A method of operating an apparatus for the layerwise manufacture of 3D objects. The method includes two or more operational cycles of a warm up phase, starting from ambient, followed by a build phase and a cooling phase. The warm up phase and the build phase each include a layer cycle of: (a) dosing build material to the work surface; (b) distributing a portion of the dosed amount over a build area; (c) heating the dosed amount; and (d) monitoring a temperature of the build material to determine a thermal state. The build phase includes melting layer-specific regions. These steps are repeated until the warm up and build phases are completed. A property of the subsequent warm up phases is determined such that the duration of a subsequent warm up phase is shorter than the duration of a preceding warm up phase.
B29C 64/153 - Procédés de fabrication additive n’utilisant que des matériaux solides utilisant des couches de poudre avec jonction sélective, p. ex. par frittage ou fusion laser sélectif
A method of determining layer anomalies in a powder bed fusion process. The method includes obtaining measured pre-fuse temperatures and measured post-fuse temperatures for at least a subset of a plurality of layers of a build process; providing for each layer an estimated pre-fuse temperature; determining a temperature difference between the estimated and the measured pre-fuse temperature for each layer and generating a temperature difference data set; determining a level of deviation from the temperature difference data set; determining a layer anomaly in the fusion process if the level of deviation exceeds a predefined threshold; and upon determining an anomaly in one or more layers, generating a user alert and/or stopping the build process. A powder bed fusion apparatus comprising a processor configured to carry out the method is also provided.
An additive manufacturing apparatus for 3D object formation includes a process chamber, a gas extraction duct and a controller. The gas extraction duct main and secondary ducts. The main duct has an extraction opening connectable to an extraction source and an inflow opening drawing in gas from an external environment. The secondary duct has an inlet opening connected to a process chamber outlet and an outlet opening coupled to the main duct. One or more temperature sensors is thermally coupled to the gas flow temperature within the interior of the gas extraction duct. The temperature sensors include an extraction temperature sensor and/or an inflow temperature sensor. A heater is arranged to provide a baseline temperature to the inflow temperature sensor. The controller determines, based on the temperature measurements, whether a gas flow rate applied by the extraction source is within a predefined range.
A method for recirculating powder in an apparatus for manufacturing a three-dimensional object from the powder. The powder recirculation method includes: providing powder in a powder repository, the powder being one of fresh powder, excess powder or a blend thereof; transferring the powder from the repository to a work surface; distributing the powder across a build surface and resulting in a portion of the powder defining excess powder; returning the excess powder back to the repository; monitoring the amount of powder in the repository relative to a predetermined amount of powder; and delivering fresh powder from a powder tank to the repository when the amount of powder in the repository is less than the predetermined amount and not delivering fresh powder when excess powder is being returned to repository and the amount of powder in the repository is greater than the predetermined amount of powder.
B22F 12/90 - Moyens de commande ou de régulation des opérations, p. ex. caméras ou capteurs
B29C 64/153 - Procédés de fabrication additive n’utilisant que des matériaux solides utilisant des couches de poudre avec jonction sélective, p. ex. par frittage ou fusion laser sélectif
A heater arrangement for an apparatus for layer-by-layer formation of a three-dimensional object by the consolidation of particulate matter, the heater arrangement having a heater arrangement area, and comprising: one or more shrouded radiative heating elements, arranged over the heater arrangement area, the shrouded radiative heating elements being operable to heat particulate matter at a build bed surface of said apparatus to a desired temperature profile; and one or more radiation-restricting shrouds, which are arranged in communication with the shrouded radiative heating elements, and each of which form one or more passages for restricting the solid angle over which radiation is emitted by the shrouded radiative elements, each passage having a first end which opens towards at least one of said shrouded radiative heating elements, and a second end which opens to the exterior. Also provided is an apparatus for layer-by-layer formation of a three-dimensional object by the consolidation of particulate matter, the apparatus comprising: a working space having opposing bottom and top sides; a build bed surface on said bottom side of the working space and upon which successive layers of said object are formed, the build bed surface comprising a printable area; and a heater arrangement area on said top side of the working space and comprising a plurality of spaced-apart radiative heating elements arranged on said top side of the working space, the radiative heating elements being operable to heat particulate matter at the build bed surface to a desired temperature profile; wherein said plurality of spaced-apart radiative heating elements comprises a first group of four or more radiative heating elements; and wherein, as viewed from said top side of the working space, said first group of four or more spaced-apart heating elements is arranged beyond and around the perimeter of printable area and within the heater arrangement area.
B29C 64/153 - Procédés de fabrication additive n’utilisant que des matériaux solides utilisant des couches de poudre avec jonction sélective, p. ex. par frittage ou fusion laser sélectif
A heater arrangement for an apparatus for layer-by-layer formation of a three-dimensional object by the consolidation of particulate matter, the heater arrangement having a heater arrangement area, and comprising: one or more shrouded radiative heating elements, arranged over the heater arrangement area, the shrouded radiative heating elements being operable to heat particulate matter at a build bed surface of said apparatus to a desired temperature profile; and one or more radiation-restricting shrouds, which are arranged in communication with the shrouded radiative heating elements, and each of which form one or more passages for restricting the solid angle over which radiation is emitted by the shrouded radiative elements, each passage having a first end which opens towards at least one of said shrouded radiative heating elements, and a second end which opens to the exterior. Also provided is an apparatus for layer-by-layer formation of a three-dimensional object by the consolidation of particulate matter, the apparatus comprising: a working space having opposing bottom and top sides; a build bed surface on said bottom side of the working space and upon which successive layers of said object are formed, the build bed surface comprising a printable area; and a heater arrangement area on said top side of the working space and comprising a plurality of spaced-apart radiative heating elements arranged on said top side of the working space, the radiative heating elements being operable to heat particulate matter at the build bed surface to a desired temperature profile; wherein said plurality of spaced-apart radiative heating elements comprises a first group of four or more radiative heating elements; and wherein, as viewed from said top side of the working space, said first group of four or more spaced-apart heating elements is arranged beyond and around the perimeter of printable area and within the heater arrangement area.
