The invention relates to a method for estimating a powder layer thickness in an additive manufacturing machine (1) when forming a three-dimensional article (2) layer by layer by successive fusion of selected areas of powder layers, which selected areas correspond to successive layers of the three-dimensional article. The method comprises the steps of applying a first powder layer and selectively melting the first powder layer with an energy beam (11) and thereafter measuring the temperature of the first powder layer at a plurality of time point. The method further comprises the step of providing a mathematical function giving a reference temperature as a function of time, which mathematical function is based on the measured temperatures of the first powder layer at the plurality of time points, applying a second powder layer on top of the first powder layer and measuring the temperature of the second powder layer at a predetermined time point, and estimating the powder layer thickness of the second powder layer based on the measured temperature of the second powder layer and the reference temperature calculated by means of the mathematical function for the predetermined time point.
B33Y 50/02 - Data acquisition or data processing for additive manufacturing for controlling or regulating additive manufacturing processes
B29C 64/153 - Processes of additive manufacturing using only solid materials using layers of powder being selectively joined, e.g. by selective laser sintering or melting
B29C 64/393 - Data acquisition or data processing for additive manufacturing for controlling or regulating additive manufacturing processes
G01B 21/08 - Measuring arrangements or details thereof, where the measuring technique is not covered by the other groups of this subclass, unspecified or not relevant for measuring length, width, or thickness for measuring thickness
2.
X-RAY REFERENCE OBJECT, X-RAY DETECTOR, ADDITIVE MANUFACTURING APPARATUS AND METHOD FOR CALIBRATING THE SAME
The present invention relates to an additive manufacturing apparatus comprising an X-ray reference object (18) for calibrating an electron beam unit in the additive manufacturing apparatus by detecting X-rays generated by sweeping an electron beam from the electron beam unit over a reference surface (19) of the X-ray reference object (18) and processing the detected signals, the X-ray reference object (18) comprising a support body (20) that has a top surface (21) and comprises a plurality of holes (22) in the top surface (21), The X-ray reference object (18) comprises a plurality of target members (23) inserted into the plurality of holes (22) of the support body (20). The present invention also relates to an X-ray detector to be used in the additive manufacturing apparatus, and to a method for calibrating such an additive manufacturing apparatus.
B33Y 30/00 - ADDITIVE MANUFACTURING, i.e. MANUFACTURING OF THREE-DIMENSIONAL [3D] OBJECTS BY ADDITIVE DEPOSITION, ADDITIVE AGGLOMERATION OR ADDITIVE LAYERING, e.g. BY 3D PRINTING, STEREOLITHOGRAPHY OR SELECTIVE LASER SINTERING - Details thereof or accessories therefor
B29C 64/153 - Processes of additive manufacturing using only solid materials using layers of powder being selectively joined, e.g. by selective laser sintering or melting
B29C 64/386 - Data acquisition or data processing for additive manufacturing
H01J 37/304 - Controlling tubes by information coming from the objects, e.g. correction signals
H01J 37/244 - Detectors; Associated components or circuits therefor
H01J 37/305 - Electron-beam or ion-beam tubes for localised treatment of objects for casting, melting, evaporating, or etching
B29C 64/268 - Arrangements for irradiation using electron beams [EB]
G01T 1/29 - Measurement performed on radiation beams, e.g. position or section of the beam; Measurement of spatial distribution of radiation
3.
METHOD AND APPARATUS FOR PROVIDING ILLUMINATION IN AN ADDITIVE MANUFACTURING PROCESS
An apparatus for forming at least one three-dimensional article through successive fusion of parts of a powder bed, which parts corresponds to successive cross sections of the three-dimensional article, the apparatus comprising: a powder distributor configured for evenly distributing a layer of powder on top of a work table provided inside a build chamber; and at least one high energy beam source emanating at least one high energy beam configured for fusing the powder layer in selected locations corresponding to the cross section of the three-dimensional article, wherein the apparatus further comprising at least one target area arranged spaced apart from the layer of powder for emanating light when irradiated by the at least one high energy beam.
B33Y 30/00 - ADDITIVE MANUFACTURING, i.e. MANUFACTURING OF THREE-DIMENSIONAL [3D] OBJECTS BY ADDITIVE DEPOSITION, ADDITIVE AGGLOMERATION OR ADDITIVE LAYERING, e.g. BY 3D PRINTING, STEREOLITHOGRAPHY OR SELECTIVE LASER SINTERING - Details thereof or accessories therefor
B33Y 40/00 - Auxiliary operations or equipment, e.g. for material handling
B29C 64/153 - Processes of additive manufacturing using only solid materials using layers of powder being selectively joined, e.g. by selective laser sintering or melting
4.
APPARATUS AND METHOD FOR FORMING A THREE-DIMENSIONAL ARTICLE
In a first aspect the invention relates to an apparatus for forming a three-dimensional article (2) through successively depositing individual layers of powder material that are fused together with an electron beam (16) from an electron beam source (7) so as to form the article (2) according to a computer model thereof, the apparatus (1) comprising a chamber (3) having a first section (4) and a second section (5) openly connected to each other, the individual layers of powder material that are fused together are provided in the first section (4), the second section (5) comprising the electron beam source (7) and an electromagnetic focus coil (9) having an axially extending center axis. The apparatus is characterized in that the second section (5) further comprises a reflector coil (19) arranged radially outside the electromagnetic focus coil (9), wherein the direction of windings of the reflector coil (19) is opposite the direction of windings of the electromagnetic focus coil (9). In a second aspect the invention relates to a coil arrangement for such an apparatus. In a third aspect the invention also relates to a method for controlling the apparatus.
B33Y 30/00 - ADDITIVE MANUFACTURING, i.e. MANUFACTURING OF THREE-DIMENSIONAL [3D] OBJECTS BY ADDITIVE DEPOSITION, ADDITIVE AGGLOMERATION OR ADDITIVE LAYERING, e.g. BY 3D PRINTING, STEREOLITHOGRAPHY OR SELECTIVE LASER SINTERING - Details thereof or accessories therefor
H01J 37/305 - Electron-beam or ion-beam tubes for localised treatment of objects for casting, melting, evaporating, or etching
B22F 3/105 - Sintering only by using electric current, laser radiation or plasma
B33Y 40/00 - Auxiliary operations or equipment, e.g. for material handling
The invention relates to a method for controlling an energy beam (3) in an additive manufacturing machine when forming a three-dimensional article layer by layer by successive fusion of selected areas of powder layers, which selected areas correspond to successive layers of the three-dimensional article. The method comprises the steps of radiating a powder layer (6) by the energy beam (3) and creating a set of images of the powder layer for a set of positions on the powder layer by detecting particles emitted, backscattered or reflected from the powder layer (6) when being radiated, comparing data representing the set of images and reference data with each other for identifying a difference between the energy beam (3) when used on the powder layer (6) and the reference data, with respect to at least one energy beam parameter, and adjusting the energy beam (3) based on such an identified difference between the energy beam (3) when used on the powder layer (6) and the reference data.
B33Y 50/02 - Data acquisition or data processing for additive manufacturing for controlling or regulating additive manufacturing processes
G01N 23/2251 - Investigating or analysing materials by the use of wave or particle radiation, e.g. X-rays or neutrons, not covered by groups , or by measuring secondary emission from the material using electron or ion microprobes using incident electron beams, e.g. scanning electron microscopy [SEM]
A device for viewing and/or illuminating a target surface in an evacuated chamber having condensable vapor therein, the device comprising: a first section with a through hole having a first end with a first opening and a second end with a second opening; and a second section having a chamber comprising a first portion with a first opening, a second portion with a second opening and a gas inlet, where the second opening is covered with a first window, said first section is attached with the first end to the first portion of the chamber allowing free passage between the chamber and the first section, said gas inlet is connectable to a gas reservoir for feeding a gas into the chamber for prohibiting the first window in the chamber for being contaminated of the condensable vapor.
G01N 21/15 - Preventing contamination of the components of the optical system or obstruction of the light path
G01N 21/3563 - Investigating relative effect of material at wavelengths characteristic of specific elements or molecules, e.g. atomic absorption spectrometry using infrared light for analysing solids; Preparation of samples therefor
G01N 21/359 - Investigating relative effect of material at wavelengths characteristic of specific elements or molecules, e.g. atomic absorption spectrometry using infrared light using near infrared light
G01N 21/88 - Investigating the presence of flaws, defects or contamination
G02B 27/00 - Optical systems or apparatus not provided for by any of the groups ,
B33Y 30/00 - ADDITIVE MANUFACTURING, i.e. MANUFACTURING OF THREE-DIMENSIONAL [3D] OBJECTS BY ADDITIVE DEPOSITION, ADDITIVE AGGLOMERATION OR ADDITIVE LAYERING, e.g. BY 3D PRINTING, STEREOLITHOGRAPHY OR SELECTIVE LASER SINTERING - Details thereof or accessories therefor
B23K 26/14 - Working by laser beam, e.g. welding, cutting or boring using a fluid stream, e.g. a jet of gas, in conjunction with the laser beam; Nozzles therefor
B29C 64/153 - Processes of additive manufacturing using only solid materials using layers of powder being selectively joined, e.g. by selective laser sintering or melting
B29C 64/268 - Arrangements for irradiation using electron beams [EB]
C23C 14/52 - Means for observation of the coating process
C23C 14/54 - Controlling or regulating the coating process
G01N 21/84 - Systems specially adapted for particular applications
The invention relates to a powder distributor device (11) for an additive manufacturing apparatus for forming a three-dimensional article layer by layer from a powder. The powder distributor device (11) comprises a worktable (16) and a unit (17) displaceably connected to the worktable for forming a powder layer on a build area. The powder distributor device (11) comprises a spring suspension arrangement (20) by which arrangement the powder layer forming unit (17) is connected to the worktable (16) for enabling thermal expansion induced movement of the powder layer forming unit relative to the worktable.
