Additive manufacturing with energy delivery system having rotating polygon and second reflective member

Patent metadata

Field	Value
Publication number	US-2018257299-A1
Application number	US-201715811547-A
Country	US
Kind code	A1
Filing date	Nov 13, 2017
Priority date	Mar 9, 2017
Publication date	Sep 13, 2018
Grant date	—

Abstract

An additive manufacturing apparatus includes a platform, a dispenser to dispense a plurality of layers of feed material on a top surface of the platform, and an energy delivery assembly. The energy delivery assembly includes a light source to emit one or more light beams, a first reflective member having a plurality of reflective facets, and at least one second reflective member. The first reflective member is rotatable such that sequential facets sweep the light beam sequentially along a path on the uppermost layer. The at least one second reflective member is movable such that the at least one second reflective surface is repositionable to receive at least one of the at least one light beam and redirect the at least one of at least one light beam along a two-dimensional path on the uppermost layer.

First claim

1 . An additive manufacturing apparatus comprising:
a platform; a dispenser to dispense a plurality of layers of feed material on a top surface of the platform; an energy delivery assembly comprising
a light source to emit one or more light beams, and
a first reflective member having a plurality of reflective facets, the first reflective member positioned in a path of at least one of the one or more light beams to receive the at least one light beam and redirect the light beam toward the top surface of the platform to deliver energy to an uppermost layer of the layers of feed material to fuse the feed material, wherein the first reflective member is rotatable such that sequential facets sweep the light beam sequentially along a path on the uppermost layer; and
at least one second reflective member comprising at least one second reflective surface positioned in a path of at least one of the one or more light beams to receive the at least one light beam, the at least one second reflective member being movable such that the at least one second reflective surface is repositionable to receive the light beam and redirect the light beam along a two-dimensional path on the uppermost layer.

2 . The apparatus of claim 1 , wherein the one or more light sources comprise one or more lasers configured to emit the light beam toward the reflective member.

3 . The apparatus of claim 1 , wherein the light source comprises a first light source to generate a first light beam and a second light source to generate a second light beam, the first reflective member positioned in the path of the first light beam and the second reflective member positioned in the path of the second light beam.

4 . The apparatus of claim 1 , wherein the sequential facets sweep the light beam sequentially along a linear path on the uppermost layer.

5 . The apparatus of claim 4 , wherein the first reflective member comprises a polygon mirror defining a regular convex polygon.

6 . The apparatus of claim 1 , wherein the second reflective member comprises a mirror galvanometer.

7 . The apparatus of claim 6 , wherein the mirror galvanometer includes a first adjustable reflective surface to translate the light beam along a first direction and a second reflective surface to translate the light beam along a second direction perpendicular to the first direction.

8 . The apparatus of claim 1 , wherein the second reflective member comprises a first reflective surface movable to redirect the light beam along a first horizontal direction, and a second reflective surface movable to redirect the light beam along a second horizontal direction at a non-zero angle to the first horizontal direction.

9 . The apparatus of claim 1 , comprising a controller configured to store data in a non-transitory computer readable medium, the data defining a region of the uppermost layer to fuse, and the controller is configured to
cause the first reflective member to deliver energy toward an interior of the region, and cause the second reflective member to deliver energy along a perimeter of the region.

10 . The apparatus of claim 9 , wherein the energy delivery assembly comprises a first energy delivery system including the first reflective member and a first light source, and a second energy delivery system including the second reflective member and a second light source.

11 . An additive manufacturing apparatus comprising:
a platform; a dispenser to dispense a plurality of layers of feed material on a top surface of the platform; a first energy delivery system comprising
a first light source to emit a first light beam, and
a first reflective member having a plurality of reflective facets, the first reflective member positioned in a path of the first light beam to redirect the first light beam toward a first portion of top surface of the platform to deliver energy to a first region of an uppermost layer of the layers of feed material to fuse the feed material in the first region, wherein the first reflective member is rotatable such that sequential facets sweep the first light beam sequentially along a linear first path on the uppermost layer; and
a second energy delivery system comprising
a second light source to emit a second light beam, and
a second reflective member having a plurality of reflective facets, the second reflective member positioned in a path of the second light beam to redirect the second beam toward a second portion of top surface of the platform to deliver energy to a second region of the uppermost layer of the layers of feed material to fuse the feed material in the second region, wherein the second reflective member is rotatable such that sequential facets sweep the second light beam sequentially along a linear second first path on the uppermost layer.

12 . The apparatus of claim 11 , wherein the first energy system and the second energy system are mounted on a support that is movable relative to the platform along a first direction.

13 . The apparatus of claim 12 , wherein the first direction is at a non-zero angle relative to the linear first path and the linear second path.

14 . The apparatus of claim 13 , wherein the first linear path and second linear path are parallel.

15 . The apparatus of claim 14 , wherein the first direction is at a right angle to the linear first path and the linear second path.

16 . The apparatus of claim 11 , wherein a combination of the first path and the second path span a working area of the platform.

17 . An additive manufacturing apparatus comprising:
a platform; a dispenser to dispense a plurality of layers of feed material on a top surface of the platform; an energy delivery assembly comprising
a light source to emit a light beam,
a first reflective member having a plurality of reflective facets, the reflective member positioned in a path of the light beams to receive the light beam and redirect the light beam toward the top surface of the platform to deliver energy to an uppermost layer of the layers of feed material to fuse the feed material, wherein the reflective member is rotatable such that sequential facets sweep the light beam sequentially along a linear path along a first direction on the uppermost layer; and
a second reflective member comprising at least one second reflective surface positioned in the path of the light beam, the second reflective member being movable so as to reposition the linear path along a second direction at a non-zero angle to the first direction.

18 . The apparatus of claim 16 , wherein the second reflective member is positioned in the path of the light between the light source and the first reflective member.

19 . The apparatus of claim 16 , wherein the first reflective member comprises a polygon mirror defining a regular convex polygon.

20 . The apparatus of claim 16 , wherein the second reflective member comprises a mirror galvanometer.

Assignees

• Applied Materials Inc

Inventors

• Ng Hou T
• Patibandla Nag B
• Joshi Ajey M
• Zehavi Raanan
• Franklin Jeffrey L
• Maqsood Kashif

Classifications

• B22F12/49

  Scanners · CPC title

• B22F12/33

  translatory in the deposition plane · CPC title

• B22F12/45

  Two or more · CPC title

• B22F12/44

  characterised by the configuration of the radiation means · CPC title

• B22F12/224

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