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WO2021150248A1 - Réglage de source d'énergie - Google Patents

Réglage de source d'énergie Download PDF

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Publication number
WO2021150248A1
WO2021150248A1 PCT/US2020/015069 US2020015069W WO2021150248A1 WO 2021150248 A1 WO2021150248 A1 WO 2021150248A1 US 2020015069 W US2020015069 W US 2020015069W WO 2021150248 A1 WO2021150248 A1 WO 2021150248A1
Authority
WO
WIPO (PCT)
Prior art keywords
test
build
energy source
additive manufacturing
manufacturing system
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Ceased
Application number
PCT/US2020/015069
Other languages
English (en)
Inventor
Pol FORNOS MARTINEZ
Maria de las Mercedes BLANCO ROLLAN
Theodore ROBINSON
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
Hewlett Packard Development Co LP
Original Assignee
Hewlett Packard Development Co LP
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by Hewlett Packard Development Co LP filed Critical Hewlett Packard Development Co LP
Priority to PCT/US2020/015069 priority Critical patent/WO2021150248A1/fr
Publication of WO2021150248A1 publication Critical patent/WO2021150248A1/fr
Anticipated expiration legal-status Critical
Ceased legal-status Critical Current

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Classifications

    • G—PHYSICS
    • G01—MEASURING; TESTING
    • G01K—MEASURING TEMPERATURE; MEASURING QUANTITY OF HEAT; THERMALLY-SENSITIVE ELEMENTS NOT OTHERWISE PROVIDED FOR
    • G01K13/00—Thermometers specially adapted for specific purposes
    • G01K13/10—Thermometers specially adapted for specific purposes for measuring temperature within piled or stacked materials
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B22—CASTING; POWDER METALLURGY
    • B22F—WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
    • B22F10/00—Additive manufacturing of workpieces or articles from metallic powder
    • B22F10/30—Process control
    • B22F10/36—Process control of energy beam parameters
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B22—CASTING; POWDER METALLURGY
    • B22F—WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
    • B22F10/00—Additive manufacturing of workpieces or articles from metallic powder
    • B22F10/80—Data acquisition or data processing
    • B22F10/85—Data acquisition or data processing for controlling or regulating additive manufacturing processes
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B22—CASTING; POWDER METALLURGY
    • B22F—WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
    • B22F12/00—Apparatus or devices specially adapted for additive manufacturing; Auxiliary means for additive manufacturing; Combinations of additive manufacturing apparatus or devices with other processing apparatus or devices
    • B22F12/40—Radiation means
    • B22F12/41—Radiation means characterised by the type, e.g. laser or electron beam
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B22—CASTING; POWDER METALLURGY
    • B22F—WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
    • B22F12/00—Apparatus or devices specially adapted for additive manufacturing; Auxiliary means for additive manufacturing; Combinations of additive manufacturing apparatus or devices with other processing apparatus or devices
    • B22F12/90—Means for process control, e.g. cameras or sensors
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C64/00—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
    • B29C64/10—Processes of additive manufacturing
    • B29C64/165—Processes of additive manufacturing using a combination of solid and fluid materials, e.g. a powder selectively bound by a liquid binder, catalyst, inhibitor or energy absorber
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C64/00—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
    • B29C64/20—Apparatus for additive manufacturing; Details thereof or accessories therefor
    • B29C64/264—Arrangements for irradiation
    • B29C64/291—Arrangements for irradiation for operating globally, e.g. together with selectively applied activators or inhibitors
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C64/00—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
    • B29C64/30—Auxiliary operations or equipment
    • B29C64/386—Data acquisition or data processing for additive manufacturing
    • B29C64/393—Data acquisition or data processing for additive manufacturing for controlling or regulating additive manufacturing processes
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B33—ADDITIVE MANUFACTURING TECHNOLOGY
    • B33Y—ADDITIVE MANUFACTURING, i.e. MANUFACTURING OF THREE-DIMENSIONAL [3-D] OBJECTS BY ADDITIVE DEPOSITION, ADDITIVE AGGLOMERATION OR ADDITIVE LAYERING, e.g. BY 3-D PRINTING, STEREOLITHOGRAPHY OR SELECTIVE LASER SINTERING
    • B33Y10/00—Processes of additive manufacturing
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B33—ADDITIVE MANUFACTURING TECHNOLOGY
    • B33Y—ADDITIVE MANUFACTURING, i.e. MANUFACTURING OF THREE-DIMENSIONAL [3-D] OBJECTS BY ADDITIVE DEPOSITION, ADDITIVE AGGLOMERATION OR ADDITIVE LAYERING, e.g. BY 3-D PRINTING, STEREOLITHOGRAPHY OR SELECTIVE LASER SINTERING
    • B33Y30/00—Apparatus for additive manufacturing; Details thereof or accessories therefor
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B33—ADDITIVE MANUFACTURING TECHNOLOGY
    • B33Y—ADDITIVE MANUFACTURING, i.e. MANUFACTURING OF THREE-DIMENSIONAL [3-D] OBJECTS BY ADDITIVE DEPOSITION, ADDITIVE AGGLOMERATION OR ADDITIVE LAYERING, e.g. BY 3-D PRINTING, STEREOLITHOGRAPHY OR SELECTIVE LASER SINTERING
    • B33Y50/00—Data acquisition or data processing for additive manufacturing
    • B33Y50/02—Data acquisition or data processing for additive manufacturing for controlling or regulating additive manufacturing processes
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B22—CASTING; POWDER METALLURGY
    • B22F—WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
    • B22F2998/00—Supplementary information concerning processes or compositions relating to powder metallurgy
    • G—PHYSICS
    • G01—MEASURING; TESTING
    • G01K—MEASURING TEMPERATURE; MEASURING QUANTITY OF HEAT; THERMALLY-SENSITIVE ELEMENTS NOT OTHERWISE PROVIDED FOR
    • G01K2213/00—Temperature mapping
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
    • Y02P—CLIMATE CHANGE MITIGATION TECHNOLOGIES IN THE PRODUCTION OR PROCESSING OF GOODS
    • Y02P10/00—Technologies related to metal processing
    • Y02P10/25—Process efficiency