B22F 3/105 - Sintering only by using electric current, laser radiation or plasma
B33Y 30/00 - ADDITIVE MANUFACTURING, i.e. MANUFACTURING OF THREE-DIMENSIONAL [3D] OBJECTS BY ADDITIVE DEPOSITION, ADDITIVE AGGLOMERATION OR ADDITIVE LAYERING, e.g. BY 3D PRINTING, STEREOLITHOGRAPHY OR SELECTIVE LASER SINTERING - Details thereof or accessories therefor
Provided is an additive manufacturing apparatus for additive manufacturing of three dimensional objects by selectively solidifying a powder material layer by layer in a process chamber, wherein the apparatus comprises a powder distributor movable across a build area of a build tank for applying a layer of powder material thereon and a solidification device for selectively solidifying the applied powder layer at positions corresponding to a cross section of the object to be manufactured and a control unit adapted to repeat the steps of applying and selectively solidifying until the object is completed, wherein at least one support structure for supporting the powder distributor and/or a bellows assembly associated there-with is connectable to a cooling/heating media supply outside the process chamber and the support structure and/or the bellows assembly is adapted for transporting the cooling/heating media to and from the powder distributor. Certain embodiments further or alternatively include a bellows assembly connected or connectable to a cooling/heating media supply positioned outside the process chamber, the bellows assembly being configured for transporting the cooling/heating media to and from the powder distributor.
B33Y 30/00 - ADDITIVE MANUFACTURING, i.e. MANUFACTURING OF THREE-DIMENSIONAL [3D] OBJECTS BY ADDITIVE DEPOSITION, ADDITIVE AGGLOMERATION OR ADDITIVE LAYERING, e.g. BY 3D PRINTING, STEREOLITHOGRAPHY OR SELECTIVE LASER SINTERING - Details thereof or accessories therefor
B29C 64/153 - Processes of additive manufacturing using only solid materials using layers of powder being selectively joined, e.g. by selective laser sintering or melting
Described is an additive manufacturing apparatus for additive manufacturing of three dimensional objects, said apparatus comprises a powder distribution unit movable across a build area for applying a layer of powder material thereon and a solidification device for selectively solidifying the applied powder layer at positions corresponding to a cross section of the object to be manufactured. Said powder distribution unit comprises at least a first and a second powder distributors essentially in parallel with each other and extending in a first direction, said first and second powder distributors are arranged to be adjustably spaced apart in a second direction transversely to said first direction which second direction is essentially in parallel with the direction of movement of said powder distribution unit over said build area.
B22F 3/105 - Sintering only by using electric current, laser radiation or plasma
B33Y 30/00 - ADDITIVE MANUFACTURING, i.e. MANUFACTURING OF THREE-DIMENSIONAL [3D] OBJECTS BY ADDITIVE DEPOSITION, ADDITIVE AGGLOMERATION OR ADDITIVE LAYERING, e.g. BY 3D PRINTING, STEREOLITHOGRAPHY OR SELECTIVE LASER SINTERING - Details thereof or accessories therefor
10.
A BUILD TANK FOR AN ADDITIVE MANUFACTURING APPARATUS
Described is a build chamber (1) for an additive manufacturing apparatus (100) for forming a three-dimensional article layer by layer from a powder. The build chamber (1) comprising a build chamber base body (2) and said build chamber base body (2) is formed by at least two segments (4) telescopically coupled together.
B22F 3/105 - Sintering only by using electric current, laser radiation or plasma
B33Y 30/00 - ADDITIVE MANUFACTURING, i.e. MANUFACTURING OF THREE-DIMENSIONAL [3D] OBJECTS BY ADDITIVE DEPOSITION, ADDITIVE AGGLOMERATION OR ADDITIVE LAYERING, e.g. BY 3D PRINTING, STEREOLITHOGRAPHY OR SELECTIVE LASER SINTERING - Details thereof or accessories therefor
11.
A COMPACT BUILD TANK FOR AN ADDITIVE MANUFACTURING APPARATUS
The invention relates to a build chamber (1) for an additive manufacturing apparatus (100) for forming a three-dimensional article layer by layer from a powder. The build chamber (1) comprising a build chamber base body (2) and the build chamber base body (2) is formed by at least two segments (4) telescopically coupled together. Associated with the telescopically coupled segments are one or more bellows assemblies, further coupled to support structure configured to raise and/or lower the build table. An associated method is also provided.
B22F 3/105 - Sintering only by using electric current, laser radiation or plasma
B33Y 30/00 - ADDITIVE MANUFACTURING, i.e. MANUFACTURING OF THREE-DIMENSIONAL [3D] OBJECTS BY ADDITIVE DEPOSITION, ADDITIVE AGGLOMERATION OR ADDITIVE LAYERING, e.g. BY 3D PRINTING, STEREOLITHOGRAPHY OR SELECTIVE LASER SINTERING - Details thereof or accessories therefor
12.
A COMPACT BUILD TANK FOR AN ADDITIVE MANUFACTURING APPARATUS
Described is a build chamber that comprises a telescopic build tank operatively connected at opposing ends to a powder table and a build table, the telescopic build tank comprising at least two segments telescopically coupled relative to one another, each of the at least two segments comprising a set of engagement grooves located on an interior surface of the at least two segments and a set of engagement pins located on an exterior surface of the at least two segments. The set of engagement pins is configured to engage with and travel along a corresponding set of engagement grooves of another of the at least two segments, and each engagement groove comprises a first axially extending channel positioned along a single axis and having at least one closed end, the at least one closed end being configured to impede separation of the at least two segments relative to one another.
B22F 3/105 - Sintering only by using electric current, laser radiation or plasma
B33Y 30/00 - ADDITIVE MANUFACTURING, i.e. MANUFACTURING OF THREE-DIMENSIONAL [3D] OBJECTS BY ADDITIVE DEPOSITION, ADDITIVE AGGLOMERATION OR ADDITIVE LAYERING, e.g. BY 3D PRINTING, STEREOLITHOGRAPHY OR SELECTIVE LASER SINTERING - Details thereof or accessories therefor
An electron beam source comprising a cathode, an anode, a means for deflecting an electron beam over a target surface and at least one vacuum pump, the electron beam source further comprising a contraction area arranged between the anode and the means for deflecting the electron beam where a hole in the contraction area is aligned with a hole in the anode with respect to the cathode, a first vacuum pump is arranged between the contraction area and the anode and a second vacuum pump is arranged above the anode, a gas inlet is provided between the contraction area and the means for deflecting the electron beam, wherein a first crossover of the electron beam is arranged at or in close proximity to the contraction area.
B33Y 30/00 - ADDITIVE MANUFACTURING, i.e. MANUFACTURING OF THREE-DIMENSIONAL [3D] OBJECTS BY ADDITIVE DEPOSITION, ADDITIVE AGGLOMERATION OR ADDITIVE LAYERING, e.g. BY 3D PRINTING, STEREOLITHOGRAPHY OR SELECTIVE LASER SINTERING - Details thereof or accessories therefor
B33Y 50/02 - Data acquisition or data processing for additive manufacturing for controlling or regulating additive manufacturing processes
B29C 64/153 - Processes of additive manufacturing using only solid materials using layers of powder being selectively joined, e.g. by selective laser sintering or melting
B29C 64/393 - Data acquisition or data processing for additive manufacturing for controlling or regulating additive manufacturing processes
B29C 64/268 - Arrangements for irradiation using electron beams [EB]
H01J 37/304 - Controlling tubes by information coming from the objects, e.g. correction signals
B23K 15/06 - Electron-beam welding or cutting within a vacuum chamber
Provided is an electron beam source (200) for generating an electron beam comprising a cathode (240), an anode and a grid for regulating an electron beam current. The cathode has a base (242) and a protrusion (244) with sidewalls (247) and a top surface (248). The base surface and the top surface are essentially flat. The base surface and the top surface are arranged at a predetermined distance D from each other. The base is larger than the protrusion. The electron beam source further comprising a control unit adapted for changing an applied voltage to the grid for switching a spot size of the electron beam on a target surface between at least a first a first spot size corresponding to emission from the top surface of the cathode only and to a second spot size corresponding to emission from the top surface and the base surface of the cathode.