B29C 64/153 - Procédés de fabrication additive n’utilisant que des matériaux solides utilisant des couches de poudre avec jonction sélective, p. ex. par frittage ou fusion laser sélectif
A radiation source assembly for an apparatus for layer-by-layer formation of a three-dimensional object by the consolidation of particulate material, the radiation source assembly comprising a plurality of radiation sources, each radiation source being operable to emit a respective beam of radiation towards a build bed surface of the apparatus and one or more collimators arranged to collimate the beams of radiation to produce one or more collimated beams of radiation and to direct said collimated beams of radiation towards the particulate material on the build bed surface.
B29C 64/277 - Agencements pour irradiation utilisant des moyens de rayonnement multiples, p. ex. des micro-miroirs ou des diodes électroluminescentes multiples [LED]
B22F 10/28 - Fusion sur lit de poudre, p. ex. fusion sélective par laser [FSL] ou fusion par faisceau d’électrons [EBM]
B22F 12/13 - Moyens de chauffage auxiliaires pour préchauffer le matériau
B29C 64/188 - Procédés de fabrication additive impliquant des opérations supplémentaires effectuées sur les couches ajoutées, p. ex. lissage, meulage ou contrôle d’épaisseur
A method for preparing virtual build volumes for the manufacture of three-dimensional objects. The virtual build volume represents an actual build volume over which one or more objects are to be built. The method includes the steps of: (a) receiving one or more object models, the object model(s) defining the intended dimensions of each of the objects; (b) applying a transformation to an initial virtual build volume to create a reduced virtual build volume smaller than the virtual build volume; (c) positioning the object model(s) within the reduced virtual build volume; and (d) applying an inverse transformation to expand the reduced virtual build volume to create an expanded virtual build volume including expanded object model(s); wherein each of the expanded object model(s) is larger than the respective object model(s).
An apparatus for the layer-by-layer formation of three-dimensional objects. The apparatus includes a gas extraction system and an enclosed working space. The working space includes a working space inlet allowing gas to enter, a working space outlet allowing gas to exit, and a build bed surface in which a the object is formed. The gas extraction system includes: a primary conduit having a first primary inlet, a first interfacing inlet, and a primary outlet connectable to an external extraction source; and a first secondary conduit having a first secondary inlet and outlet. The first secondary inlet is in fluidic communication with the working space. The first secondary outlet is in fluidic communication with the first interfacing inlet. The gas extraction system further includes a flow controller to control the flow of gas from the working space into the first secondary conduit, and thereafter into the primary outlet.
B08B 15/00 - Précautions prises pour empêcher les crasses ou les fumées de s'échapper de la zone où elles sont produitesRamassage ou enlèvement des crasses ou des fumées de cette zone
B29C 64/393 - Acquisition ou traitement de données pour la fabrication additive pour la commande ou la régulation de procédés de fabrication additive
B33Y 30/00 - Appareils pour la fabrication additiveLeurs parties constitutives ou accessoires à cet effet
B33Y 40/00 - Opérations ou équipements auxiliaires, p. ex. pour la manipulation de matériau
B33Y 50/02 - Acquisition ou traitement de données pour la fabrication additive pour la commande ou la régulation de procédés de fabrication additive
10.
Thermal control for apparatus for the manufacture of three-dimensional objects
An apparatus for manufacturing a three-dimensional object from particulate material. The apparatus includes a work space bounded by a first side wall on a first side of the work space, and a second side wall on a second side of the work space, the first side wall opposing the second side wall: a build bed having a build bed surface, the build bed surface being comprised in the floor of the work space and having a first edge on the first side of the work space, towards the first side wall, and a second edge on the second side of the work space, towards the second side wall: a first gas inlet at or near the first side wall; a second gas inlet at or near the second side wall; a first gas outlet above the floor of the work space, the position of the first gas outlet being coincident with the first edge of the build bed surface, or between the first edge of the build bed surface and the first gas inlet; and a second gas outlet above the floor of the work space, the position of the second gas outlet being coincident with the second edge of the build bed surface, or between the second edge of the build bed surface and the second gas inlet: wherein the first gas outlet is positioned higher in the work space than the first gas inlet, and the second gas outlet is positioned higher in the work space than the second gas inlet; and wherein one or more flow devices are operable to create first and second gas flows between the first gas inlet and the first gas outlet, and between the second gas inlet and the second gas outlet, respectively, such as to create respective first and second gas curtains on the first and second sides of the work space in use.
B29C 64/165 - Procédés de fabrication additive utilisant une combinaison de matériaux solides et liquides, p. ex. une poudre avec liaison sélective par liant liquide, catalyseur, inhibiteur ou absorbeur d’énergie
A controller and method for layer-by-layer manufacturing of a three-dimensional object from a powder. The method includes, in a first direction across a build area: moving a droplet deposition unit and depositing a radiation absorber onto regions of a previously applied layer of powder; moving a first radiation source according to a first velocity profile whilst activating the first radiation source to fuse the regions of powder where the absorber has been deposited; moving a powder distributor according to a second velocity profile and distributing a fresh layer of powder; and moving a second radiation source whilst activating the second radiation source to preheat the fresh layer of powder. The method further includes adjusting the first and/or second velocity profiles to control a time interval between the passing of the first radiation source and the powder distributor.
