Method for additively manufacturing at least one three-dimensional object

Patent metadata

Field	Value
Publication number	US-11267048-B2
Application number	US-201916273131-A
Country	US
Kind code	B2
Filing date	Feb 11, 2019
Priority date	Mar 14, 2018
Publication date	Mar 8, 2022
Grant date	Mar 8, 2022

Abstract

Method for additively manufacturing at least one three-dimensional object, whereby a process gas stream streams across the build plane (BP), whereby the process gas stream is adapted to transport respective fume particles from a layer of build material (3) which are generated during selective irradiation and consolidation of the respective layer of build material (3); wherein it is determined that the process gas stream fulfils a pre-definable or pre-defined scheduling criterion; wherein the start time for starting irradiating and consolidating of a first area (A1) and/or the start time for starting irradiating and consolidating the at least one further area (A2, An) is determined on the basis of the determination that the process gas stream has fulfilled the pre-definable or pre-defined scheduling criterion.

First claim

The invention claimed is:

1. A method for additively manufacturing at least one three-dimensional object, the method comprising:
selectively irradiating and consolidating at least one layer of build material, wherein the at least one layer of build material comprises a first area to be irradiated and consolidated, and at least one further area to be irradiated and consolidated; and,
streaming a process gas stream capable of being charged with fume particles generated during selectively irradiating and consolidating the at least one layer of build material;
wherein, a start time for selectively irradiating and consolidating for the first area and/or for selectively irradiating and consolidating for the at least one further area is determined at least in part on whether streaming of the process gas stream has fulfilled a pre-defined scheduling criterion, the pre-defined scheduling criterion comprising a time criterion or a local criterion.

2. The method of claim 1 , wherein the scheduling criterion comprises a time criterion.

3. The method of claim 2 , wherein the start time is determined at least in part on a charge time comprising a time required to charge the process gas stream with fume particles generated during selectively irradiating and consolidating the first area and/or the second area.

4. The method of claim 2 , wherein the time criterion is determined at least in part on a transport time comprising a time required for the process gas stream to transport the fume particles to a specific area in a process chamber.

5. The method of claim 2 , wherein the time criterion is determined at least in part on a transport time comprising a time required for the process gas stream to transport the fume particles from the first area across the at least one further area.

6. The method of claim 2 , wherein the time criterion is determined at least in part on a transport time comprising a time required for the process gas stream to transport the fume particles out of a process chamber.

7. The method of claim 1 , wherein the scheduling criterion comprises a local criterion.

8. The method of claim 7 , wherein the local criterion is fulfilled when the process gas stream has crossed a specific area in a process chamber.

9. The method of claim 8 , wherein the specific area comprises an area located downstream in the transport direction of the process gas stream relative to the at least one further area to be irradiated and consolidated.

10. The method of claim 1 , wherein the start time for selectively irradiating and consolidating for the at least one further area comprises a minimum time interval after starting irradiating and consolidating for the first area.

11. The method of claim 1 , further comprising determining whether a spatial relation of the first area and the at least one further area causes the process gas stream to transport fume particles from the first area across the at least one further area.

12. An apparatus for additively manufacturing at least one three-dimensional object, the apparatus comprising a control unit configured to implement a method for controlling the apparatus comprising:
selectively irradiating and consolidating at least one layer of build material with at least one energy beam generated by an irradiation unit of the apparatus, wherein the at least one layer of build material comprises a first area to be irradiated and consolidated, and at least one further area to be irradiated and consolidated; and,
streaming a process gas stream capable of being charged with fume particles generated during selectively irradiating and consolidating the at least one layer of build material from an inlet to an outlet of the apparatus;
wherein, a start time for selectively irradiating and consolidating for the first area and/or for selectively irradiating and consolidating for the at least one further area is determined via the control unit based at least in part on whether streaming of the process gas stream has fulfilled a pre-defined scheduling criterion, the pre-defined scheduling criterion comprising a time criterion or a local criterion.

13. The apparatus of claim 12 , wherein the scheduling criterion comprises a time criterion.

14. The apparatus of claim 13 , wherein the start time is determined at least in part on a charge time comprising a time required to charge the process gas stream with fume particles generated during selectively irradiating and consolidating the first area and/or the second area.

15. The apparatus of claim 13 wherein the time criterion is determined at least in part on a transport time comprising a time required for the process gas stream to transport the fume particles to a specific area in a process chamber.

16. The apparatus of claim 13 , wherein the time criterion is determined at least in part on a transport time comprising a time required for the process gas stream to transport the fume particles from the first area across the at least one further area.

17. The apparatus of claim 12 , wherein the scheduling criterion comprises a local criterion.

18. The apparatus of claim 17 , wherein the local criterion is fulfilled when the process gas stream has crossed a specific area in a process chamber.

19. The apparatus of claim 12 , wherein the start time for selectively irradiating and consolidating for the at least one further area comprises a minimum time interval after starting irradiating and consolidating for the first area.

20. The apparatus of claim 12 , wherein the method further comprises determining whether a spatial relation of the first area and the at least one further area causes the process gas stream to transport fume particles from the first area across the at least one further area.

Assignees

• Concept Laser Gmbh

Inventors

• Hertel Kai

Classifications

• B22F10/322

  of the gas flow, e.g. rate or direction · CPC title

• B22F12/70

  Gas flow means · CPC title

• B22F10/366

  Scanning parameters, e.g. hatch distance or scanning strategy · CPC title

• B22F10/28

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

• B29C64/393 Primary

  for controlling or regulating additive manufacturing processes · CPC title