B33Y 30/00 - ADDITIVE MANUFACTURING, i.e. MANUFACTURING OF THREE-DIMENSIONAL [3D] OBJECTS BY ADDITIVE DEPOSITION, ADDITIVE AGGLOMERATION OR ADDITIVE LAYERING, e.g. BY 3D PRINTING, STEREOLITHOGRAPHY OR SELECTIVE LASER SINTERING - Details thereof or accessories therefor
B29C 64/153 - Processes of additive manufacturing using only solid materials using layers of powder being selectively joined, e.g. by selective laser sintering or melting
Provided is a seal (19) for sealing against powder between a cylinder (14) of a build tank (5) and a build table (9) arranged in the cylinder of an additive manufacturing apparatus (1) for forming a three-dimensional article layer by layer from a powder. The seal (19) has an endless ring portion (21) for extending along a circumference of an inner surface (20) of the cylinder (14) and abutting against the inner surface (20).
Provided is an additive manufacturing apparatus (1) for forming a three-dimensional article (2) layer by layer from a powder. The apparatus comprising an outer casing (3) forming a build chamber (4), and a build tank (5) arranged inside the casing in the build chamber. The apparatus (1) further comprises an arrangement (20) for controlling a temperature of the apparatus. The temperature control arrangement (20) comprises at least a first circuit (21) for a first working fluid. The first circuit being arranged at a wall portion (40; 50) of the apparatus for transferring heat between the build chamber (4) and the first working fluid.
B29C 64/153 - Processes of additive manufacturing using only solid materials using layers of powder being selectively joined, e.g. by selective laser sintering or melting
B29C 64/255 - Enclosures for the building material, e.g. powder containers
B33Y 30/00 - ADDITIVE MANUFACTURING, i.e. MANUFACTURING OF THREE-DIMENSIONAL [3D] OBJECTS BY ADDITIVE DEPOSITION, ADDITIVE AGGLOMERATION OR ADDITIVE LAYERING, e.g. BY 3D PRINTING, STEREOLITHOGRAPHY OR SELECTIVE LASER SINTERING - Details thereof or accessories therefor
B33Y 40/00 - Auxiliary operations or equipment, e.g. for material handling
B22F 3/105 - Sintering only by using electric current, laser radiation or plasma
17.
A METHOD FOR ANALYSING A BUILD LAYER IN ADDITIVE MANUFACTURING
Described is a method for analyzing a build layer (1; 11) in an additive manufacturing machine when forming a three-dimensional article layer by layer by successive fusion of selected areas of powder layers, which selected areas correspond to successive layers of the three- dimensional article. The method comprises the steps of radiating a portion (4; 14) of the build layer (1; 11) by an energy beam and detecting particles emitted, backscattered or reflected from the radiated portion of the build layer, and scanning the portion (4; 14) of the build layer by moving the energy beam along a main path (5; 15) and simultaneously moving the energy beamback-and- forth across the main path in a meandering pattern (6; 16).
B22F 3/105 - Sintering only by using electric current, laser radiation or plasma
B33Y 50/00 - Data acquisition or data processing for additive manufacturing
B29C 64/153 - Processes of additive manufacturing using only solid materials using layers of powder being selectively joined, e.g. by selective laser sintering or melting
B29C 64/386 - Data acquisition or data processing for additive manufacturing
The invention relates to a platform device (4) for forming a three-dimensional article (2) in an additive manufacturing machine layer by layer by successive fusion of selected areas of powder layers (3), which selected areas correspond to successive layers of the three-dimensional article. The platform device (4) has a support member (5) with a surface (6) for receiving powder. The support member (5) is rotatable about a first rotation axis (13) extending in a direction (15) substantially perpendicular to the surface (6). The support member (5) and the first rotation axis (13) are rotatable about a second rotation axis (14) arranged substantially in parallel with and offset to the first rotation axis (13).
B22F 3/105 - Sintering only by using electric current, laser radiation or plasma
B33Y 30/00 - ADDITIVE MANUFACTURING, i.e. MANUFACTURING OF THREE-DIMENSIONAL [3D] OBJECTS BY ADDITIVE DEPOSITION, ADDITIVE AGGLOMERATION OR ADDITIVE LAYERING, e.g. BY 3D PRINTING, STEREOLITHOGRAPHY OR SELECTIVE LASER SINTERING - Details thereof or accessories therefor
B29C 64/153 - Processes of additive manufacturing using only solid materials using layers of powder being selectively joined, e.g. by selective laser sintering or melting
19.
METHOD AND APPARATUS FOR DETECTING ELECTRON BEAM SOURCE FILAMENT WEAR
A method for detecting electron beam filament wear in an electron beam source, the method comprising the steps of: enlarging a beam spot emanating from the electron beam source on a work table to a predetermined minimum size, capturing an image of the beam spot on the work table by a camera, comparing the captured image of the beam spot with a reference image, and detecting filament wear if the captured image is deviating more than a predetermined value from the reference image.
B29C 64/153 - Processes of additive manufacturing using only solid materials using layers of powder being selectively joined, e.g. by selective laser sintering or melting
B29C 64/393 - Data acquisition or data processing for additive manufacturing for controlling or regulating additive manufacturing processes
B22F 3/105 - Sintering only by using electric current, laser radiation or plasma
A method for forming at least one three-dimensional article through successive fusion of parts of a powder bed on a support structure, the method comprising the steps of: providing at least one model of the three-dimensional article, lowering the support structure a predetermined distance and rotating the support structure a predetermined angle in a first direction before applying a first powder layer covering the lowered and rotated support structure, rotating the at least one model by the predetermined angle in the first direction before directing the at least one first energy beam from the at least one first energy beam source at selected locations for fusing the first powder layer, the at least one first energy beam source causing the first powder layer on the stationary support structure which is stationary to fuse in the selected locations according to the model to form first portions of the three- dimensional article.
B33Y 30/00 - ADDITIVE MANUFACTURING, i.e. MANUFACTURING OF THREE-DIMENSIONAL [3D] OBJECTS BY ADDITIVE DEPOSITION, ADDITIVE AGGLOMERATION OR ADDITIVE LAYERING, e.g. BY 3D PRINTING, STEREOLITHOGRAPHY OR SELECTIVE LASER SINTERING - Details thereof or accessories therefor
B29C 64/153 - Processes of additive manufacturing using only solid materials using layers of powder being selectively joined, e.g. by selective laser sintering or melting
B29C 64/20 - Additive manufacturing, i.e. manufacturing of three-dimensional [3D] objects by additive deposition, additive agglomeration or additive layering, e.g. by 3D printing, stereolithography or selective laser sintering - Details thereof or accessories therefor
A method for forming at least one three-dimensional article through successive fusion of parts of a powder bed on a support structure, the method comprising the steps of: providing at least one model of the three-dimensional article, lowering the support structure a predetermined distance and rotating the support structure a predetermined angle in a first direction before applying a first powder layer covering the lowered and rotated support structure, rotating the at least one model by the predetermined angle in the first direction before directing the at least one first energy beam from the at least one first energy beam source at selected locations for fusing the first powder layer, the at least one first energy beam source causing the first powder layer on the stationary support structure which is stationary to fuse in the selected locations according to the model to form first portions of the three- dimensional article.
B22F 3/105 - Sintering only by using electric current, laser radiation or plasma
B29C 64/153 - Processes of additive manufacturing using only solid materials using layers of powder being selectively joined, e.g. by selective laser sintering or melting
B29C 64/20 - Additive manufacturing, i.e. manufacturing of three-dimensional [3D] objects by additive deposition, additive agglomeration or additive layering, e.g. by 3D printing, stereolithography or selective laser sintering - Details thereof or accessories therefor
B33Y 30/00 - ADDITIVE MANUFACTURING, i.e. MANUFACTURING OF THREE-DIMENSIONAL [3D] OBJECTS BY ADDITIVE DEPOSITION, ADDITIVE AGGLOMERATION OR ADDITIVE LAYERING, e.g. BY 3D PRINTING, STEREOLITHOGRAPHY OR SELECTIVE LASER SINTERING - Details thereof or accessories therefor
22.
METHOD AND DEVICE FOR PRODUCING THREE-DIMENSIONAL OBJECTS
A method for producing three-dimensional objects layer by layer using a powdery material which can be solidified by irradiating it with at least two electron beams, said method comprises a pre-heating step, wherein the pre-heating step comprises the sub-step of scanning a pre-heating powder layer area (100) by scanning a first electron beam in a first region (I) and by scanning a second electron beam in a second region (II) distributed over the pre-heating powder layer area (100), wherein consecutively scanned paths are separated by, at least, a security distance (ΔY), said sub-step further comprising the step of synchronising the preheating of said first and second electron beams when simultaneously preheating said powder material within said first and second regions respectively, so that said first and second electron beams are always separated to each other with at least a minimum security distance (ΔX).