B29C 64/153 - Procédés de fabrication additive n’utilisant que des matériaux solides utilisant des couches de poudre avec jonction sélective, p. ex. par frittage ou fusion laser sélectif
B29C 64/236 - Moyens d’entraînement pour un mouvement dans une direction dans le plan d’une couche
B29C 64/277 - Agencements pour irradiation utilisant des moyens de rayonnement multiples, p. ex. des micro-miroirs ou des diodes électroluminescentes multiples [LED]
A method of operating an apparatus for the layerwise manufacture of 3D objects. The method includes a warm up phase followed by a build phase. The phases each include a cycle of (a) dosing an amount of build material from a dosing device; (b) pushing a portion of the dosed amount across a build area into a receiving chamber; (c) heating the dosed amount at one or both of (a) and (b); repeating (a) to (c) until each phase is complete. During the build phase, at step (b) a layer is formed over the build area and, at step (c), build material within a layer-specific region is selectively melted. Over a given duration of time, an aggregate volume of build material pushed into the receiving chamber during the warm up phase is larger than an aggregate volume of build material pushed into the receiving chamber during the build phase.
A method of operating an apparatus for the layerwise manufacture of 3D objects. The method includes two or more operational cycles of a warm up phase, starting from ambient, followed by a build phase and a cooling phase. The warm up phase and the build phase each include a layer cycle of: (a) dosing build material to the work surface; (b) distributing a portion of the dosed amount over a build area; (c) heating the dosed amount; and (d) monitoring a temperature of the build material to determine a thermal state. The build phase includes melting layer-specific regions. These steps are repeated until the warm up and build phases are completed. A property of the subsequent warm up phases is determined such that the duration of a subsequent warm up phase is shorter than the duration of a preceding warm up phase.
B29C 64/153 - Procédés de fabrication additive n’utilisant que des matériaux solides utilisant des couches de poudre avec jonction sélective, p. ex. par frittage ou fusion laser sélectif
An apparatus for formation of three-dimensional objects and having an infrared radiation deflector. The radiation deflector includes opposing first and second elongate side walls; at least one end support connecting the side walls; an upper opening and a lower opening arranged to pass lamp radiation to an exterior of the radiation deflector; and a mounting point provided at the/each end support for mounting an infrared lamp. The side walls include first and second elongate mirrors extending parallel to a lamp axis and along a lower internal portion of the respective side walls. The lamp axis extends along and between the first and second mirrors, each of which has a concave surface with respect to the lamp axis. The first mirror is an upward deflecting mirror and is arranged for redirecting at least a portion of direct lamp radiation through the upper opening.
B29C 64/153 - Procédés de fabrication additive n’utilisant que des matériaux solides utilisant des couches de poudre avec jonction sélective, p. ex. par frittage ou fusion laser sélectif
B29C 64/236 - Moyens d’entraînement pour un mouvement dans une direction dans le plan d’une couche
B29C 64/282 - Agencements pour irradiation utilisant des moyens de rayonnement multiples, p. ex. des micro-miroirs ou des diodes électroluminescentes multiples [LED] du même type, p. ex. utilisant des niveaux d’énergie différents
B33Y 30/00 - Appareils pour la fabrication additiveLeurs parties constitutives ou accessoires à cet effet
15.
Apparatus for the manufacture of three-dimensional objects
A method for recirculating powder in an apparatus for manufacturing a three-dimensional object from the powder. The powder recirculation method includes: providing powder in a powder repository, the powder being one of fresh powder, excess powder or a blend thereof; transferring the powder from the repository to a work surface; distributing the powder across a build surface and resulting in a portion of the powder defining excess powder; returning the excess powder back to the repository; monitoring the amount of powder in the repository relative to a predetermined amount of powder; and delivering fresh powder from a powder tank to the repository when the amount of powder in the repository is less than the predetermined amount and not delivering fresh powder when excess powder is being returned to repository and the amount of powder in the repository is greater than the predetermined amount of powder.
B22F 12/50 - Moyens d’alimentation en matériau, p. ex. têtes
B29C 64/153 - Procédés de fabrication additive n’utilisant que des matériaux solides utilisant des couches de poudre avec jonction sélective, p. ex. par frittage ou fusion laser sélectif
A method of manufacturing a three-dimensional object from a powder to form each layer of the object. The method includes the steps of driving a powder distribution sled in a first direction to distribute a layer of powder; driving a print sled in the first direction; driving the print sled and the powder distribution sled in a second direction; preheating the layer of powder by activating multiple radiation sources during various ones of the driving steps; during some of the driving steps, depositing a pattern of fluid onto the layer of powder; and sintering the powder on which fluid was deposited only in the second direction, by activating the at least one radiation source assembly during various ones of the driving steps in that direction. Repeating the above steps to distribute the next layer of powder.
B29C 64/165 - Procédés de fabrication additive utilisant une combinaison de matériaux solides et liquides, p. ex. une poudre avec liaison sélective par liant liquide, catalyseur, inhibiteur ou absorbeur d’énergie
B22F 10/14 - Formation d’un corps vert par projection de liant sur un lit de poudre
B22F 10/28 - Fusion sur lit de poudre, p. ex. fusion sélective par laser [FSL] ou fusion par faisceau d’électrons [EBM]
B22F 12/13 - Moyens de chauffage auxiliaires pour préchauffer le matériau
B29C 64/236 - Moyens d’entraînement pour un mouvement dans une direction dans le plan d’une couche
B29C 64/277 - Agencements pour irradiation utilisant des moyens de rayonnement multiples, p. ex. des micro-miroirs ou des diodes électroluminescentes multiples [LED]
B29C 64/282 - Agencements pour irradiation utilisant des moyens de rayonnement multiples, p. ex. des micro-miroirs ou des diodes électroluminescentes multiples [LED] du même type, p. ex. utilisant des niveaux d’énergie différents
A method for determining a set point for measurements from a temperature sensor of an apparatus for the layer-by-layer formation of a three-dimensional object from particulate material, and associated controllers. The method includes distributing a calibration layer of particulate material over a build bed surface; selectively applying absorption-modifying fluid to a reference area or a surrounding area thereof, on the build bed surface; (c) lowering the build bed surface to a calibration depth, (d) applying heat to the reference area using a moveable heat source while measuring the temperature increase of a sub-reference area over a duration of time and/or taking optical readings of an optical property of the sub-reference area over the duration of time; (e) determining the onset of fusion of the particulate material; and (f) applying the onset of fusion as the set point for subsequent temperature measurements.
