Fabrication of base plate, fabrication of enclosure, and fabrication of support posts in additive manufacturing

Patent metadata

Field	Value
Publication number	US-2017072467-A1
Application number	US-201615268176-A
Country	US
Kind code	A1
Filing date	Sep 16, 2016
Priority date	Sep 16, 2015
Publication date	Mar 16, 2017
Grant date	—

Abstract

An apparatus for forming an object includes a platform and a dispensing system overlying the platform to dispense successive layers of powder. The successive layers include support layers and object layers on the support layers. The apparatus further includes an energy source to fuse the powder. A controller is configured to cause the energy source to fuse a support region of each of the support layers to form a part support base. The controller is further configured to cause the energy source to fuse an enclosure region of each of the object layers to form an enclosure dividing each of the object layers into an inner region and outer region. The controller is also configured to cause the energy source to fuse an object portion of the inner region of each of the object layers. A parallel projection of the object defines a part area contained within the inner region.

First claim

What is claimed is:

1 . An additive manufacturing apparatus for forming an object, the additive manufacturing apparatus comprising:
a platform; a dispensing system overlying the platform to dispense a plurality of successive layers of powder over a top surface of the platform, the plurality of successive layers comprising a plurality of object layers; a energy source to fuse the powder dispensed on the top surface of the platform; and a controller coupled to the dispensing system and the energy source and configured to cause the energy source to
fuse an enclosure region of each of the plurality of object layers to form an enclosure dividing each of the plurality of object layers into an inner region and outer region, and
fuse an object portion of the inner region of each of the plurality of object layers to form the object,
wherein a parallel projection of the object on the top surface of the platform defines a part area contained within the inner region.

2 . The additive manufacturing apparatus of claim 1 , wherein the inner region comprises an area at least 120% to 150% of the part area.

3 . The additive manufacturing apparatus of claim 1 , wherein a lateral dimension of the inner region is about 110% to 125% of a lateral dimension of the part area.

4 . The additive manufacturing apparatus of claim 1 , wherein a perimeter of the inner region is a substantially constant distance from a perimeter of the part area.

5 . The additive manufacturing apparatus of claim 1 , wherein the plurality of successive layers comprise a plurality of support layers and the plurality of object layers are disposed on the plurality of support layers, and wherein the controller is configured to fuse a support region of each of the plurality of support layers to form a part support base in which a top surface of the part support base supports a bottommost layer of the plurality of object layers.

6 . The additive manufacturing apparatus of claim 5 , wherein the enclosure is formed along a perimeter of the part support base.

7 . The additive manufacturing apparatus of claim 5 , wherein the controller is configured to cause the dispensing system to dispense the plurality of object layers over only the part support base.

8 . The additive manufacturing apparatus of claim 1 , wherein the platform comprises a plurality of holes configured to collect powder deposited outside the enclosure region.

9 . A method for forming an object, the method comprising:
dispensing a plurality of successive layers of powder over a top surface a platform, the plurality of successive layers comprising a plurality of object layers; fusing an enclosure region of each of the plurality of object layers to form an enclosure dividing each of the plurality of object layers into an inner region and outer region; and fusing an object portion of the inner region of each of the plurality of object layers to form the object, wherein a projection of the object on the top surface of the platform defines a part area contained within the inner region.

10 . The method of claim 9 , wherein a perimeter of the inner region is a substantially constant distance from a perimeter of the part area.

11 . The method of claim 9 , wherein the plurality of layers comprise a plurality of support layers, and the plurality of object layers are disposed on the plurality of support layers, and the method comprises fusing a support region of each of the plurality of support layers to form a part support base in which a top surface of the part support base supports a bottommost layer of the plurality of object layers.

12 . The method of claim 11 , wherein the enclosure is formed along a perimeter of the part support base.

13 . The method of claim 11 , wherein the plurality of object layers are dispensed over only the part support base.

14 . The method of claim 9 , comprising collecting powder deposited outside the enclosure region.

15 . An additive manufacturing apparatus for forming an object, the additive manufacturing apparatus comprising:
a platform; a dispensing system overlying the platform to dispense a plurality of successive layers of powder over a top surface of the platform, the plurality of successive layers comprising a plurality of part support layers, and a plurality of object layers on the plurality of support layers; a energy source to fuse the powder dispensed on the top surface of the platform; and a controller coupled to the dispensing system and the energy source and configured to cause the energy source to
fuse a support region of each of the plurality of part support layers to form a part support base in which a top surface of the part support base supports a bottommost layer of the plurality of object layers, and
fuse an object region of each of the plurality of object layers to form the object.

16 . The additive manufacturing apparatus of claim 15 , wherein controller is configured to cause the dispensing system to dispense the plurality of object layers over only the part support base.

17 . The additive manufacturing apparatus of claim 15 , wherein the platform comprises a plurality of holes configured to collect powder deposited outside the part support base.

18 . A method of forming an object by additive manufacturing, the method comprising:
dispensing a plurality of successive layers of powder over a top surface of a platform, the plurality of successive layers comprising a plurality of part support layers, and a plurality of object layers on the plurality of support layers; fusing a support region of each of the plurality of part support layers to form a part support base in which a top surface of the part support base supports a bottommost layer of the plurality of object layers; and fusing an object region of each of the plurality of object layers to form the object.

19 . The method of claim 18 , comprising dispensing the plurality of object layers over only the part support base.

20 . The method of claim 18 , comprising collecting powder deposited outside the part support base.

21 . An additive manufacturing apparatus for forming an object, the additive manufacturing apparatus comprising:
a platform; a dispensing system overlying the platform to dispense a plurality of successive layers of powder over a top surface of the platform, the plurality of successive layers comprising a plurality of post layers, and a plurality of object layers over the plurality of post layers; a energy source to fuse the powder dispensed on the top surface of the platform; and a controller coupled to the dispensing system and the energy source and configured to cause the energy source to
fuse a post region of each of the plurality of post layers to form a plurality of posts, and
fuse an object region of each of the plurality of object layers to form the object, and wherein the plurality of posts support the object such that a gap separates the object from the platform.

22 . The additive manufacturing apparatus of claim 21 , wherein the controller is configured to cause the energy source to fuse the post region such that the plurality of posts each comprise a height between 1 and 100 mm.

23 . The additive manufacturing apparatus of claim 21 , wherein the controller is configured to cause the energy source to fuse the post region such that the plurality of posts have a diameter of between 1 and 10 mm.

24 . The additive manufacturing appara

Assignees

• Applied Materials Inc

Inventors

• Zehavi Raanan
• Ng Hou T
• Patibandla Nag B

Classifications

• B29C64/153 Primary

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

• B22F12/84

  Parallel processing within single device · CPC title

• B22F12/224

  for motion along a direction within the plane of a layer · CPC title

• B22F10/40

  Structures for supporting workpieces or articles during manufacture and removed afterwards · CPC title

• B22F10/00

  Additive manufacturing of workpieces or articles from metallic powder (apparatus or devices therefor B22F12/00) · CPC title