B33Y 30/00 - ADDITIVE MANUFACTURING, i.e. MANUFACTURING OF THREE-DIMENSIONAL [3D] OBJECTS BY ADDITIVE DEPOSITION, ADDITIVE AGGLOMERATION OR ADDITIVE LAYERING, e.g. BY 3D PRINTING, STEREOLITHOGRAPHY OR SELECTIVE LASER SINTERING - Details thereof or accessories therefor
B33Y 50/02 - Data acquisition or data processing for additive manufacturing for controlling or regulating additive manufacturing processes
B29C 64/153 - Processes of additive manufacturing using only solid materials using layers of powder being selectively joined, e.g. by selective laser sintering or melting
B29C 64/20 - Additive manufacturing, i.e. manufacturing of three-dimensional [3D] objects by additive deposition, additive agglomeration or additive layering, e.g. by 3D printing, stereolithography or selective laser sintering - Details thereof or accessories therefor
B29C 64/277 - Arrangements for irradiation using multiple radiation means, e.g. micromirrors or multiple light-emitting diodes [LED]
B29C 64/268 - Arrangements for irradiation using electron beams [EB]
23.
ELECTRON BEAM MELTING APPARATUS FOR FORMING THREE-DIMENSIONAL ARTICLES AND METHOD OF MANUFACTURING OF SAID ARTICLES
The present invention relates to an apparatus for forming a three-dimensional article through successively depositing individual layers of powder material that are fused together so as to form the article, the apparatus comprising an electron beam source emanating an electron beam for fusing the powder material in a build tank, a hollow construction having an upper opening and a lower opening, means for moving the hollow construction between a first position and a second position, a synchronising unit for synchronising the movement of a powder distributor for applying the individual layers of powder material on the work table with the movement of the hollow construction so that the hollow metal construction is at the first position when fusing and/or heating the powder layer and at the second position when the powder distributor is distributing the powder material for forming the individual powder layers.
B33Y 30/00 - ADDITIVE MANUFACTURING, i.e. MANUFACTURING OF THREE-DIMENSIONAL [3D] OBJECTS BY ADDITIVE DEPOSITION, ADDITIVE AGGLOMERATION OR ADDITIVE LAYERING, e.g. BY 3D PRINTING, STEREOLITHOGRAPHY OR SELECTIVE LASER SINTERING - Details thereof or accessories therefor
B29C 64/153 - Processes of additive manufacturing using only solid materials using layers of powder being selectively joined, e.g. by selective laser sintering or melting
B29C 64/20 - Additive manufacturing, i.e. manufacturing of three-dimensional [3D] objects by additive deposition, additive agglomeration or additive layering, e.g. by 3D printing, stereolithography or selective laser sintering - Details thereof or accessories therefor
24.
METHOD AND APPARATUS FOR FORMING A THREE-DIMENSIONAL ARTICLE
An apparatus for forming a three-dimensional article through successive fusion of parts of a powder bed, which parts corresponds to successive cross sections of the three-dimensional article, said apparatus comprising: a powder distributor configured for evenly distributing a layer of powder on top of a work table provided inside a vacuum chamber; and an electron beam source emanating an electron beam configured for fusing the powder layer in selected locations corresponding to said cross section of the three-dimensional article, wherein: said powder distributor being an elongated rod provided movable at a predetermined distance above the powder bed and with its central axis in parallel with a top surface of said work table, wherein at least one sensor is provided on said powder distributor facing towards said electron beam source, a detector for detecting a signal sent out from said sensor when said sensor is interacting with said electron beam.
A method is provided for forming a three-dimensional article through successively depositing individual layers of powder material that are fused together so as to form the article. The method includes: providing at least one electron beam source emitting an electron beam; providing a leakage current detector for sensing a current through the anode and/or the Wehnelt cup; providing a low impedance voltage source connectable to the Wehnelt cup via a switch, where the voltage source is having a more negative potential than a negative potential applied to the cathode; and protecting the cathode against vacuum arc discharge energy currents when forming the three-dimensional article by providing the Wehnelt cup to the low impedance negative voltage by closing the switch when the leakage current detector is sensing a current through the anode and/or the Wehnelt cup which is higher than a predetermined value.
B22F 3/105 - Sintering only by using electric current, laser radiation or plasma
B22F 7/06 - Manufacture of composite layers, workpieces, or articles, comprising metallic powder, by sintering the powder, with or without compacting of composite workpieces or articles from parts, e.g. to form tipped tools
B29C 64/153 - Processes of additive manufacturing using only solid materials using layers of powder being selectively joined, e.g. by selective laser sintering or melting
Provided is a method for forming a three-dimensional article through successively depositing individual layers of powder material that are fused together so as to form the article in a vacuum chamber, said method comprising the steps of: providing at least one electron beam source emitting an electron beam for at least one of heating or fusing said powder material in said vacuum chamber, applying a first set of beam parameters for formation of a fused bulk material of said three- dimensional article, where said bulk material has a predetermined microstructure, applying a second set of beam parameters for formation of a top portion of said three-dimensional article, wherein said second set of beam parameters is applied a predetermined number of layers prior to reaching a top surface of said three-dimensional article for encapsulating chimney porosities into said bulk material. Associated apparatus and computer program product are also provided.
A method for forming at least one three-dimensional article through successive fusion of parts of a powder bed, the method comprising the steps of: providing a model of the at least one three dimensional article; applying a first powder layer on at least one build platform; directing an electron beam from an inclined electron beam source over the at least one build platform where a central electron beam emanating from the source is building an angle α with respect to a normal to the build platform ≠0º, the directing of the first energy beam causing the first powder layer to fuse in a first selected locations according to the model; rotating or tilting the electron beam source a predetermined angle, directing the electron beam from the tilted or rotated electron beam source causing a first powder layer to fuse in a second selected locations according to the model.
B22F 3/105 - Sintering only by using electric current, laser radiation or plasma
B33Y 30/00 - ADDITIVE MANUFACTURING, i.e. MANUFACTURING OF THREE-DIMENSIONAL [3D] OBJECTS BY ADDITIVE DEPOSITION, ADDITIVE AGGLOMERATION OR ADDITIVE LAYERING, e.g. BY 3D PRINTING, STEREOLITHOGRAPHY OR SELECTIVE LASER SINTERING - Details thereof or accessories therefor
B33Y 50/02 - Data acquisition or data processing for additive manufacturing for controlling or regulating additive manufacturing processes
28.
ADDITIVE MANUFACTURING OF THREE-DIMENSIONAL ARTICLES
A method is provided for forming a three-dimensional article through successively depositing individual layers of powder material that are fused together so as to form the article, the method comprising the steps of: providing at least one electron beam source emitting an electron beam for at least one of heating or fusing the powder material, where the electron beam source comprises a cathode, an anode, and a Wehnelt cup between the cathode and anode; providing a guard ring between the Wehnelt cup and the anode and in close proximity to the Wehnelt cup, where the guard ring is having an aperture which is larger than an aperture of the Wehnelt cup; protecting the cathode and/or the Wehnelt cup against vacuum arc discharge energy currents when forming the three-dimensional article by providing the guard ring with a higher negative potential than the Wehnelt cup and cathode.
H01J 37/305 - Electron-beam or ion-beam tubes for localised treatment of objects for casting, melting, evaporating, or etching
B29C 64/153 - Processes of additive manufacturing using only solid materials using layers of powder being selectively joined, e.g. by selective laser sintering or melting
A method is provided for forming a three-dimensional article through successive fusion of parts of a metal powder bed, which parts corresponds to successive cross sections of the three-dimensional article, the method comprising the steps of: directing the at least one electron beam from the at least one electron beam source over a work table causing a powder layer to fuse in selected locations to form a first cross section of the three-dimensional article, preheating, with the at least one electron beam, an area of non-fused powder to a temperature within a predetermined temperature range a predetermined distance in Z-direction before the area is to be fused, where the area times the distance in z-direction is defining a preheating volume of non-fused powder when the three dimensional article is finished.
A method for forming a three-dimensional article through successive fusion of parts of a metal powder bed is provided, comprising the steps of: distributing a first metal powder layer on a work table inside a build chamber, directing at least one high energy beam from at least one high energy beam source over the work table causing the first metal powder layer to fuse in selected locations, distributing a second metal powder layer on the work table, directing at least one high energy beam over the work table causing the second metal powder layer to fuse in selected locations, introducing a first supplementary gas into the build chamber, which first supplementary gas comprising hydrogen, is capable of reacting chemically with or being absorbed by a finished three-dimensional article, and releasing a predefined concentration of the gas which had reacted chemically with or being absorbed by the finished three dimensional article.
B33Y 30/00 - ADDITIVE MANUFACTURING, i.e. MANUFACTURING OF THREE-DIMENSIONAL [3D] OBJECTS BY ADDITIVE DEPOSITION, ADDITIVE AGGLOMERATION OR ADDITIVE LAYERING, e.g. BY 3D PRINTING, STEREOLITHOGRAPHY OR SELECTIVE LASER SINTERING - Details thereof or accessories therefor
B33Y 40/00 - Auxiliary operations or equipment, e.g. for material handling
B33Y 70/00 - Materials specially adapted for additive manufacturing
31.