B29C 64/165 - Procédés de fabrication additive utilisant une combinaison de matériaux solides et liquides, p. ex. une poudre avec liaison sélective par liant liquide, catalyseur, inhibiteur ou absorbeur d’énergie
B22F 10/28 - Fusion sur lit de poudre, p. ex. fusion sélective par laser [FSL] ou fusion par faisceau d’électrons [EBM]
B22F 10/31 - Étalonnage des étapes de procédé ou réglages des appareils, p. ex. avant ou en cours de fabrication
B22F 12/46 - Moyens de rayonnement avec mouvement de translation
B22F 12/90 - Moyens de commande ou de régulation des opérations, p. ex. caméras ou capteurs
B29C 64/153 - Procédés de fabrication additive n’utilisant que des matériaux solides utilisant des couches de poudre avec jonction sélective, p. ex. par frittage ou fusion laser sélectif
Provided is a method for the layer-by-layer manufacture of an object from particulate material, the method comprising the steps of: (a) distributing a layer of particulate material over a build bed, the layer forming a build bed surface and having a layer thickness; (b) preheating the layer to a preheat temperature; (c) heating a cross section of the object of the layer to at least a sintering temperature to cause the particulate material of the cross section to sinter or melt; (d) lowering the build bed by an increment; and (e) distributing a further layer of particulate material of substantially an intended layer thickness, the further layer forming the build bed surface; wherein an object layer cycle comprises the steps (b) to (d); and (f) optionally, repeating the object layer cycle until the object is complete; wherein the increment is different to the intended layer thickness. Further provided is a controller for carrying out the method and an apparatus comprising the controller.
B29C 64/153 - Procédés de fabrication additive n’utilisant que des matériaux solides utilisant des couches de poudre avec jonction sélective, p. ex. par frittage ou fusion laser sélectif
B29C 64/188 - Procédés de fabrication additive impliquant des opérations supplémentaires effectuées sur les couches ajoutées, p. ex. lissage, meulage ou contrôle d’épaisseur
B29C 64/393 - Acquisition ou traitement de données pour la fabrication additive pour la commande ou la régulation de procédés de fabrication additive
An apparatus for the layer-by-layer formation of three-dimensional objects, the apparatus comprising a gas extraction system and an enclosed working space from which gas is to be extracted, wherein the working space is enclosed by side walls, a ceiling and a working surface, and comprises a working space inlet for allowing gas to enter into the working space, a working space outlet for allowing gas to exit the working space, and a build bed surface in which a layer of the object is formed; wherein the gas extraction system comprises: a primary conduit comprising at least a first primary inlet, at least a first interfacing inlet, and a primary outlet; and at least a first secondary conduit comprising a respective first secondary inlet and a respective first secondary outlet, the first secondary inlet being in fluidic communication with the working space for extracting gas from the working space, and the first secondary outlet being in fluidic communication with the first interfacing inlet; wherein the or each primary inlet is open to an environment external to the working space, and wherein the primary outlet is connectable to an external extraction source so as to suction gas from the primary conduit; and wherein the gas extraction system further comprises one or more flow control devices for controlling the flow of gas from the working space into the first secondary conduit, and thence into the primary outlet of the primary conduit. Methods for operating the apparatus, and a controller for controlling the apparatus and carrying out the methods, are also provided.
A method for calibrating heat source(s) in an apparatus for manufacturing 3D objects including layer cycle steps of: distributing a layer of particulate material over a build bed; heating the layer with a heat source at a first power profile; measuring a set of temperatures at multiple regions; depositing absorption modifier (absorber) over each region and/or depositing absorption modifier (inhibitor) over a surrounding area; heating each region with the heat source or a second heat source at a second input power profile; and measuring a second set of temperatures at each region; repeating the layer cycle using different input power profiles; and determining an adjusted first and/or second input power profile, wherein when applied during a subsequent layer cycle, causes a subsequent measured set of temperatures to be within a range of target temperatures, such that the ranges are reduced over those measured for each of the calibration layers.
B29C 64/393 - Acquisition ou traitement de données pour la fabrication additive pour la commande ou la régulation de procédés de fabrication additive
B29C 64/153 - Procédés de fabrication additive n’utilisant que des matériaux solides utilisant des couches de poudre avec jonction sélective, p. ex. par frittage ou fusion laser sélectif
A method for determining a set point for a thermal sensor. The method includes: (a) distributing a layer of particulate material forming a build bed surface; (b) optionally, preheating the layer to a temperature below its melting temperature; (c) measuring a first temperature value with a primary or secondary thermal sensor; (d) depositing absorption modifier over the test region and/or surrounding area; (e) heating the test region; (f) measuring a second temperature value with the primary sensor; (g) distributing another layer of material over the preceding layer; repeating steps (b) to (g), such that the test region of each layer reaches a higher temperature than that of the preceding layer, at least until the test region starts to melt; determining a set point for the primary sensor from a characteristic in the evolution of the measured temperature values; and applying the set point to subsequent measurements of the primary sensor.
