Accurate three-dimensional printing

Patent metadata

Field	Value
Publication number	US-9919360-B2
Application number	US-201715435128-A
Country	US
Kind code	B2
Filing date	Feb 16, 2017
Priority date	Feb 18, 2016
Publication date	Mar 20, 2018
Grant date	Mar 20, 2018

Abstract

The present disclosure provides three-dimensional (3D) printing methods, apparatuses, and systems using, inter alia, a controller that regulates formation of at least one 3D object (e.g., in real time during the 3D printing); and a non-transitory computer-readable medium facilitating the same. For example, a controller that regulates a deformation of at least a portion of the 3D object. The control may be in situ control. The control may be real-time control during the 3D printing process. For example, the control may be during a physical-attribute pulse. The present disclosure provides various methods, apparatuses, systems and software for estimating the fundamental length scale of a melt pool, and for various tools that increase the accuracy of the 3D printing.

First claim

What is claimed is:

1. A system for three-dimensional printing of at least one three-dimensional object comprising:
an energy source that is configured to generate an energy beam directed to a target surface, which energy beam transforms a pre-transformed material into a transformed material as part of the at least one three-dimensional object, which energy beam optionally causes a fraction of the transformed material to separate from the target surface;
a detector that is configured to detect a temperature at a position of the target surface, wherein the detector is operatively coupled to the target surface; and
at least one controller that is operatively coupled to the energy source and to the detector, wherein the at least one controller is programmed to: (i) direct the energy beam to irradiate the pre-transformed material; (ii) use the detector to detect a temperature at the position; (iii) evaluate a deviation between the temperature and a target temperature profile; and (iv) based at least in part on the deviation, control at least one characteristic of the energy beam to alter an amount of the fraction that separates from the target surface.

2. The system of claim 1 , wherein the target temperature profile is a single value, a temperature range, or a temperature function.

3. The system of claim 1 , wherein the at least one controller is programmed to control the at least one characteristic of the energy beam to reduce or prevent separation of the fraction from the target surface.

4. The system of claim 1 , wherein the at least one controller is programmed to control the at least one characteristic of the energy beam to reduce an amount of the fraction that separates from the target surface.

5. The system of claim 1 , wherein the target surface is an exposed surface of a material bed.

6. The system of claim 5 , wherein the exposed surface is planarized by a layer dispensing mechanism comprising a cyclonic separator.

7. The system of claim 1 , wherein the pre-transformed material comprises at least one member of the group consisting of an elemental metal, metal alloy, ceramic, an allotrope of elemental carbon, and an organic material.

8. The system of claim 1 , wherein the pre-transformed material comprises a particulate material.

9. The system of claim 8 , wherein the particulate material comprises a powder material.

10. The system of claim 1 , wherein separate(s) from the target surface comprises becoming gas-borne, evaporate, or form plasma.

11. The system of claim 1 , wherein the position comprises a footprint of the energy beam on the target surface, or a position adjacent to the footprint, wherein the position adjacent to the footprint is in an area having a radius of at most about six fundamental length scales of the footprint that centers at the footprint.

12. The system of claim 1 , wherein the at least a portion comprises a melt pool.

13. The system of claim 1 , wherein the fraction that separates from the target surface forms debris.

14. The system of claim 13 , wherein the debris comprises soot.

15. The system of claim 1 , wherein the target surface is disposed in an enclosure, and wherein the fraction that separates from the target surface further reacts with one or more gases in the enclosure.

16. The system of claim 15 , wherein the one or more gases comprise oxygen or water.

17. The system of claim 15 , wherein the fraction that separates from the target surface chemically reacts with the one or more gases in the enclosure.

18. The system of claim 17 , wherein the fraction that separates from the target surface chemically reacts with the one or more gases in the enclosure by being oxidized by the one or more gases.

19. The system of claim 1 , wherein the fraction that separates from the target surface affects the transformation of the pre-transformed material into the transformed material.

20. The system of claim 1 , wherein the target temperature is less than (I) a temperature at which the fraction separates from the target surface, (II) an evaporation temperature of a type of the pre-transformed material, (III) a plasma forming temperature of the type of the pre-transformed material, or (IV) any combination thereof.

21. The system of claim 1 , wherein the at least one characteristic of the energy beam comprises dwell time, footprint, cross section, power per unit area, translation speed, focus, fluence, flux, or intensity.

22. The system of claim 1 , wherein the energy beam is configured to cause the fraction of the transformed material to separate from the target surface.

23. The system of claim 1 , wherein the at least one controller comprises one or more computer processors that are individually or collectively programmed to perform (i)-(iv).

24. A method for three-dimensional printing of at least one three-dimensional object implemented by at least one controller that is operatively coupled to (i) an energy source that is configured to generate an energy beam directed to a target surface, and (ii) a detector that is configured to detect a temperature at a position of the target surface, the method comprising:
(a) directing the energy source to generate the energy beam to irradiate a pre-transformed material to transform the pre-transformed material into a transformed material as part of the at least one three-dimensional object, which energy beam optionally causes a fraction of the transformed material to separate from the target surface;
(b) using the detector to detect a temperature at the position;
(c) evaluating a deviation between the temperature and a target temperature profile; and
(d) based at least in part on the deviation, controlling at least one characteristic of the energy beam to alter an amount of the fraction that separates from the target surface,
wherein the at least one controller is programmed to evaluate the deviation; and, based on at least in part on the deviation, control at least one characteristic of the energy beam to alter an amount of the fraction that separates from the target surface.

25. The method of claim 24 , further comprising controlling at least one characteristic of the energy beam to reduce or prevent the fraction from separating from the (i) at least a portion of the at least one three-dimensional object and/or (ii) from the transformed material.

26. The method of claim 24 , wherein (d) comprises reducing or preventing the amount of the fraction that separates from the at least the portion of the at least one three- dimensional object.

27. The method of claim 24 , wherein the pre-transformed material forms a material bed comprising an exposed surface.

28. The method of claim 24 , wherein separate(s) from the target surface comprises becoming gas-borne, evaporate or form plasma.

29. The method of claim 24 , wherein the position comprises an area occupied by a footprint of the energy beam on the target surface, or a position adjacent to the area occupied by the footprint, wherein position adjacent to the area occupied by the footprint is in an area having a radius of at most about six fundamental length scales of the footprint that centers at the footprint.

30. The method of claim 29 , wherein the target surface comprises (i) an exposed surface of a material bed or (ii) an exposed surface of the at least the portion of the at least one three-dimensional ob

Assignees

• Velo3D Inc

Inventors

• Buller Benyamin
• LAPPAS Tasso
• Lappen Alan Rick

Classifications

• B29C64/393 Primary

  for controlling or regulating additive manufacturing processes · CPC title

• B22F10/80

  Data acquisition or data processing · CPC title

• B22F10/12

  by photopolymerisation, e.g. stereolithography [SLA] or digital light processing [DLP] · CPC title

• B22F12/90

  Means for process control, e.g. cameras or sensors · CPC title

• B22F12/49

  Scanners · CPC title