METHOD FOR ADDITIVE MANUFACTURING USING HYDROGENATED TITANIUM POWDER IN EBM
A method comprising the steps of: distributing a titanium alloy or pure titanium powder layer on a work table inside a vacuum chamber, directing at least one electron beam from at least one electron beam source over the work table causing the powder layer to fuse in selected locations, distributing a second powder layer on the work table of a titanium alloy or pure titanium inside the build chamber, directing the at least one electron beam over the work table causing the second powder layer to fuse in selected locations, and releasing a predefined concentration of the gas from the metal powder into the vacuum chamber when at least one of heating or fusing the metal powder layer, wherein at least one gas comprising hydrogen is absorbed into or chemically bonded to the titanium or titanium alloy powder to a concentration of 0.01-0.5 % by weight of the hydrogen.
B33Y 30/00 - ADDITIVE MANUFACTURING, i.e. MANUFACTURING OF THREE-DIMENSIONAL [3D] OBJECTS BY ADDITIVE DEPOSITION, ADDITIVE AGGLOMERATION OR ADDITIVE LAYERING, e.g. BY 3D PRINTING, STEREOLITHOGRAPHY OR SELECTIVE LASER SINTERING - Details thereof or accessories therefor
B33Y 40/00 - Auxiliary operations or equipment, e.g. for material handling
B33Y 70/00 - Materials specially adapted for additive manufacturing
32.
ADDITIVE MANUFACTURING OF THREE-DIMENSIONAL ARTICLES
The present invention relates to a method of forming a three- dimensional article through successively depositing individual layers of powder material that are fused together so as to form the article, comprising a method of operating a triode electron beam source including a cathode (102), a grid (104) and an anode (106) with the following steps: (a) setting an electron beam current, a cathode heating power, a grid potential Ug and a cathode potential Uc to predetermined start values; (b) reducing the cathode heating power and decreasing a Ug - Uc potential difference for mainintainig a predetermined electron beam current; (c) detecting an X-ray signal emanating from the electron beam source with at least one X-ray detector (190); (d) repeating said reducing and detecting steps until the detected X- ray signal is above a predetermined value; and (e) increasing the cathode heating power by a predetermined safety value above the heating power value which resulted in X-ray signals above said predetermined value. Thereby, the lowest acceptable cathode heating power without affacting the electron beam current is determined and thus the lifetime of the cathode element is prolonged.
The present invention relates to a methods, computer program products, program elements, and apparatuses for forming a three-dimensional article through successively depositing individual layers of powder material that are fused together so as to form the article. The method comprising the steps of providing at least one electron beam source emitting an electron beam for at least one of heating or fusing the powder material, where the electron beam source comprises a cathode and an anode, and varying an accelerator voltage between the cathode and the anode between at least a first and second predetermined value during the forming of the three-dimensional article.
Apparatus (100) for producing a three-dimensional object layer by layer using a powdery material which can be solidified by irradiating it with an energy beam, said apparatus (100) comprising: a working area (190) onto which layers of powdery material are to be placed; a powder storage unit (110), where a base surface (130) is supporting a supply of powder in said powder storage unit (110); a powder distribution member (185), a pivoted powder pushing device (125) for bringing a portion of powder from said base surface (130) to a position between said distribution member (185) and said working area (190), said distribution member (185) further being arranged to be moveable towards and across the working area (190) so as to distribute the portion of powder onto the working area (190), wherein a first portion (170) of said pivoted powder pushing device (125) is movable under said distribution member (185). An associated method and computer program product are also provided.
B29C 67/00 - Shaping techniques not covered by groups , or
B22F 3/00 - Manufacture of workpieces or articles from metallic powder characterised by the manner of compacting or sintering; Apparatus specially adapted therefor
B22F 3/105 - Sintering only by using electric current, laser radiation or plasma
B33Y 30/00 - ADDITIVE MANUFACTURING, i.e. MANUFACTURING OF THREE-DIMENSIONAL [3D] OBJECTS BY ADDITIVE DEPOSITION, ADDITIVE AGGLOMERATION OR ADDITIVE LAYERING, e.g. BY 3D PRINTING, STEREOLITHOGRAPHY OR SELECTIVE LASER SINTERING - Details thereof or accessories therefor
35.
METHOD AND APPARATUS FOR PRODUCING A THREE-DIMENSIONAL ARTICLE
A pivoted powder pushing device (125) is provided, comprising a first portion (170) and a contact member (154), wherein: the contact member (154) is configured to operatively engage a grip arm (150) of a distribution member (185) when the distribution member (185) is positioned at least in part above a base surface (130), and the first portion (170) is moved via the engagement of the grip arm (150) and the contact member (154) in a first direction opposite a direction of travel of the distribution member (185), such that the first portion (170) of said pivoted powder pushing device (125) passes under said distribution member (185). An associated apparatus (100), method, and computer program product are also provided.
B29C 67/00 - Shaping techniques not covered by groups , or
B22F 3/00 - Manufacture of workpieces or articles from metallic powder characterised by the manner of compacting or sintering; Apparatus specially adapted therefor
B22F 3/105 - Sintering only by using electric current, laser radiation or plasma
B33Y 30/00 - ADDITIVE MANUFACTURING, i.e. MANUFACTURING OF THREE-DIMENSIONAL [3D] OBJECTS BY ADDITIVE DEPOSITION, ADDITIVE AGGLOMERATION OR ADDITIVE LAYERING, e.g. BY 3D PRINTING, STEREOLITHOGRAPHY OR SELECTIVE LASER SINTERING - Details thereof or accessories therefor
An X-ray standard reference object for calibrating a scanning electron beam in an additive manufacturing apparatus by measuring X-ray signals generated by scanning the electron beam onto the reference object, the reference object comprises: a lower and an upper plate being essentially in parallel and attached spaced apart from each other, the upper plate comprises a plurality of holes, wherein a predetermined hollow pattern is provided inside the holes.
A method for non-destructive evaluation of a manufacturing process when forming a three-dimensional article through successive fusion of parts of a metal powder bed, which parts corresponds to successive cross sections of the three-dimensional article, the method comprising the steps of collecting an X-ray signal, created by the electron beam, from at least one position of the first and/or second metal powder layer and/or a melt pool of the first and/or second metal powder layer and/or a fused first and/or second powder layer by an X-ray detector, comparing the X-ray signal with a reference signal, alarming if the generated X-ray signal compared to the reference signal is indicating contamination material of larger amount than a predetermined value and/or a deviation in Atomic% of the powder material larger than a predetermined value.
G01N 23/22 - Investigating or analysing materials by the use of wave or particle radiation, e.g. X-rays or neutrons, not covered by groups , or by measuring secondary emission from the material
G01N 23/225 - Investigating or analysing materials by the use of wave or particle radiation, e.g. X-rays or neutrons, not covered by groups , or by measuring secondary emission from the material using electron or ion microprobes
B33Y 30/00 - ADDITIVE MANUFACTURING, i.e. MANUFACTURING OF THREE-DIMENSIONAL [3D] OBJECTS BY ADDITIVE DEPOSITION, ADDITIVE AGGLOMERATION OR ADDITIVE LAYERING, e.g. BY 3D PRINTING, STEREOLITHOGRAPHY OR SELECTIVE LASER SINTERING - Details thereof or accessories therefor
A method of using of a focus lens (630) in additive manufacturing for forming a three-dimensional article through successive fusion, with a high energy beam (605), of parts of at least one layer of a powder bed (660) provided on a work table, which parts correspond to successive cross sections of the three dimensional article, said method comprising the step of using said focus lens (630) for varying a spot size of said high energy beam (605) on said powder bed as a function of an already fused thickness of said three-dimensional article below said powder which is to be fused.
B33Y 30/00 - ADDITIVE MANUFACTURING, i.e. MANUFACTURING OF THREE-DIMENSIONAL [3D] OBJECTS BY ADDITIVE DEPOSITION, ADDITIVE AGGLOMERATION OR ADDITIVE LAYERING, e.g. BY 3D PRINTING, STEREOLITHOGRAPHY OR SELECTIVE LASER SINTERING - Details thereof or accessories therefor
B33Y 50/02 - Data acquisition or data processing for additive manufacturing for controlling or regulating additive manufacturing processes
A method is provided for forming at least one three-dimensional article through successive fusion of parts of a powder bed. The method involves: providing a model of the at least one three dimensional article, dividing at least two cross sections in said model into a first inner area portion, a second inner area portion and a contour portion, applying a first material layer on a work table, directing at least one energy beam over the work table causing the first material layer to join in selected locations according to the model for forming a partial first cross section of the three dimensional article, applying a second material layer on said work table; and directing at least one energy beam over the work table causing the second material layer to join in selected locations and form a partial second cross section of said three dimensional article.
B22F 3/105 - Sintering only by using electric current, laser radiation or plasma
G03F 7/00 - Photomechanical, e.g. photolithographic, production of textured or patterned surfaces, e.g. printed surfaces; Materials therefor, e.g. comprising photoresists; Apparatus specially adapted therefor
40.
