Melt pool monitoring in multi-laser systems

Patent metadata

Field	Value
Publication number	US-11225027-B2
Application number	US-201916667832-A
Country	US
Kind code	B2
Filing date	Oct 29, 2019
Priority date	Oct 29, 2019
Publication date	Jan 18, 2022
Grant date	Jan 18, 2022

Abstract

An additive manufacturing apparatus including a platform and a dispenser configured to deliver successive layers of feed material onto the platform. One or more light sources generate multiple light beams to selectively fuse feed material in a layer on the platform and multiple optical assemblies receive the multiple light beams, where each respective optical assembly transmits a respective light beam along a respective optical path through the optical assembly. Each light beam is directed to a scan spot on the layer of feed material on the platform to scan the light beam to sweep the scan spot along a controllable path across the layer of feed material on the platform. An optical multiplexer selectively transmits the return light emitted or reflected from the respective scan spot from a respective optical path of a selected respective optical assembly of the multiple optical assemblies to the measurement device.

First claim

What is claimed is:

1. An additive manufacturing apparatus comprising:
a platform;
a dispenser configured to deliver a plurality of successive layers of feed material onto the platform;
one or more light sources configured to generate a plurality of light beams to selectively fuse feed material in a layer on the platform;
a plurality of optical assemblies to receive the plurality of light beams, each respective optical assembly configured to transmit a respective light beam along a respective optical path through the optical assembly, to direct the respective light beam to a respective scan spot on the layer of feed material on the platform, to scan the light beam to sweep the respective scan spot along a respective controllable path across the layer of feed material on the platform, and to receive return light emitted or reflected from the respective scan spot;
a measurement device; and
an optical multiplexer configured to selectively transmit the return light from a respective optical path of a selected respective optical assembly of the plurality of optical assemblies to the measurement device.

2. The apparatus of claim 1 , wherein the optical multiplexer is configured to selectively transmit the return light from only the respective optical path of a plurality of optical paths via only the respective optical assembly of the plurality of optical assemblies.

3. The apparatus of claim 2 , wherein the optical multiplexer comprises a plurality of adjustable mirrors, wherein each adjustable mirror is configured to selectively align the return light from the respective optical path via the respective optical assembly of the plurality of optical assemblies with the measurement device.

4. The apparatus of claim 2 , wherein the optical multiplexer comprises:
a plurality of optical fibers, each optical fiber configured to transmit return light from the respective optical path via the respective optical assembly of the plurality of optical assemblies; and
an adjustable filter wheel, wherein each optical fiber of the plurality of optical fibers is aligned with the adjustable filter wheel and wherein the adjustable filter wheel is configured to selectively allow the return light from a particular optical fiber of the plurality of optical fibers to align with the measurement device.

5. The apparatus of claim 1 , wherein the measurement device comprises one or more of a high-speed, high resolution camera or an infrared camera.

6. The apparatus of claim 1 , comprising a controller is configured to operate the optical multiplexer to direct light from the plurality of optical assemblies to the measurement device in a particular sampling sequence.

7. The apparatus of claim 1 , further comprising, a data processing apparatus in data communication with the measurement device and configured to perform the operations comprising:
collecting, from the measurement device, return light along the plurality of optical paths via respective optical assemblies of the plurality of optical assemblies;
receiving, from the controller, position data from the optical multiplexer, the one or more light sources, and the plurality of optical assemblies;
determining, from the position data and the return light, one or more melt pool characteristics; and
providing, as output to the controller, the one or more melt pool characteristics.

8. The apparatus of claim 7 , wherein the controller is further configured to receive the one or more melt pool characteristics and, in response, adjusting one or more process parameters for one or more of the plurality of optical assemblies and light sources.

9. The apparatus of claim 1 , wherein a first wavelength range of the plurality of light beams is different that a second wavelength range of the return light.

10. The apparatus of claim 1 , further comprising an air knife.

11. The apparatus of claim 1 , further comprising a heat source configured to pre-heat the feed material.

Assignees

• Applied Materials Inc

Inventors

• Raghavan Kamala Chakravarthy
• Franklin Jeffrey L

Classifications

• B29C64/393 Primary

  for controlling or regulating additive manufacturing processes · CPC title

• B29C64/268

  using laser beams; using electron beams [EB] · CPC title

• B22F12/41

  characterised by the type, e.g. laser or electron beam · CPC title

• B29C64/153

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

• B22F12/33

  translatory in the deposition plane · CPC title