Energy dosing for additive manufacturing

Patent metadata

Field	Value
Publication number	US-11207827-B2
Application number	US-201716074805-A
Country	US
Kind code	B2
Filing date	Mar 29, 2017
Priority date	Mar 29, 2017
Publication date	Dec 28, 2021
Grant date	Dec 28, 2021

Abstract

In one example, a processor readable medium having instructions thereon that when executed cause an additive manufacturing machine to vary operating characteristics of a fusing laser beam at multiple different voxel locations in a layer of build material according to an energy dosage to be applied at each voxel location in an object slice, including multiple different energy dosages for corresponding multiple different voxel locations in the slice.

First claim

The invention claimed is:

1. A processor readable medium having instructions thereon that when executed cause an additive manufacturing machine to:
irradiate fusible build material in a layer of fusible build material with a fusing laser beam and a heating laser beam overlapping the fusing laser beam, the heating laser beam having a larger spot size and a lower intensity than the fusing laser beam;
vary an intensity, spot size, and/or overlap of the laser beams at multiple different voxel locations in the layer of build material according to an energy dosage to be applied at each voxel location in an object slice, including multiple different energy dosages for corresponding multiple different voxel locations in the slice; and
adjust a position of the laser beams along a scan path that follows a perimeter edge of the object slice such that the position of each laser beam with respect to the scan path along the perimeter edge remains constant.

2. The processor readable medium of claim 1 , where each energy dosage is represented by an energy value associated with each voxel of the object slice.

3. The processor readable medium of claim 2 , having instructions thereon that when executed cause the additive manufacturing machine to associate the energy value with each of the voxels of the object slice.

4. An additive manufacturing machine controller implementing the processor readable medium of claim 3 .

5. An additive manufacturing process, comprising:
irradiating fusible build material in a layer of fusible build material with a fusing laser beam and a heating laser beam overlapping the fusing laser beam the heating laser beam having a larger spot size and a lower intensity than the fusing laser beam;
varying an intensity, spot size, and/or overlap of the laser beams at multiple different voxel locations in the layer of build material according to an energy value associated with each voxel of an object slice, including multiple different energy values for corresponding multiple different voxels;
adjusting a position of the laser beams along a scan path that follows a perimeter edge of an object slice such that the position of each laser beam with respect to the scan path along the perimeter edge remains constant; and
repeating the irradiating, varying, and adjusting for successive layers of build material.

6. The process of claim 5 , comprising associating the energy value with each of the voxels of the object slice.

7. The process of claim 6 , where each energy value represents an energy dosage to be applied at the voxel location associated with the energy value.

8. The process of claim 5 , comprising:
detecting a characteristic of the laser beams and/or a temperature of fused build material;
based on the detecting, changing the energy values associated with some or all of the voxels; and then
varying the intensity, spot size and/or overlap of the laser beams according to the changed energy values.

9. The process of claim 5 , where:
the irradiating includes scanning the laser beams over the build material; and
the varying includes varying the speed at which the laser beams are scanned over the build material.

10. The process of claim 5 , where the varying includes varying the intensity and the spot size of the fusing laser beam and/or the heating laser beam at multiple different voxel locations in the build material.

11. The process of claim 5 , where the irradiating includes scanning the laser beams across the build material with the heating laser beam leading the fusing laser beam across the build material in two directions.

12. An additive manufacturing machine, comprising:
a layering device to layer build material over a work area;
a laser to generate a first laser beam and a second laser beam overlapping the first laser beam, the second laser beam having a larger spot size and a lower intensity than the first laser beam;
a scanner to scan the first laser beam over the work area at a first scan speed and to scan the second laser beam over the work area at a second scan speed;
optical elements between the laser and the scanner to adjust an intensity, spot size, and position of the laser beams; and
a controller operatively connected to the laser, the scanner and the optical elements to vary an intensity, spot size, overlap, and/or scan speed of the laser beams at multiple different voxel locations in a layer of build material according to an energy dosage associated with each voxel location of an object slice and to adjust a position of the laser beams along a scan path that follows a perimeter edge of the object slice such that the position of each laser beam with respect to the scan path along the perimeter edge remains constant.

13. The machine of claim 12 , comprising an optical sensor to measure the intensity of one or both laser beams, the controller operatively connected to the optical sensor to change the energy dosages associated with some or all of the voxel locations based on optical sensor measurements and then vary the intensity, spot size, overlap and/or scan speed of the laser beams according to the changed energy dosages.

14. The machine of claim 13 , comprising a thermal sensor to measure the temperature of fused and/or unfused build material in the work area, the controller operatively connected to the thermal sensor to change the energy dosages associated with some or all of the voxel locations based on thermal sensor measurements and then vary the intensity, spot size, overlap and/or scan speed of the laser beams according to the changed energy dosages.

Assignees

• Hewlett Packard Development Co

Inventors

• Addington Cary G
• Champion David A
• Shaarawi Mohammed S
• Mckinnell James
• Hammerstad Diane R

Classifications

• B33Y50/02

  for controlling or regulating additive manufacturing processes · CPC title

• B29C64/393

  for controlling or regulating additive manufacturing processes · CPC title

• B33Y10/00

  Processes of additive manufacturing · CPC title

• B33Y30/00

  Apparatus for additive manufacturing; Details thereof or accessories therefor · CPC title

• B29C64/153 Primary

  using layers of powder being selectively joined, e.g. by selective laser sintering or melting · CPC title