METHOD AND DEVICE FOR CHARACTERIZING AN ELECTRON BEAM
A device for detecting X-rays radiated out of a substrate surface, said device comprising at least one X-ray detector, a resolver grating and a modulator grating, said resolver grating with at least one opening facing towards said X-ray detector is arranged in front of said X-ray detector. Said modulator grating is provided between said resolver grating and said substrate at a predetermined distance from said resolver grating and said substrate, where said modulator grating having a plurality of openings in at least a first direction, wherein said x-rays from said surface is spatially modulated with said modulator grating and resolver grating.
A device for detecting X-rays radiated out of a substrate surface, said device comprising at least one X-ray detector, a resolver grating and a modulator grating, said resolver grating with at least one opening facing towards said X-ray detector is arranged in front of said X-ray detector. Said modulator grating is provided between said resolver grating and said substrate at a predetermined distance from said resolver grating and said substrate, where said modulator grating having a plurality of openings in at least a first direction, wherein said x-rays from said surface is spatially modulated with said modulator grating and resolver grating.
A method for forming at least one three-dimensional article through successive fusion of parts of a powder bed, which parts correspond to successive portions of the three- dimensional article, said method comprising the steps of: providing at least one model of said three-dimensional article, wherein said model of said three-dimensional article is described in a 2-dimensional angular coordinate system; applying a powder layer on a support structure; directing at least one energy beam from at least one energy beam source over said powder layer causing said powder layer to fuse in first selected locations according to said model to form a first portion of said three-dimensional article, providing a first portion of said powder layer simultaneous as fusing a second portion of said powder layer, wherein said second portion of the powder layer is fused along a line perpendicular to a rotational axis of said support structure.
A method for forming at least one three-dimensional article through successive fusion of parts of a powder bed (4), comprising the steps of: providing at least one model of said three-dimensional article, moving a support structure (5) in z-direction at a predetermined speed while rotating said support structure at a predetermined speed, directing a first and second energy beam (2,22) causing said powder layer to fuse in first and second selected locations according to said model, wherein a first cover area (30) of said first energy beam on said powder layer is arranged at a predetermined minimum distance and non-overlapping from a second cover area (40) of said second energy beam on said powder layer, a trajectory of said first cover area and a trajectory of said second cover area are at least one of overlapping each other, abutting each other or separated to each other when said support structure is rotated a full lap.
B22F 3/105 - Sintering only by using electric current, laser radiation or plasma
B29C 67/00 - Shaping techniques not covered by groups , or
B33Y 30/00 - ADDITIVE MANUFACTURING, i.e. MANUFACTURING OF THREE-DIMENSIONAL [3D] OBJECTS BY ADDITIVE DEPOSITION, ADDITIVE AGGLOMERATION OR ADDITIVE LAYERING, e.g. BY 3D PRINTING, STEREOLITHOGRAPHY OR SELECTIVE LASER SINTERING - Details thereof or accessories therefor
44.
METHOD FOR IMPROVED POWDER LAYER QUALITY IN ADDITIVE MANUFACTURING
Various embodiments of the present invention relate to a method for forming at a three- dimensional article through successively depositing individual layers of powder material that are fused together with at least one energy beam so as to form the article, said method comprising the steps of generating a model of said three-dimensional article; applying a first powder layer on a work table; directing said at least one energy beam from at least one energy beam source over said work table causing said first powder layer to fuse in first selected locations according to said model to form a first cross section of said three-dimensional article; introducing a predetermined pattern laterally separated from said first cross section for reducing thickness variations in a powder layer provided on top of said first cross section.
A method for forming at a three-dimensional article through successively depositing individual layers of powder material that are fused together with at least one energy beam so as to form the article, the method comprising the steps of: generating a model of the three-dimensional article; applying a first powder layer on a work table; directing the at least one energy beam from at least one energy beam source over the work table causing the first powder layer to fuse in first selected locations according to the model to form a first cross section of the three-dimensional article; introducing a predetermined surface topography on the first cross section for reducing thickness variations and or increasing the powder packing density in a powder layer provided on top of the first cross section.
A method for verifying a size of an energy beam spot, said method comprising the steps of providing a first beam spot having a predetermined size and power at a first position on a work piece, varying a focus and/or astigmatism lens setting for said first beam spot until max intensity for the beam spot is detected, comparing the detected settings of said focus lens and/or astigmatism lens for said maximum intensity of the beam spot with stored settings of said focus lens and/or astigmatism lens for the beam spot with said predetermined size and power, repeating step a-c for different predetermined beam powers, repeating step a-d for different positions on said work piece, wherein said beam spot size is verified if each detected settings of said focus lens and/or astigmatism lens are deviating less than a predetermined value from corresponding stored settings of said focus lens and/or astigmatism lens.
G02B 7/10 - Mountings, adjusting means, or light-tight connections, for optical elements for lenses with mechanism for focusing or varying magnification by relative axial movement of several lenses, e.g. of varifocal objective lens
A method for verifying a position of an energy beam spot, said method comprising the steps of: providing a calibrated energy beam having a first focus in a at least two positions at a work table, detecting said at least two positions of said energy beam spot on said work table created with said energy beam having said first focus, providing said calibrated energy beam having a second focus in said at least two positions at a work table, detecting said at least two positions of said energy beam spot on said work table created with said energy beam having said second focus, comparing said at least two positions created with said first and second focus, wherein said position of the energy beam is verified if said positions created with said first focus are deviating less than a predetermined distance from said positions created with said second focus.
A method for verifying a deflection speed of an energy beam spot, the method comprising the steps of: providing a predetermined pattern on a work table with the energy beam spot while deflecting the energy beam spot with a first deflection speed, detecting first positions of the energy beam spot on the work table created with the first deflection speed, providing the predetermined pattern on a work table with the energy beam spot while deflecting the energy beam spot with a second deflection speed, detecting second positions of the energy beam spot on the work table created with the second deflection speed, comparing the first and second positions, wherein the deflection speed is verified if each one of the first positions are deviating less than a predetermined distance from corresponding second positions.
A method for forming a three dimensional article (3) through successively depositing individual layers of powder material that are fused together with an electron beam from an electron beam source (6) so as to form the article. Providing a model of said three-dimensional article; a vacuum chamber (20, 20a, 20b) having at least a first (20a) and a second (20b) section, powder material that are fused together is provided in said first section, the at least one electron beam source is provided in said second section, wherein said first and second sections are openly connected to each other. Directing an electron beam from said at least one electron beam source over said work table (2) to fuse in first selected locations according to said model to form a first cross section of said three-dimensional article while supplying a gas (from 46, via 44, 50) to said second section of said vacuum chamber.
Various embodiments of the present invention relate to a method for operating an additive manufacturing apparatus (21) in which a three-dimensional article (3) is formed. Said method comprising the steps of: providing a vacuum chamber (20a, 20b) having at least a first (20a) and a second (20b) section, wherein said first and second sections are openly connected to each other, providing a predetermined vacuum level inside said vacuum chamber, providing a layer of powder material on a work table (2) in said first section of said vacuum chamber, directing an electron beam from said at least one electron beam source (6) provided in said second section over said work table to fuse in first selected locations according to said model to form a first cross section of said three-dimensional article, purging said second section with a dry gas (from 46, via 44, 50) when said vacuum chamber is open for prohibiting ambient air into said second section.
Various embodiments of the present invention relate to a method for welding a workpiece (660) comprising the steps of: making a first weld at a first position on said workpiece with a high energy beam (605), deflecting the high energy beam with at least one deflection lens (640) for making a second weld at a second position on said workpiece, focusing the high energy beam on said workpiece with at least one focusing lens (630), shaping the high energy beam on said workpiece with at least one astigmatism lens (620) so that the shape of the high energy beam on said workpiece is longer in a direction parallel to a deflection direction of said high energy beam than in a direction perpendicular to said deflection direction of said high energy beam. The invention is also related to the use of an astigmatism lens and to a method for forming a three dimensional article.
A method for forming at least one three-dimensional article through successive fusion of parts of a powder bed, which parts correspond to successive cross sections of the three-dimensional article, the method comprising the steps of: providing a model of the at least one three- dimensional article; applying a first powder layer on a work table; directing a first energy beam from a first energy beam source over the work table causing the first powder layer to fuse in first selected locations according to corresponding models to form a first cross section of the three-dimensional article, where the first energy beam is fusing at least a first region of a first cross section with parallel scan lines in a first direction; varying a distance between two adjacent scan lines, which are used for fusing the powder layer, as a function of a mean length of the two adjacent scan lines.
A method for forming a three-dimensional article through successive fusion of parts of a powder bed comprising: providing a model of the three dimensional article, applying a first powder layer on a work table, directing an energy beam over the work table causing the first powder layer to fuse in selected locations according to the model to form a first cross section of the three-dimensional article, applying a second powder layer on the work table, directing the energy beam over the work table causing the second powder layer to fuse in selected locations according to the model to form a second cross section of the three-dimensional article, wherein the second layer is bonded to the first layer, detecting a local thickness in at least two positions in at least the second powder layer, varying an energy beam parameter depending on the detected local thickness of the second powder layer.
