3D Printing

Patent metadata

Field	Value
Publication number	US-2017190112-A1
Application number	US-201614987516-A
Country	US
Kind code	A1
Filing date	Jan 4, 2016
Priority date	Jan 4, 2016
Publication date	Jul 6, 2017
Grant date	—

Abstract

A system and method for Selective Laser Fusing of a 3D part is disclosed. The system may comprise a platform, a gantry, a dispenser, a first press, a laser configured to emit a laser beam onto powdered material, a positive pressure chamber at least partially surrounding the laser, and a controller. The controller may be configured to: (a) receive data that includes a representation of the 3D part sliced into a plurality of layers; (b) rotate on a path about an axis either the platform or simultaneously each of the dispenser, the first press, the positive pressure chamber and the laser; (c) activate the dispenser to deposit the powdered material during (b); (d) activate the laser to emit during (b) the laser beam onto the powdered material to Fuse the powdered material into a layer of the plurality of layers; and (e) repeat (b)-(d) to make the 3D part.

First claim

What is claimed is:

1 . A system for Selective Laser Fusing of a 3D part, the system comprising:
a platform, the platform moveable in at least one degree of freedom; a gantry; a dispenser attached to the gantry and configured to deposit powdered material on top of the platform; a first press attached to the gantry and configured to spread the powdered material deposited by the dispenser; a laser attached to the gantry and configured to emit a laser beam onto the powdered material; a positive pressure chamber at least partially surrounding the laser, the positive pressure chamber having a cavity in which the laser is disposed, the positive pressure chamber configured to fill the cavity with shielding gas; and a controller configured to:
(a) receive data that includes a representation of the 3D part sliced into a plurality of layers;
(b) rotate on a path about an axis either the platform or simultaneously each of the dispenser, the first press, the positive pressure chamber and the laser;
(c) activate the dispenser to deposit the powdered material during (b);
(d) activate the laser to emit during (b) the laser beam onto the powdered material to Fuse the powdered material into a layer of the plurality of layers; and
(e) repeat (b)-(d) to make the 3D part.

2 . The system of claim 1 , further comprising a second press attached to the gantry and disposed between the first press and the laser, the second press configured to compact the powdered material.

3 . The system of claim 1 , further comprising an outer retaining wall and an inner retaining wall, each disposed above the platform, the outer retaining wall surrounding the inner retaining wall, the inner retaining wall defining a center area of the platform, wherein the center area is substantially free of powdered material.

4 . The system of claim 1 , wherein the platform is moveable in a direction along the axis.

5 . The system of claim 1 , wherein the laser is configured to position, without the use of reflection, the laser beam to Fuse each portion of the layer.

6 . The system of claim 1 , wherein the controller is configured to use polar coordinates to determine a position of the powdered material to be Fused.

7 . A method for Selective Laser Fusing of a 3D part, the method comprising:
(a) rotating, by a controller, simultaneously on a path around an axis a dispenser, a first press, a positive pressure chamber and a laser, the laser disposed inside a cavity defined by the positive pressure chamber, the laser following a rotation of the dispenser about the axis; (b) depositing by the dispenser a powdered material during (a); (c) spreading by the first press during (a) the powdered material; (d) emitting a laser beam onto the powdered material during (a) to Fuse a layer of the powdered material; and (e) repeating (a)-(d) to form the 3D part.

8 . The method of claim 7 , wherein the dispenser, the first press and the laser are each disposed over a plate and an outer retaining wall that encircles an inner retaining wall, the plate disposed on a platform and generally ring-shaped, the inner retaining wall and the outer retaining wall disposed on top of the plate, the inner retaining wall defining a center area of the platform, wherein after the depositing and before the emitting the center area is substantially free of the powdered material.

9 . The method of claim 7 , further including Fusing an outer retaining wall and an inner retaining wall during Fusing of a portion of the 3D part, the outer retaining wall encircling the inner retaining wall, the 3D part disposed between the outer retaining wall and the inner retaining wall.

10 . The method of claim 7 , further comprising receiving, by the controller, data that includes a representation of the 3D part sliced into a plurality of layers, each layer of (d) part of the plurality of layers.

11 . The method of claim 7 , in which the rotating further includes rotating a second press on the path around the axis to compact the powdered material, the second press disposed between the first press and the laser.

12 . The method of claim 7 , wherein the dispenser, the first press and the laser are suspended from a gantry.

13 . The method of claim 7 , wherein polar coordinates are used, by the controller, to determine a position of the target powdered material.

14 . The method of claim 7 , further comprising positioning the laser beam directly onto the powdered material without the use of reflection.

15 . A system for Selective Laser Fusing of a 3D part, the system comprising:
a platform moveable in at least one degree of freedom; a housing, the housing and the platform defining a chamber; a gantry disposed inside the chamber above the platform, the platform movable along an axis; a plate disposed on the platform inside the chamber; an outer retaining wall and an inner retaining wall, each disposed on the plate, the outer retaining wall encircling the inner retaining wall; a dispenser suspended from the gantry and rotatable about the axis, the dispenser configured to deposit powdered material; a first press integral with the dispenser, the first press configured to spread the powdered material deposited by the dispenser; a laser suspended from the gantry and rotatable about the axis, the laser configured to emit a laser beam directly onto the powdered material; a positive pressure chamber at least partially surrounding the laser, the positive pressure chamber having a cavity in which the laser is disposed, the positive pressure chamber configured to fill the cavity with shielding gas; and a controller configured to:
(a) receive data that includes a representation of the 3D part sliced into a plurality of layers;
(b) rotate simultaneously the dispenser, the first press, the positive pressure chamber and the laser on a path around the axis;
(c) activate the dispenser to deposit the powdered material during (b);
(d) activate the laser to emit during (b) the laser beam onto the powdered material to Fuse the powdered material into a layer of the plurality of layers;
(e) move the platform in a direction along the axis; and
(f) repeat (b)-(e) to form the 3D part.

16 . The system of claim 15 , further comprising a second press suspended from the gantry and rotatable on the path about the axis, the second press disposed between the first press and the laser and configured to compress the powdered material.

17 . The system of claim 15 , wherein the platform is substantially free of direct contact by the powdered material.

18 . The system of claim 15 , wherein polar coordinates are used to determine a position of the target powdered material.

19 . The system of claim 15 , wherein the dispenser, the first press and the laser are movable in a radial direction.

20 . The system of claim 15 , in which the laser may be a VCSEL semiconductor-based laser.

Assignees

• Caterpillar Inc

Inventors

• Thorson Timothy
• Marchione Thierry A

Classifications

• B29C64/153

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

• B33Y10/00 Primary

  Processes of additive manufacturing · CPC title

• B33Y50/00

  Data acquisition or data processing for additive manufacturing · CPC title

• B33Y30/00

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

• B29C64/241 Primary

  for rotary motion · CPC title