B29C 64/165 - Procédés de fabrication additive utilisant une combinaison de matériaux solides et liquides, p. ex. une poudre avec liaison sélective par liant liquide, catalyseur, inhibiteur ou absorbeur d’énergie
B29C 64/277 - Agencements pour irradiation utilisant des moyens de rayonnement multiples, p. ex. des micro-miroirs ou des diodes électroluminescentes multiples [LED]
B33Y 50/02 - Acquisition ou traitement de données pour la fabrication additive pour la commande ou la régulation de procédés de fabrication additive
B29C 64/153 - Procédés de fabrication additive n’utilisant que des matériaux solides utilisant des couches de poudre avec jonction sélective, p. ex. par frittage ou fusion laser sélectif
A method for calibrating a heat source, used in manufacturing 3D object(s) from particulate material, including layer cycle steps of: (a) distributing a layer of particulate material; (b) heating a region of the layer with a heat source at a power input over a period of time; (c) measuring the temperature of the region; (d) depositing a radiation absorber over the region and/or an absorption inhibitor over a surrounding area; (e) heating the region and a second region within the surrounding area at a second power input and period of time; and (f) measuring a second temperature of the region and a third temperature of the second region; repeating the layer cycle using different pairs of input powers from the preceding pairs; and determining for each layer an adjusted input power(s); and applying the adjusted input powers to the heat source in steps (b) and (e) for a subsequent cycle.
B33Y 50/02 - Acquisition ou traitement de données pour la fabrication additive pour la commande ou la régulation de procédés de fabrication additive
B29C 64/165 - Procédés de fabrication additive utilisant une combinaison de matériaux solides et liquides, p. ex. une poudre avec liaison sélective par liant liquide, catalyseur, inhibiteur ou absorbeur d’énergie
23.
Method of operation for an apparatus for layer-by-layer manufacture of 3D objects
A method of manufacturing 3D objects in an apparatus having a thermal sensor, a stationary heat source and one or more further heat sources. The method includes a warm up and a build process; each processing multiple layers by a layer cycle. The layer cycles include (a) providing build bed surface of particulate material; (b) heating the surface using the stationary or a first moving heat source; (b1) depositing absorption modifier (absorber) over one or more layer-specific regions and/or depositing absorption modifier (inhibitor) over a surrounding area; (c) heating the surface by the first or a second moving heat source; and (d) measuring the temperature of the surface after (a) and/or (b) and/or (c). During one or more of (a) to (c), heating the surface to a target temperature, such that (c) causes the layer-specific region of each layer to melt and form a portion of the 3D object.
B29C 64/393 - Acquisition ou traitement de données pour la fabrication additive pour la commande ou la régulation de procédés de fabrication additive
B29C 64/153 - Procédés de fabrication additive n’utilisant que des matériaux solides utilisant des couches de poudre avec jonction sélective, p. ex. par frittage ou fusion laser sélectif
A method of manufacturing 3D objects with an apparatus having first and second heat sources and a thermal sensor. The method includes carrying out a build process after a thermal calibration process for a thermal control component(s). The calibration and build processes include a layer cycle including (i) providing a layer of particulate material defining a build bed surface; (ia) heating the surface; (ii) depositing absorption modifier over a layer-specific region and/or a surrounding area; (iii) heating the layer-specific region with the first heat source; and (iv) measuring a temperature of the surface after at least one of (i) to (iii). The layer cycle includes heating the surface of each layer with the second heat source and repeating until the calibration/build processes are complete. The outcome of each calibration routine being based on the measured temperature and being applied to the thermal control component for the subsequent layer cycle.
B29C 64/393 - Acquisition ou traitement de données pour la fabrication additive pour la commande ou la régulation de procédés de fabrication additive
B29C 64/153 - Procédés de fabrication additive n’utilisant que des matériaux solides utilisant des couches de poudre avec jonction sélective, p. ex. par frittage ou fusion laser sélectif
B33Y 50/02 - Acquisition ou traitement de données pour la fabrication additive pour la commande ou la régulation de procédés de fabrication additive
A method for determining a set point for a thermal sensor. The method includes (a) distributing a layer of particulate material to provide a build bed surface; (b) depositing an amount of absorption modifier over a test region or a surrounding area; (c) heating the test region; (d) measuring a temperature value within the test region with the sensor; (e) distributing a new layer of material over the preceding layer; repeating (b) to (e) until the material of the test region starts to melt, wherein repeated step (b) deposits additional absorption modifier over the test region to absorb more energy from the heat source than the preceding layer; determining a set point for the thermal sensor from a characteristic in the evolution of the measured temperature value within the test region; and applying the set point to subsequent measurements of the thermal sensor.
B29C 64/165 - Procédés de fabrication additive utilisant une combinaison de matériaux solides et liquides, p. ex. une poudre avec liaison sélective par liant liquide, catalyseur, inhibiteur ou absorbeur d’énergie
B29C 64/282 - Agencements pour irradiation utilisant des moyens de rayonnement multiples, p. ex. des micro-miroirs ou des diodes électroluminescentes multiples [LED] du même type, p. ex. utilisant des niveaux d’énergie différents
A structure for delivering a flow of gas across a window or aperture of an imaging or measurement device within an apparatus for the manufacture of three-dimensional objects by layer-by-layer consolidation of particulate matter, the structure comprising: a hollow body having an upper aperture for mounting in correspondence with the window/aperture of said device, a gas flow intake region below the upper aperture, and a lower aperture; wherein the gas flow intake region is provided on opposing sides of the hollow body when viewed in cross-section along a longitudinal axis that runs from the upper aperture to the lower aperture, and comprises one or more channels configured to allow, in use, a flow of intake gas to enter the hollow body from the opposing sides of the hollow body with a flow component that predominantly lies in a plane parallel to the plane of the upper aperture, and to come into confluence within the hollow body; and wherein the hollow body is symmetrically shaped about the longitudinal axis so as to redirect the confluent flow of intake gas to form a substantially axial flow of gas along the longitudinal axis, and a backflow of gas near the internal wall of the hollow body, wherein the upper aperture is substantially shielded from the backflow by the intake flow, and wherein the velocity of the backflow is relatively low in comparison to the velocity of the intake flow. Also provided is an apparatus for the manufacture of three-dimensional objects by layer-by-layer consolidation of particulate matter, incorporating such a structure, and a method of delivering a flow of gas using such a structure.