Method for forming a three-dimensional article (3) through successively depositing individual layers of powder material (5) that are fused together so as to form the article, said method comprising the steps of: providing at least one electron beam source (6) emitting an electron beam for heating and/or fusing said powder material. Controlling the electron beam source in a first mode when said formation of said three dimensional article is in a first process step. Controlling said electron beam in a second mode when said formation of said three dimensional article is in a second process step, wherein in said first mode an electron beam current from said electron beam source is controlled in a feed-forward mode and in said second mode said electron beam current is controlled in a feed-back mode.
The present invention relates to a method for forming a three-dimensional article through successively depositing individual layers of powder material that are fused together so as to form the article, the method comprising the step of heating a first portion of a support surface while depositing a layer of powder material on a second portion of the support surface.
The invention relates to a method for forming a three-dimensional article through successive fusion of locations of a powder bed. The method comprising: providing a model of said three-dimensional article; applying a powder layer on a work table; determining a maximum scan length of an energy beam; directing said energy beam from a first energy beam source over said work table with constant energy causing said first powder layer to fuse in first selected locations according to said model to form a first cross section of said three-dimensional article, wherein locations with a shorter scan length than said maximum scan length is provided with a time sink before and/or after said scan line so that the time period between each two adjacent scan lines is constant throughout the manufacture of said three-dimensional article.
A method for forming a three-dimensional article comprising applying a first powder layer on a work table; directing a first energy causing said first powder layer to fuse in first selected locations to form a first cross section where said first energy beam is fusing a first region with parallel scan lines in a first direction and a second region with parallel scan lines in a second direction; fusing at least one of the scan lines in said first region in said first direction immediately before fusing at least one of said scan lines in said second region in said second direction; applying a second powder layer and directing the energy beam causing said second powder layer to fuse in second selected locations where the energy beam is fusing said first region with parallel scan lines in a third direction and said second region in a fourth direction.
The present invention relates to a method for forming a three-dimensional article through successive fusion of parts of at least one layer of a powder bed provided on a work table. Said method comprising the steps of: providing at least a first and second powder tank, providing a first type of powder in said first powder tank having a first particle size distribution, providing a second type of powder in said second powder tank having a second particle size distribution, providing a first sub-layer of said first type of powder on said work table, providing a second sub-layer of said second type of powder on top of said first layer of said first type of powder, fusing said first and second sub-layers simultaneously with a high energy beam from a high energy beam source for forming a first cross section of said three-dimensional article.
A method for forming a three-dimensional article comprising the steps of: applying a model of the three dimensional article, applying a first powder layer on a work table, directing a first electron beam from a first electron beam source over the work table causing the first powder layer to fuse in first selected locations according to the model to form a first cross section of the three-dimensional article, directing a second electron beam from a second electron beam source over the work table, registering at least one setting of the first electron beam source, registering at least one setting of the second electron beam source, correcting the position of the second electron beam depending on the at least one setting of the first electron beam source and the at least one setting of the second electron beam source.
A method for forming a three-dimensional article through successive fusion of parts of a powder bed, which parts corresponds to successive cross sections of the three-dimensional article, said method comprising the steps of: providing a model of said three dimensional article, providing a first powder layer on a work table, directing a first energy beam from a first energy beam source over said work table causing said first powder layer to fuse in first selected locations according to said model to form a first cross section of said three-dimensional article, directing a second energy beam from a second energy beam source over said work table causing said first powder layer to fuse in second selected locations according to said model to form the first cross section of said three-dimensional article, wherein said first and second locations of said first powder layer are at least partially overlapping each other.
An apparatus for forming at least one three-dimensional article by fusing parts of a powder bed layer-wise. The apparatus comprising a powder distributor and an energy beam for fusing the powder layer. Said powder distributor comprises a first part being an elongated rod provided movable at a predetermined distance above the powder bed and with its central axis in parallel with a top surface of said work table and second part being a metal foil having at least a first and a second opposite edge portions. Said metal foil is provided between said elongated rod and said work table, said first and second opposite edge portions are attached to said elongated rod so that a distance between said first and second edge portions is smaller than the distance between said first and second edge portions of said metal foil when said metal foil is in a fiat position.
Various embodiments provide a method and apparatus for forming a three- dimensional article through successive fusion of parts of at least one layer of a powder bed provided on a work table in an additive manufacturing machine, which parts corresponds to successive cross sections of the three-dimensional article. The method comprises the steps of: applying a layer of predetermined thickness of powder particles on the work table, applying a coating on at least a portion of the powder particles, which coating is at least partially covering the powder particles, and fusing the powder particles on the work table with an electron beam.
B22F 3/105 - Sintering only by using electric current, laser radiation or plasma
B28B 1/00 - Producing shaped articles from the material
B29C 67/00 - Shaping techniques not covered by groups , or
C23C 14/00 - Coating by vacuum evaporation, by sputtering or by ion implantation of the coating forming material
B22F 1/02 - Special treatment of metallic powder, e.g. to facilitate working, to improve properties; Metallic powders per se, e.g. mixtures of particles of different composition comprising coating of the powder
A method for forming a three-dimensional article, said method comprising the steps of: providing a predetermined amount of powder for forming a first powder layer on a start plate, distributing said predetermined amount of powder with a powder distributor for forming said first powder layer, directing an energy beam over said start plate causing said first powder layer to fuse in selected locations according to a model to form a first cross section of said three-dimensional article. At least one image of the powder to be distributed is captured with a camera at least one time during said distribution of said powder on said start plate for forming said first powder layer and at least one value of at least one parameter in said image detected with said camera is compared with a reference parameter value.
The present invention relates to a method for forming a three-dimensional article through successive fusion of applied powder. Said method comprising the steps of: providing at least one powder hopper comprising powder to be used for forming said three- dimensional article, providing a predetermined amount of powder at a build support, directing an energy beam over said build support causing at least a portion of said powder to sinter and causing at least a portion of said powder to bond to said build support, directing an energy beam over said build support causing said powder to fuse in selected locations according to a model to form a first portion of said three-dimensional article, rotating said build support around an axis of rotation for creating said three-dimensional article, which three-dimensional article is build up layer by layer in a radial direction with respect to said axis of rotation.
The present invention relates to a vacuum chamber in which metallic vapours are deposited, said vacuum chamber comprising at least one reflector and a tube, where a first end of said tube is arranged inside said vacuum chamber and provided for receiving electromagnetic radiation, a second end of said tube is extending inside said vacuum chamber and a central axis of said tube is slanted with respect to a surface of a substrate surface which is generating metallic vapour. Said reflector is arranged inside said vacuum chamber to reflect electromagnetic radiation which is exiting from said second end of said tube onto said substrate surface which is generating metallic vapour.
B22F 3/105 - Sintering only by using electric current, laser radiation or plasma
B29C 67/00 - Shaping techniques not covered by groups , or
C23C 14/52 - Means for observation of the coating process
C23C 16/48 - Chemical coating by decomposition of gaseous compounds, without leaving reaction products of surface material in the coating, i.e. chemical vapour deposition (CVD) processes characterised by the method of coating by irradiation, e.g. photolysis, radiolysis, particle radiation
The present invention relates to a method for removing moisture from powder to be used in an additive manufacturing process for forming a three- dimensional article through successive fusion of parts of at least one layer of a powder bed provided on a work table, which parts corresponds to successive cross sections of the three- dimensional article,characterized in that said method comprising the steps of: providing at least a first powder tank and at least at least a second powder tank,providing a predetermined amount of powder on a movable table inside said first powder tank,heating the top surface of the powder in said first powder tank to a predetermined temperature interval for removing moisture from said powder, raising said movable table a predetermined distance, moving a predetermined thickness of the powder material from said first powder tank to said second powder tank.
The present invention relates to a plasma electron source apparatus (150). The apparatus comprises a cathode discharge chamber (100) in which a plasma is generated, an exit hole (120) provided in the cathode discharge chamber from which electrons from the plasma (107) are extracted by an accelerating field provided between the cathode discharge chamber (100) and an anode (104), at least one plasma confinement device (e.g. an electromagnetic coil 103), and a switching mechanism (190) for switching the at least one plasma confinement device between a first value allowing for electron extraction from the plasma and a second value prohibiting electron extraction from the plasma. Associated methods are also provided, in particular use of the apparatus (150) for forming a three dimensional article through successive fusion of parts of at least one layer of a powder bed provided on a work table.
An additive manufacturing method for forming a three-dimensional article through successive fusion of parts of at least one layer of a powder bed provided on a work table. Providing at least one rotatable powder container above said work table, said powder container comprising at least one exit for providing powder to a powder table arranged beside said work table, at least one opening inside said container is spatially separated from and connected to said at least one exit. Ejecting a fixed amount of powder from said powder container during at least one predetermined segment of rotational angles of said powder container, from the exit of said powder container onto said powder table, wherein said fixed amount is determined by the shape and size of the at least one opening inside said container. Distributing said powder onto said work table with a powder distributor.
B22F 3/00 - Manufacture of workpieces or articles from metallic powder characterised by the manner of compacting or sintering; Apparatus specially adapted therefor
B22F 3/105 - Sintering only by using electric current, laser radiation or plasma
B29C 67/00 - Shaping techniques not covered by groups , or
69.
