P); a laser (5) configured to selectively sinter or melt the powder (P) within the fabrication powder bed (4); an endless chain conveyor (2) arranged on two sprockets (7), wherein the endless chain conveyor (2) has a lower run (21) and an upper run (22) and wherein the endless chain conveyor (2) arranged between the fabrication powder bed (4) and the laser (5), and wherein the endless chain conveyor (2) is configured to travel only in forward direction, a recoating arm (1) attached to the endless chain conveyor (2) so that the recoating arm (1) is movable along the lower run (21) of the endless chain conveyor (2) conveying the powder (P) from the powder delivery assembly (3) to the fabrication powder bed (4) recoating thereof and moving along the upper run (22) of the endless chain conveyor (2) repositioning the recoating arm (1) for the next convey of the powder (P) from the powder delivery assembly (3) to the fabrication powder bed (4), wherein the endless chain conveyor (2) is arranged on each sprocket (7) so that it bends around the sprocket (7) by at least 180 degrees.
2. The powder recoating system according to any of preceding Claim 1, characterized in that the system further comprises an auxiliary recoating arm (11) attached to the endless conveyor (2).
3. The powder recoating system according to Claim 2, characterized in that the auxiliary recoating arm (11) is positioned at the endless conveyor (2) so that the distance of the auxiliary recoating arm (11) from and to the recoating arm (1) is generally equal.
4. The powder recoating system according to any of preceding Claim 1 to 3, characterized in that the system further comprises a cleaning unit positioned in the upper run (22) of the endless conveyor (2) and configured to clean the recoating arm (1; 11) from the residual powder.
5. The powder recoating system according to any of preceding Claim 1 to 4, characterized in that a diameter of the sprocket (7) is in a range of 30 to 90 mm, preferably 45 to 65 mm, more preferably 50 mm.
6. A method for recoating of the fabrication powder bed (4) using the powder recoating system according to any of preceding Claim 1 to 5, wherein the method comprising: a) feeding of a powder (P) in the powder delivery assembly (3) so that the powder (P) can be transferred by a recoating arm (1: 11); b) moving the recoating arm (1; 11) along the powder delivery assembly (3) to the fabrication powder bed (4) so that the powder (P) present in the powder delivery assembly (3) is transferred to the fabrication powder bed (4) providing a recoated layer of the powder (P) therein; c) irradiating by means of a laser (5) at least a portion of the recoated layer of the powder (P) to form a fused region; d) moving down a fabrication piston (41) of the fabrication powder bed (4) to prepare a fabrication powder bed (4) for providing the next recoated layer of the powder (P); e) repeating steps a) and d) until a fabricated object (6) is made; characterized in that the recoating arm (1; 11) moves only in forward direction from the powder delivery assembly (3) to the fabrication powder bed (4); and in that the fabrication piston (41) of the fabrication powder bed (4) moves only downwards until the fabricated object (6) is made.
7. The method according to Claim 6, characterized in that in the step a) a powder delivery piston (31) of the powder delivery assembly (3) is moved upwards so that the powder (P) is arranged above a level where the recoating arm (1; 11) can move the powder (P); and in that the powder delivery piston (31) of the powder delivery assembly (3) moves only upwards until the fabricated object (6) is made.
PCT/LV2022/050005 2021-04-21 2022-04-04 A powder recoating system for additive manufacturing application WO2022225383A1 (en)

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LVP-21-23A LV15688B (en) 2021-04-21 2021-04-21 Powder recoating systems for additive manufacturing applications

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LV15688B (en) 2023-08-20
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