B29C 64/153 - Procédés de fabrication additive n’utilisant que des matériaux solides utilisant des couches de poudre avec jonction sélective, p. ex. par frittage ou fusion laser sélectif
An infrared radiation deflector (100) for an elongate infrared lamp (110), the radiation deflector (100) comprising opposing first and second elongate side walls (130_1, 130_2); at least one end support (170) connecting the ends of the side walls (130_1, 130_2); an upper opening (140) and a lower opening (150) arranged to pass lamp radiation to an exterior of the radiation deflector (100); and a mounting point (172) provided at the/each end support (170) for mounting the infrared lamp (110) and defining between them a lamp axis location (114); wherein the first and second elongate side walls (130_1, 130_2) comprise a first elongate mirror (130_1) and a second elongate mirror (130_2) extending parallel to the lamp axis location (114) and along at least a lower internal portion of the respective first and second side walls (130_1, 130_2); wherein the lamp axis location (114) extends along and between the first mirror (130_1) and the second mirror (130_2), the first and second mirror (130_1, 130_2) each having a concave surface with respect to the lamp axis location (114); and wherein the first mirror (130_1) is an upward deflecting mirror and further arranged to be concave with respect to the upper opening (140) for redirecting at least a portion of direct lamp radiation through the upper opening (140).
B33Y 30/00 - Appareils pour la fabrication additiveLeurs parties constitutives ou accessoires à cet effet
B29C 64/282 - Agencements pour irradiation utilisant des moyens de rayonnement multiples, p. ex. des micro-miroirs ou des diodes électroluminescentes multiples [LED] du même type, p. ex. utilisant des niveaux d’énergie différents
B29C 64/153 - Procédés de fabrication additive n’utilisant que des matériaux solides utilisant des couches de poudre avec jonction sélective, p. ex. par frittage ou fusion laser sélectif
An apparatus (1) for manufacturing a three-dimensional object from particulate material, the apparatus comprising: • a work space (100) bounded by a first side wall (100A) on a first side of the work space, and a second side wall (100B) on a second side of the work space, the first side wall opposing the second side wall; • a build bed (170) having a build bed surface (160), the build bed surface being comprised in the floor of the work space and having a first edge (160′) on the first side of the work space, towards the first side wall, and a second edge (160″) on the second side of the work space, towards the second side wall; • a first gas inlet (101A) at or near the first side wall; • a second gas inlet (101B) at or near the second side wall; • a first gas outlet (102A) above the floor (100C) of the work space, the position of the first gas outlet being coincident with the first edge of the build bed surface, or between the first edge of the build bed surface and the first gas inlet; and • a second gas outlet (102B) above the floor of the work space, the position of the second gas outlet being coincident with the second edge of the build bed surface, or between the second edge of the build bed surface and the second gas inlet; • wherein the first gas outlet is positioned higher in the work space than the first gas inlet, and the second gas outlet is positioned higher in the work space than the second gas inlet; and • wherein one or more flow devices (210, 211, 212) are operable to create first and second gas flows between the first gas inlet and the first gas outlet, and between the second gas inlet and the second gas outlet, respectively, such as to create respective first and second gas curtains on the first and second sides of the work space in use.
B29C 64/165 - Procédés de fabrication additive utilisant une combinaison de matériaux solides et liquides, p. ex. une poudre avec liaison sélective par liant liquide, catalyseur, inhibiteur ou absorbeur d’énergie
Apparatus (1) for manufacturing a three-dimensional object from a powder, the apparatus (1) comprising: a build bed (201) having a build area (190), wherein successive layers of said three-dimensional object are formed in the build bed (201); a powder distribution sled (300) operable to distribute a layer of powder within the build area (190), the powder distribution sled (300) being driveable in a first direction along a first axis, across the build area (190), and driveable in a second direction, opposite to the first direction, along the first axis; and a print sled (350) operable to deposit a pattern of fluid onto the layer of powder within the build area (190) to define the cross section of said object in said layer, the print sled (350) being driveable in the first direction along a second axis across the build area, and driveable in the second direction along the second axis; wherein the first axis is parallel to, or coaxial with, the second axis; wherein the print sled (350) comprises one or more droplet deposition heads (370) for depositing the fluid, a first radiation source assembly (L1), and a second radiation source assembly (L2); wherein the powder distribution sled (300) comprises a powder distribution device (320) for distributing the powder, a third radiation source assembly (L3) and a fourth radiation source assembly (L4); and wherein each of the first, second, third and fourth radiation source assemblies is operable to both preheat and sinter powder within the build area (190). A method of manufacturing a three-dimensional object from a powder using such apparatus is also provided.
