Additive manufacturing systems and methods

Patent metadata

Field	Value
Publication number	US-2018161925-A1
Application number	US-201615378116-A
Country	US
Kind code	A1
Filing date	Dec 14, 2016
Priority date	Dec 14, 2016
Publication date	Jun 14, 2018
Grant date	—

Abstract

An additive manufacturing method includes patterning a laser beam using a mirror array; and reflecting the patterned laser beam from the mirror array onto a powder to melt the powder, wherein the pattern corresponds to a portion of a layer of an article.

First claim

1 . An additive manufacturing method, comprising:
patterning a laser beam using a mirror array; and reflecting the patterned laser beam from the mirror array onto a powder to melt the powder, wherein the pattern corresponds to a portion of a layer of an article.

2 . A method according to claim 1 , further comprising:
spreading a layer of powder over the layer of the article after solidification of the layer of the article.

3 . A method according to claim 12 , further comprising:
adjusting a position of build table that supports the article.

4 . A method according to claim 1 , further comprising:
providing a desired distribution profile to the laser beam.

5 . A method according to claim 4 , further comprising:
controlling an energy intensity of the patterned beam through changes of a reflection angle of each mirror.

6 . A method according to claim 1 , wherein the patterned laser beam comprises a plurality of laser spots, and groups of 9-25 mirrors are configured to provide each laser spot of the patterned laser beam.

7 . A method according to claim 6 , wherein a power capacity of each mirror is 1 to 3 watts and the groups of mirrors are configured to provide laser spots of 10 to 25 watts.

8 . A method according to claim 7 , wherein each laser spot is 0.1 mm.

9 . A method according to claim 1 , wherein the pattern corresponds to a 10% to 100% of the layer of the article.

10 . A method according to claim 1 , wherein the powder is a superalloy having a particle size of 10 to 60 μm.

11 . An additive manufacturing system, comprising:
a build table configured to support an article to be manufactured from powder; a laser source configured to generate a laser beam; and a mirror array configured to pattern the laser beam and reflect the patterned laser beam onto the powder to melt the powder, wherein the pattern corresponds to a portion of a layer of the article.

12 . A system according to claim 11 , further comprising:
a powder spreader configured to spread a layer of powder over the layer of the article after solidification of the layer of the article.

13 . A system according to claim 12 , wherein the build table is configured to move to adjust a position of the build table relative to the powder spreader.

14 . A system according to claim 11 , further comprising:
an optical system configured to provide a desired distribution profile to the laser beam.

15 . A system according to claim 14 , wherein the optical system is further configured to control an energy intensity of the patterned beam through changes of a reflection angle of each mirror.

16 . A system according to claim 11 , wherein the patterned laser beam comprises a plurality of laser spots, and groups of 9-25 mirrors are configured to provide each laser spot of the patterned laser beam.

17 . A system according to claim 16 , wherein a power capacity of each mirror is 1 to 3 watts and the groups of mirrors are configured to provide laser spots of 10 to 25 watts.

18 . A system according to claim 17 , wherein each laser spot is 0.1 mm.

19 . A system according to claim 11 , wherein the pattern corresponds to a 10% to 100% of the layer of the article.

20 . A system according to claim 11 , wherein the powder is a superalloy having a particle size of 10 to 60 μm.

Assignees

• Gen Electric

Inventors

• Harding Kevin George

Classifications

• B22F12/52

  Hoppers · CPC title

• B22F10/36

  of energy beam parameters · CPC title

• B22F12/49

  Scanners · CPC title

• B22F10/28

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

• B22F12/30

  Platforms or substrates · CPC title