Method for additive manufacturing of a three-dimensional object

Patent metadata

Field	Value
Publication number	US-10821670-B2
Application number	US-201715812963-A
Country	US
Kind code	B2
Filing date	Nov 14, 2017
Priority date	Nov 21, 2016
Publication date	Nov 3, 2020
Grant date	Nov 3, 2020

Abstract

A method for additive manufacturing of a three-dimensional object ( 6 ) by successive, selective layer-by-layer solidification of layers of a construction material ( 9 ) by at least one energy beam, wherein the successive, selective solidification of the construction material ( 9 ) is carried out due to a data record describing the three-dimensional object to be additively manufactured ( 6 ), wherein construction material sections provided for sintering and/or melting on or melting through are heated in a temperature range lying below the solidification temperature of the construction material ( 9 ), wherein the heating of the construction material section(s) is carried out by at least one heating beam ( 17 ) either surrounding at least one main beam ( 18 ) provided for melting on or melting through in sections or going ahead or following the main beam ( 18 ), wherein the main beam ( 18 ) and the heating beam ( 17 ) are together guided synchronously along the surface of the construction material ( 9 ).

First claim

The invention claimed is:

1. A method for additive manufacturing of a three-dimensional object by successive, selective layer-by-layer solidification of layers of a construction material by at least one energy beam, wherein the successive, selective solidification of the construction material is carried out in accordance with a data record describing the three-dimensional object to be additively manufactured, the method comprising:
providing a plurality of construction material sections for sintering and/or melting on or melting through,
heating the plurality of construction material sections in a temperature range lying below the solidification temperature of the construction material, wherein the heating of the plurality of construction material sections is carried out by at least one heating beam, section-wise surrounding at least one main beam, provided for melting on or melting through,
guiding the main beam and the heating beam synchronously along a surface of the construction material,
extracting or splitting the heating beam from the main beam, and
varying a beam splitting ratio of the main beam and the heating beam and a spot size ratio of the main beam and the heating beam on the construction material surface during the selective layer-by-layer solidification of layers of the construction material.

2. The method according to claim 1 , further comprising:
coaxially guiding the heating beam to the main beam.

3. The method according to claim 2 , further comprising:
obtaining the heating beam from the main beam by beam extraction.

4. The method according to claim 1 , further comprising:
guiding the heating beam through a beam expansion optic after the heating beam diverges from the main beam.

5. The method according to claim 1 , further comprising:
reuniting the heating beam with the main beam in a beam coupling device.

6. The method according to claim 1 , further comprising:
guiding both the main beam and the heating beam over a scanner.

7. The method according to claim 1 , further comprising:
directing, to the construction material surface, the focus of the main beam, lying within an irradiation section of the heating beam.

8. The method according to claim 1 , wherein an arrangement of the main beam and the heating beam inside each other is displaced or decentralized on the construction material surface in a process-controlled manner.

9. The method according to claim 1 , wherein the surrounding area of the construction material surface covered by the heating beam is larger than the surface area on the construction material layer covered by the main beam.

10. The method according to claim 1 , further comprising:
selectively heating, with the heating beam, exclusively the direct surroundings of the main beam at the time of the solidification process.

11. The method according to claim 6 , further comprising:
generating the main beam with a first beam source,
generating the heating beam with a second beam source different from the first beam source, and
bringing together the main beam and the heating beam in a beam coupling device prior to the main beam and the heating beam being delivered to the scanner.

12. The method according to claim 11 , wherein the first beam source and the second beam source irradiate at different wavelengths.

13. An apparatus for additive manufacturing of a three-dimensional object by successive, selective layer-by-layer solidification of layers of a construction material by at least one energy beam, wherein the successive, selective solidification of the construction material is carried out in accordance with a data record describing the three-dimensional object to be additively manufactured, wherein construction material sections provided for sintering and/or melting on or melting through are heated in a temperature range lying below the solidification temperature of the construction material, the apparatus comprising:
a housing,
a process chamber accommodated in the housing,
a construction room,
a carrying device arranged in the construction room, the carrying device having a height adjustable carrier configured for carrying an object to be manufactured,
an application device configured for applying layers of the construction material onto the carrying device or a layer previously formed,
a metering device configured for delivering the construction material, and
at least one irradiation device configured for irradiating layers of the construction material at the positions corresponding to the respective cross-section of the object, wherein in the housing a device for section-wise preheating of sections of the construction material layer is provided, wherein the device comprises at least one beam coupling device, with which a heating beam is configured for coupling with a main beam effecting a solidification process of the construction material such that both the heating beam and the main beam can together be guided over a plurality of construction material surface sections to be heated or to be solidified, wherein the focus of the main beam is arranged in that section in which the heating beam is delivered to the surface of the construction material, and wherein a beam splitting ratio of the main beam and the heating beam and a spot size ratio of the main beam and the heating beam on the construction material surface are varied during the selective layer-by-layer solidification of layers of the construction material.

14. The apparatus according to claim 13 , wherein the heating beam is coaxially guided to the main beam.

15. The apparatus according to claim 14 , wherein the heating beam is obtained from the main beam by beam extraction.

16. The apparatus according to claim 13 , wherein the heating beam is guided through a beam expansion optic after the heating beam diverges from the main beam.

17. The apparatus according to claim 16 , wherein the heating beam is reunited with the main beam in the beam coupling device.

18. The apparatus according to claim 13 , wherein both the main beam and the heating beam are guided over a scanner.

19. The apparatus according to claim 18 , wherein:
the main beam is generated with a first beam source,
the heating beam is generated with a second beam source different from the first beam source, and
the main beam and the heating beam are brought together in a beam coupling device prior to the main beam and the heating beam being delivered to the scanner.

20. The apparatus according to claim 13 , wherein the focus of the main beam, lying within an irradiation section of the heating beam, is directed to the construction material surface.

Assignees

• Cl Schutzrechtsverwaltungs Gmbh
• Concept Laser Gmbh

Inventors

• Döhler Tim
• Pontiller-Schymura Peter
• Popp Alexandra

Classifications

• B22F10/364

  for post-heating, e.g. remelting · CPC title

• B22F12/45

  Two or more · CPC title

• B22F12/44

  characterised by the configuration of the radiation means · CPC title

• B22F10/362

  for preheating · CPC title

• B22F10/28

  Powder bed fusion, e.g. selective laser melting [SLM] or electron beam melting [EBM] · CPC title