SAFETY PROTECTION METHOD AND APPARATUS FOR ADDITIVE MANUFACTURING DEVICE
The present invention relates to a method for providing safety protection in an additive manufacturing apparatus for forming a three- dimensional article through successive fusion of parts of a powder bed in an enclosable chamber, which parts corresponds to successive cross sections of the three-dimensional article. Said method comprising the steps of: -providing a position detecting device connected to a control unit to detect if a foreign item is within said enclosable chamber, -switching off at least one device belonging to said additive manufacturing apparatus controlled by said control unit when said position detecting device is detecting said foreign item to be within said enclosable chamber, -providing power to a powder suction device only when said position detecting device is detecting said foreign item to be within said enclosable chamber.
A method for increasing the resolution when forming a three-dimensional article through successive fusion of parts of a powder bed, said method comprising providing a vacuum chamber, providing an electron gun, providing a first powder layer on a work table inside said vacuum chamber, directing an electron beam from said electron gun over said work table causing the powder layer to fuse in selected locations to form a first cross section of said three-dimensional article, providing a second powder layer on said work table, directing the electron beam over said work table causing said second powder layer to fuse in selected locations to form a second cross section of said three-dimensional article, reducing the pressure in the vacuum chamber from a first pressure level to a second pressure level between the providing of said first powder layer and said second powder layer.
A method for detecting defects in three-dimensional articles. Providing a model of said article. Providing a first powder layer on a substrate, directing an energy beam over said substrate causing said first powder layer to fuse in selected locations forming a first cross section of said three-dimensional article, providing a second powder layer on said substrate, directing the energy beam over said substrate causing said second powder layer to fuse in selected locations to form a second cross section of said three-dimensional article. A first and second image of a first and second fusion zone of said first powder layer respectively is captured. Comparing said first and second images with corresponding layers in said model. Detecting a defect in the three-dimensional article if a deviation in said first image with respect to said model is at least partially overlapping a deviation in said second image with respect to said model.
Disclosed is a method for manufacturing three-dimensional articles with porosity. A model is created of a porous structure, said creating step comprising the steps of: defining a three-dimensional space comprising a predetermined pattern of nodes, wherein said nodes are connected together in a predetermined manner with struts, moving each node in said three-dimensional space a randomized distance, which distance is less than a predetermined value and in a randomized direction, slicing said three-dimensional space into a predetermined number of two-dimensional layers with a predetermined thickness, slicing said three-dimensional article into two-dimensional layers with a predetermined thickness, applying one two-dimensional layer of said article on one two-dimensional layer of said porous structure resulting in a porous two-dimensional layer of said article, repeating said applying step for all two dimensional layers of said article, manufacturing the three-dimensional article with porosity according to the model by exposing fusible material to an energy source.
The invention concerns a method for production of a three-dimensional body by successively providing powder layers and fusing together of selected areas of said layers, which areas correspond to successive cross sections of the three-dimensional body, wherein the method comprises the following steps for at least one of said layers: applying the at least one powder layer onto a working area, and fusing together a selected area of the at least one powder layer by supplying energy from a radiation gun to the selected area. The invention is characterized in that it comprises the steps of: establishing an intended beam path that is to be used when fusing together the selected area of the at least one powder layer, calculating a temperature in the at least one powder layer along the intended beam path as a function of a specific energy deposition of an imaginary beam that is assumed to move along the intended beam path, adjusting the specific energy deposition of the imaginary beam along the intended beam path depending on the calculated temperature and on conditions set for the step of fusing together the selected area, and providing, based on the calculations and the adjustments, an operating scheme for the specific energy deposition of the real beam to be used for the intended beam path when fusing together the selected area of the at least one layer.
The invention concerns a method for producing three-dimensional objects (6) layer by layer using a powdery material (7) which can be solidified by irradiating it with a high-energy beam(4), said method comprising the steps of: applying a first layer of powdery material onto a working area (5); solidifying a part of said first layer by irradiating it with a high-energy beam; andapplying a second layer (8) of powdery material onto thefirst, partly solidified layer. The invention is characterized in that the method comprises the step of: determining a rate at which the temperature of the second layer (8) increases after application onto the first layer.The invention also concerns an apparatus configured to operate according tothe above method.
The invention concerns an apparatus (1) for producing a three-dimensional object layer by layer using a powdery material which can be solidified by irradiating it with an energy beam, such as electromagnetic radiation or an electron beam, said apparatus (1) comprising: a working area (3) onto which layers of powdery material are to be placed; a powder storage unit (11) comprising a base surface (13) for supporting a supply of powder (2); and a powder distribution member (6); wherein the base surface (13) extends along a side of the working area (3), wherein the distribution member (6) extends in a direction along the base surface (13) and said side of the working area (3) and is arranged to be moveable in a plane above, and substantially parallel to, the base surface (13) and the working area (3), and wherein the distribution member (6) is arranged to be moveable into a supply of powder (2) placed onto the base surface (13) such as to bring about a transfer of a portion of powder from a side of the distribution member (6) facing away from the working area (3) to an opposite side of the distribution member (6) facing the working area (3), said distribution member (6) further being arranged to be moveable towards and across the working area (3) so as to distribute the portion of powder onto the working area (3). The invention is characterized in that at least a part (15) of the base surface (13) is arranged to be resilient in a vertical direction.
The invention concerns a method for producing three-dimensional objects (6) layer by layer using a powdery material which can be solidified by irradiating it with a beam (4) of charged particles, which method comprises the following steps: successive application of powder layers to a working area (5), and fusing together successive layers of said three-dimensional object (6) by successively irradiating the powdery layers with said beam (4). The invention is characterized in that it comprises the following steps: determining whether lifting of powdery material from the working area (5) occurs using a powder- lifting detection device (10, 10a, 10b, 10c, 1Od, 1Oe) capable of generating a signal (S) upon detection of lifting of powdery material from the working area (5), and interrupting the irradiation of at least a part of the working area (5) where powder lifting occurs using the signal (S) generated by the powder- lifting detection device (10, 10a, 10b, 10c, 10d, 1Oe) for automatically trigging the interruption. The invention also concerns an apparatus (1) for producing three-dimensional objects (6) layer by layer using a powdery material which can be solidified by irradiating it with a beam (4) of charged particles, said apparatus (1) comprising means for successive application of powder layers to a work table, and a radiation gun (3) for delivering said beam (4) of charged particles, wherein the inventive apparatus (1) comprises a powder- lifting detection device (10, 10a, 10b, 10c, 10d, 10e) capable of generating a signal (S) upon detection of lifting of powdery material from the working area (5).
The invention concerns an apparatus (1 ) for producing a three-dimensional object (6) layer by layer using a powdery material which can be solidified by irradiating it with an energy beam (4), said apparatus (1 ) comprising an electron gun (3) for generating said energy beam (4) and a working area (5) onto which the powdery material is distributed and over which the energy beam (4) sweeps during irradiation. The invention is characterized in that the apparatus (1) is provided with a system (12, 14, 16, 18) for feeding controlled amounts of a reactive gas into the apparatus (1) such as to contact the reactive gas with material positioned on the working area (5), said reactive gas being capable of, at least when having been exposed to the energy beam (4), reacting chemically and/or physically with the material positioned on the working area (5). The invention also concerns a method for operating an apparatus of the above type.
The invention concerns a method for producing three-dimensional objects (3) layer by layer using a powdery material (5) which can be solidified by irradiating it with a high-energy beam.
The invention concerns a method for producing three-dimensional objects (3) layer by layer using a powdery material (5) which can be solidified by irradiating it with a high-energy beam. The inventive method comprises a pre- heating step with the general purpose of pre-heating the powdery material (5) in a homogeneous manner, followed by a solidifying step with the general purpose of fusing together the powdery material, wherein the pre-heating step comprises the sub-step of scanning a pre-heating powder layer area (10) by scanning the beam along paths (P1.1 - P5.20) distributed over the pre-heating powder layer area (10), wherein consecutively scanned paths (PM. N, P(M+1 ).N) are separated by, at least, a minimum security distance (ﶴY), said minimum security distance (ﶴY) being adapted to prevent undesirable summation effects in the pre-heating powder layer area (10) from said consecutively scanned paths. The invention also concerns a device adapted to be operated by the inventive method.
The invention concerns a powder application system (1) for feeding and distributing a powder over a working area (3) in an apparatus for producing three-dimensional objects, said system (1) comprising a powder storage unit (11) adapted to contain a supply of powder (2) and further comprising a distribution member (6) that is arranged to be moveable across the working area (3) as to distribute a portion of powder onto the working area (3). The invention is characterized in that the distribution member 86) is arranged to be, in a first step, moveable a predetermined distance into a supply of powder (2) placed in the powder storage unit (11), said distance being sufficiently long to bring about a transfer of a portion of powder from the powder supply (2) at one side of the distribution member to another side of the distribution member (6) facing the working area (3), and that the distribution member (6) is arranged to be, in a second step, moveable towards and across the working area (3) as to distribute the portion of powder onto the working area (3).
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