Direct metal laser sintering machine

Patent metadata

Field	Value
Publication number	US-2016288207-A1
Application number	US-201514679190-A
Country	US
Kind code	A1
Filing date	Apr 6, 2015
Priority date	Apr 6, 2015
Publication date	Oct 6, 2016
Grant date	—

Abstract

An additive manufacturing apparatus includes a print bed. An arm rotates about a central axis concentric with the print bed. A print head is positioned on the arm. The print head is configured to move relative to the print bed along a cylindrical coordinate system including a z-coordinate, r-coordinate, and a φ-coordinate. A deposition nozzle is disposed on the print head. The deposition nozzle is configured to deposit powdered material onto the print bed. A laser head is disposed on the print head and includes a laser.

First claim

1 . An additive manufacturing apparatus comprising:
a print bed; an arm, wherein the arm rotates about a central axis concentric with the print bed; a print head positioned on the arm, wherein the print head is configured to move relative to the print bed along a cylindrical coordinate system including a z-coordinate, r-coordinate, and a φ-coordinate; a deposition nozzle disposed on the print head, wherein the deposition nozzle is configured to deposit powdered material onto the print bed; and a laser head disposed on the print head, wherein the laser head includes a laser.

2 . The additive manufacturing apparatus of claim 1 , wherein the additive manufacturing apparatus includes a direct metal laser sintering machine.

3 . The additive manufacturing apparatus of claim 1 , wherein the print bed includes a circular disk shape.

4 . The additive manufacturing apparatus of claim 1 , wherein the z-coordinate defines a vertical distance between the print bed and the print head, the r-coordinate defines a radial distance between the print head and the axis of rotation, and the φ-coordinate defines a degree of rotation between the arm and a defined rotational starting point.

5 . The additive manufacturing apparatus of claim 1 , wherein the material includes a powdered metal.

6 . The additive manufacturing apparatus of claim 1 , wherein the print bed includes a ring shape.

7 . The additive manufacturing apparatus of claim 4 , wherein the additive manufacturing apparatus is configured to control the vertical distance between the print bed and the print head.

8 . The additive manufacturing apparatus of claim 7 , wherein the vertical distance between the print bed and the print head is controlled by at least one of a first motor or a first actuator.

9 . The additive manufacturing apparatus of claim 4 , wherein the additive manufacturing apparatus is configured to control the radial distance between the print head and the axis of rotation.

10 . The additive manufacturing apparatus of claim 9 , wherein the radial distance between the print head and the axis of rotation is controlled by at least one of a second motor or a second actuator.

11 . The additive manufacturing apparatus of claim 4 , wherein the additive manufacturing apparatus is configured to control the degree of rotation between the arm and the defined rotational starting point.

12 . The additive manufacturing apparatus of claim 11 , wherein the degree of rotation between the arm and the defined rotational starting point is controlled by at least one of a first motor or a first actuator.

13 . An additive manufacturing method comprising:
(a) generating data defining a part to be built in an additive manufacturing apparatus; (b) positioning a print head at a starting point above a print bed, wherein the print head includes a deposition nozzle and a laser head, further wherein the print head is positioned on an arm; (c) depositing a first powdered material at a first location from a central axis of the print bed; (d) using a directed energy source to selectively melt or sinter the first powdered material, wherein the directed energy source is delivered by the laser head; (e) moving the print head relative to the print bed in a radial direction from the central axis of the print bed along a cylindrical coordinate system including a z-coordinate, r-coordinate, and a φ-coordinate, wherein the z-coordinate defines a vertical distance between the print bed and the print head, the r-coordinate defines a radial distance between the print head and the axis of rotation, and the φ-coordinate defines a degree of rotation between the arm and a defined rotational starting point; (f) depositing additional powdered material at locations other than the first location; (g) using the directed energy source to selectively melt or sinter the additional powdered material; (h) rotating the arm; (i) repeating steps (c)-(h) as necessary in accordance with the data; (j) adjusting the z-coordinate; (k) repeating steps (c)-(j) as necessary in accordance with the data; and (l) completing the part.

14 . The additive manufacturing method of claim 13 further including building the part with at least a portion of the part including a cylindrical or ring shape.

15 . The additive manufacturing apparatus of claim 13 further including controlling the vertical distance between the print bed and the print head.

16 . The additive manufacturing apparatus of claim 13 further including controlling the radial distance between the print head and the axis of rotation.

17 . The additive manufacturing apparatus of claim 13 further including controlling the degree of rotation between the arm and the defined rotational starting point.

18 . The additive manufacturing apparatus of claim 13 further including constructing an internal support structure formed onto the part.

19 . The additive manufacturing apparatus of claim 13 , wherein moving the print head includes following the data defining the part to guide the print head's motion and deposition of the first and additional powdered material.

20 . An additive manufacturing method comprising:
(a) generating data defining a part to be built in a direct metal laser sintering machine; (b) controlling a vertical distance between a print bed and a print head, a radial distance between the print head and an axis of rotation, and a degree of rotation between an arm and a defined rotational starting point, wherein the vertical distance, radial distance, and the degree of rotation are defined by a cylindrical coordinate system including a z-coordinate, r-coordinate, and a φ-coordinate, wherein the z-coordinate defines the vertical distance between the print bed and the print head, the r-coordinate defines the radial distance between the print head and the axis of rotation, and the (p-coordinate defines the degree of rotation between the arm and the defined rotational starting point; (c) positioning the print head at a starting point above the print bed, wherein the print head includes a deposition nozzle and a laser head, further wherein the print head is positioned on the arm; (d) depositing a first powdered material at a first location from a central axis of the print bed; (e) using a directed energy source to selectively melt or sinter the first powdered material, wherein the directed energy source is delivered by the laser head; (f) adjusting the r-coordinate; (g) depositing additional powdered material at locations other than the first location; (h) using the directed energy source to selectively melt or sinter the additional powdered material; (i) rotating the arm; (j) repeating steps (d)-(i) as necessary in accordance with the data; (k) adjusting the z-coordinate; (l) repeating steps (d)-(k) as necessary in accordance with the data; and (m) completing the part.

Assignees

• United Technologies Corp

Inventors

• Gambardella David Evan

Classifications

• B22F12/30

  Platforms or substrates · CPC title

• B22F10/28

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

• B22F12/53

  Nozzles · CPC title

• B22F12/22

  Driving means · CPC title

• B22F10/31 Primary

  Calibration of process steps or apparatus settings, e.g. before or during manufacturing · CPC title