B29C 64/165 - Procédés de fabrication additive utilisant une combinaison de matériaux solides et liquides, p. ex. une poudre avec liaison sélective par liant liquide, catalyseur, inhibiteur ou absorbeur d’énergie
B29C 64/282 - Agencements pour irradiation utilisant des moyens de rayonnement multiples, p. ex. des micro-miroirs ou des diodes électroluminescentes multiples [LED] du même type, p. ex. utilisant des niveaux d’énergie différents
B29C 64/277 - Agencements pour irradiation utilisant des moyens de rayonnement multiples, p. ex. des micro-miroirs ou des diodes électroluminescentes multiples [LED]
A method for correcting thermal image distortion in a thermal camera in an apparatus for the layer-by-layer manufacture of three-dimensional objects, the thermal camera comprising a plurality of sensor pixels arranged along a first direction; the method comprising the steps of: (a) causing a temperature reference to be at a first steady state temperature; (b) moving the temperature reference at the first steady state temperature through a plurality of positions along the first direction through the field of view of the thermal camera; (c) recording a plurality of thermal images with the thermal camera while moving the temperature reference during step (b), each thermal image corresponding to one of the plurality of positions and comprising the detected temperature of the temperature reference as detected by at least one pixel of the plurality of sensor pixels; (d) identifying the at least one pixel that detected the temperature of the temperature reference within a respective thermal image at the corresponding one of the plurality of positions; (e) constructing a thermal map from the identified pixels representing the detected temperature of the temperature reference at the plurality of positions; (f) generating a correction matrix for the identified pixels based on comparison between the thermal map and the first steady state temperature; and (g) applying the correction matrix to subsequent measurements of the thermal camera. A controller and an apparatus for the layer-by-layer manufacture of three-dimensional objects comprising the controller to carry out the method are also provided.
Provided is a method for determining the onset of melting of a material and comprising providing a layer of the material; defining a reference area within the layer of material; providing a temperature sensor and a heat source above the reference area, the temperature sensor comprising a plurality of pixels configured to monitor the temperature of the reference area; selecting a first pixel and a second pixel to form a first reference pair of pixels of the temperature sensor to detect the temperature of corresponding first and second regions within the reference area; operating the heat source to heat the reference area over a duration of time, while monitoring, using the reference pair of pixels, the temperature of the two regions, wherein the heat source causes a temperature difference between the two regions such that the first and second pixel detect respective different temperatures over the duration of time; and determining the onset of melting of the material from the evolution of the temperature difference over the duration of time. Further provided is a controller for carrying out the method and an apparatus for the layer by layer formation of a three-dimensional object from particulate material is also provided, comprising the temperature sensor, and in which the onset of melting as determined in situ may be applied as a set point for measurement of the temperature sensor.
B33Y 30/00 - Appareils pour la fabrication additiveLeurs parties constitutives ou accessoires à cet effet
B33Y 50/02 - Acquisition ou traitement de données pour la fabrication additive pour la commande ou la régulation de procédés de fabrication additive
B29C 64/165 - Procédés de fabrication additive utilisant une combinaison de matériaux solides et liquides, p. ex. une poudre avec liaison sélective par liant liquide, catalyseur, inhibiteur ou absorbeur d’énergie
32.
Radiation source assembly and apparatus for layer-by-layer formation of three-dimensional objects
A radiation source assembly (100) for an apparatus (110) for layer-by-layer formation of a three-dimensional object by the consolidation of particulate material, the radiation source assembly (100) comprising: a plurality of radiation sources (21), each radiation source (21) being operable to emit a respective beam of radiation (26) towards a build bed surface (12) of the apparatus (110); and one or more collimators (22) arranged to collimate the beams of radiation (26) to produce one or more collimated beams of radiation (27) and to direct said collimated beams (27) of radiation towards the particulate material on the build bed surface (12).
B29C 64/277 - Agencements pour irradiation utilisant des moyens de rayonnement multiples, p. ex. des micro-miroirs ou des diodes électroluminescentes multiples [LED]
B22F 10/28 - Fusion sur lit de poudre, p. ex. fusion sélective par laser [FSL] ou fusion par faisceau d’électrons [EBM]
B22F 12/13 - Moyens de chauffage auxiliaires pour préchauffer le matériau
B29C 64/188 - Procédés de fabrication additive impliquant des opérations supplémentaires effectuées sur les couches ajoutées, p. ex. lissage, meulage ou contrôle d’épaisseur
An infrared lamp assembly for an apparatus for the formation of three-dimensional objects by consolidation of particulate material, the assembly comprising: an elongate infrared lamp extending along a lamp axis, an elongate shield extending parallel to and along one side of the axis of the lamp, and a support structure holding at least one of the ends of the lamp and of the shield, wherein the elongate shield at least partially bounds the space to one side of the lamp, and wherein the assembly provides a lower opening below the lamp and an upper opening above the lamp, such that, in use, radiation generated by the lamp is able to radiate through the openings and away from the lamp in directions not bounded by the shield.
B29C 64/153 - Procédés de fabrication additive n’utilisant que des matériaux solides utilisant des couches de poudre avec jonction sélective, p. ex. par frittage ou fusion laser sélectif
B29C 64/236 - Moyens d’entraînement pour un mouvement dans une direction dans le plan d’une couche
B29C 64/282 - Agencements pour irradiation utilisant des moyens de rayonnement multiples, p. ex. des micro-miroirs ou des diodes électroluminescentes multiples [LED] du même type, p. ex. utilisant des niveaux d’énergie différents
B33Y 30/00 - Appareils pour la fabrication additiveLeurs parties constitutives ou accessoires à cet effet
34.
Apparatus for the manufacture of three-dimensional objects
A stirring device for a powder tank of an apparatus for manufacturing a three-dimensional object. The stirring device is configured to rotate within the powder tank about an axis of rotation, and comprises a base plate and a strut. The strut extends from the base plate and is arranged to extend into the powder tank forming an obtuse angle with the outer edge of the base plate.
B29C 64/153 - Procédés de fabrication additive n’utilisant que des matériaux solides utilisant des couches de poudre avec jonction sélective, p. ex. par frittage ou fusion laser sélectif
B01F 27/053 - Agitateurs caractérisés par leurs éléments, leurs matériaux ou leurs propriétés mécaniques caractérisés par leurs matériaux
B01F 27/112 - Agitateurs caractérisés par la configuration des agitateurs avec des bras, des pales ou des lames
B01F 27/1121 - Agitateurs caractérisés par la configuration des agitateurs avec des bras, des pales ou des lames en forme d'épingle
B01F 27/1125 - Agitateurs caractérisés par la configuration des agitateurs avec des bras, des pales ou des lames avec des pales ou des lames s'étendant parallèlement ou obliquement par rapport à l'axe de l'agitateur
Apparatus (1) for manufacturing a three-dimensional object from a powder, the apparatus comprising: a work surface (170); a build bed (201) having a build area (190), the build area (190) being comprised within the work surface (170), wherein successive layers of said three-dimensional object are formed in the build bed (201); a first powder supply module (2) fixedly arranged on a first side of the work surface (170), outward from a first side of the build bed (201); a second powder supply module (3) fixedly arranged on a second side of the work surface (170), outward from a second side of the build bed (201); a first powder distribution sled (300) operable to distribute powder dosed to the work surface (170) from the first powder supply module (2) while moving in a first direction from the first side of the work surface (170) towards the second side of the work surface (170), and from the second powder supply module (3) while moving in a second direction from the second side of the work surface (170) towards the first side of the work surface (170), so as to form a layer of powder within the build area (190), the first powder distribution sled (300) being driveable along a first axis across the build area (190); and a print sled (350) operable to deposit a pattern of fluid onto the layer of powder within the build area (170) to define the cross section of said object in said layer, the print sled (350) being driveable along a second axis across the build area (170); wherein the first powder distribution sled (300) comprises a first powder distribution device (320) for distributing the powder; wherein the print sled (350) comprises one or more droplet deposition heads (370) for depositing the fluid, a first radiation source assembly located on one side of the one or more droplet deposition heads (370), and a second radiation source assembly located on the other side of the one or more droplet deposition heads (370); and wherein the first powder distribution sled (300) further comprises a third radiation source assembly. Also provided a method of manufacturing a three-dimensional object from a powder, using apparatus according to the first aspect of the invention to form each layer of said object.
B29C 64/165 - Procédés de fabrication additive utilisant une combinaison de matériaux solides et liquides, p. ex. une poudre avec liaison sélective par liant liquide, catalyseur, inhibiteur ou absorbeur d’énergie
B22F 12/00 - Appareils ou dispositifs spécialement adaptés à la fabrication additiveMoyens auxiliaires pour la fabrication additiveCombinaisons d’appareils ou de dispositifs pour la fabrication additive avec d’autres appareils ou dispositifs de traitement ou de fabrication
B22F 12/60 - Dispositifs de planarisationDispositifs de compression
36.
HEATER ARRANGEMENTS AND APPARATUS FOR LAYER-BY-LAYER FORMATION OF THREE-DIMENSIONAL OBJECTS
A heater arrangement (20′) for an apparatus (1) for layer-by-layer formation of a three-dimensional object (2) by the consolidation of particulate matter (16), the heater arrangement having a heater arrangement area, and comprising: one or more shrouded radiative heating elements (20′), arranged over the heater arrangement area, the shrouded radiative heating elements being operable to heat particulate matter at a build bed surface of said apparatus to a desired temperature profile; and one or more radiation-restricting shrouds (210), which are arranged in communication with the shrouded radiative heating elements, and each of which form one or more passages for restricting the solid angle over which radiation is emitted by the shrouded radiative elements, each passage having a first end which opens towards at least one of said shrouded radiative heating elements, and a second end which opens to the exterior. Also provided is apparatus for layer-by-layer formation of a three-dimensional object by the consolidation of particulate matter, the apparatus comprising: a working space having opposing bottom and top sides; a build bed surface on said bottom side of the working space and upon which successive layers of said object are formed, the build bed surface comprising a printable area; and a heater arrangement area on said top side of the working space and comprising a plurality of spaced-apart radiative heating elements arranged on said top side of the working space, the radiative heating elements being operable to heat particulate matter at the build bed surface to a desired temperature profile; wherein said plurality of spaced-apart radiative heating elements comprises a first group of four or more radiative heating elements (200); and wherein, as viewed from said top side of the working space, said first group of four or more spaced-apart heating elements is arranged beyond and around the perimeter of printable area and within the heater arrangement area.
B29C 64/153 - Procédés de fabrication additive n’utilisant que des matériaux solides utilisant des couches de poudre avec jonction sélective, p. ex. par frittage ou fusion laser sélectif
A powder recirculation system for an apparatus for manufacturing a three-dimensional object (500) from powder is provided. The powder recirculation system comprises: a delivery path coupled to an outlet of a powder tank (410), the powder tank configured to store the powder; a powder repository (115) coupled to an outlet of the delivery path, the delivery path comprising a delivery mechanism for delivering the powder from the powder tank to the powder repository; a powder recirculation path coupled to an outlet (102) of the powder repository, wherein the powder recirculation path is configured to return first excess powder from the powder repository to the delivery path at a location (103, 104) upstream of the outlet of the powder tank.
B29C 64/153 - Procédés de fabrication additive n’utilisant que des matériaux solides utilisant des couches de poudre avec jonction sélective, p. ex. par frittage ou fusion laser sélectif
An agitator for an apparatus for the manufacture of three-dimensional objects. The agitator comprises at least one blade coupled to a shaft, and extending outwardly from the shaft. Cavities are defined between the at least one blade and the shaft, such that movement of the agitator within a powder repository keeps the powder in a fluidised state and prevents the powder from agglomerating.
B29C 64/153 - Procédés de fabrication additive n’utilisant que des matériaux solides utilisant des couches de poudre avec jonction sélective, p. ex. par frittage ou fusion laser sélectif
B29C 64/241 - Moyens d’entraînement pour mouvement rotatif
B29C 64/255 - Enceintes pour le matériau de construction, p. ex. récipients pour poudre
brevets