Definitions

  • Additive manufacturing systems can be used to manufacture three-dimensional (3D) objects. This can be achieved, for example, by forming successive layers of a build material on a build platform and selectively solidifying portions of those layers to build up a 3D object.
  • Objects such as product components can be built up in layers in an additive manufacturing system in accordance with object descriptions as part of a build instruction that are interpreted and applied by a print controller.
  • a fusing agent (FA) fluid can be used to promote a build powder’s absorption of energy from an energy source, to promote heating, melting, and fusing of the build powder
  • a detailing agent (DA) fluid can be used adjacent to the fusing agent fluid to inhibit unwanted fusing of adjacent powder, or to cool regions where FA is applied.
  • the FA has the effect of raising the temperature of the build powder when irradiated by an energy source
  • the DA has the effect of reducing the heating effect of this radiation on build powder that it is applied to, providing highly localised control of powder fusing.
  • Figure 1 shows a schematic view of an example of an additive manufacturing system
  • Figure 2 shows a schematic cross section view of the additive manufacturing system of Figure 1 according to an example
  • Figure 3 shows a flow chart for an example of a method
  • Figure 4 shows a graph of layer number against temperature
  • Figure 5 shows the graph of Figure 4 with temperature trends marked
  • Figure 6 flow chart for another example of a method
  • Figure 7 shows a schematic diagram of an example of a controller.
  • Some additive manufacturing systems use build material which is spread over a build platform to form a build layer. Selected portions of the build layer may be solidified, for example by fusing, sintering, melting, binding or otherwise joining the build material using, for example, heat energy applied from an energy source and a fusing agent. The build platform may then be lowered by a predetermined amount and a new build layer may be formed on the previously formed layer and the process repeated. In this way solid objects can be created.
  • the build material may comprise any suitable form of build material, for example fibres, granules or powders.
  • the build material can include thermoplastic materials, ceramic material and metallic materials.
  • a store of build material may be provided in a supply vessel and build material may be distributed from the supply vessel to form an intermediate volume of build material from which build material may be spread over a build platform, either directly such as using a roller to spread the intermediate volume, or indirectly by moving some or all of the intermediate volume to another location prior to spreading.
  • Figure 1 shows a schematic view of an additive manufacturing system 1 .
  • the additive manufacturing system 1 comprises a build unit 2 which, in this example, includes two feed trays 4.
  • the feed trays 4 are arranged on opposite sides of a build platform 6, and build material is distributed to the feed trays 4 from a build material store 8 within the build unit 2.
  • the build material store 8 is shown in dotted lines within the build unit 2.
  • the additive manufacturing system 1 includes a recoater 10 which spreads build material across the build platform 6, or a previous build layer, to form a new build layer.
  • the material to be spread is from a feed tray 4 at a side of the build platform 6, but in other examples the powder may come from other sources.
  • the recoater 10 in this example comprises a spreader having a roller which engages a volume of build material to be spread.
  • spreaders may include a blade, a brush or a roller, or combinations of these, and / or other suitable devices.
  • the volume of build material to be spread may be a ridge of build material lifted from the volume of build material in a feed tray 4 by a feed vane 12.
  • the recoater 10 is controlled to move over the build platform 6 in a first direction 14 to spread a build layer of build material.
  • the build layer is substantially planar.
  • a carriage 16 is moved over the build platform 6 to selectively solidify portions of the build layer.
  • the carriage 16 in this example moves in a second direction 18 which is substantially perpendicular to the first direction 14, although this may not be the case in all examples.
  • the carriage 16 includes thermal sensors 32 which will be described in more detail with reference to Figure 2.
  • the additive manufacturing system is controlled by a controller 78 which will be described in more detail with reference to Figure 7.
  • the build unit 2 is provided as a removable build unit which can be removed from a printer unit which comprises the recoater 10 and carriage 16.
  • the build unit may be integrally formed with a printer unit, and/or other parts of an additive manufacturing apparatus.
  • Figure 2 shows a schematic cross section view of the additive manufacturing system 1 of Figure 1.
  • the additive manufacturing system 1 is depicted during a test build operation and the vane 12 has lifted a ridge 18 of build material from a feed tray 4 on one side of the build platform 6 to allow a roller 20 of the recoater 10 to create a new build layer over the previous build layer.
  • the build platform 6 has been incrementally lowered to allow the new build layer to be created by the recoater 10.
  • the thickness of the build layer can be varied as desired and may depend upon a variety of factors including complexity of object to be created the speed of build desired and the resolution of the object desired.
  • the carriage 16 will move across the build layer to selectively solidify portions of the build layer.
  • the carriage 16 in this example includes dispensers 22 which dispense fusing and/or detailing agent onto selected portions of the build layer, and a variable energy source, in this example a fusing lamp 24, which provides energy to the build layer as the carriage 16 moves over the build layer.
  • a fusing lamp 24 is an infra-red lamp, which may comprise a halogen bulb.
  • fusing and/or detailing agent result in the selective solidification of portions of the build layer, these selectively solidified portions will be referred to as object portions.
  • object portions a fusing lamp 24 is used in this example, in other examples a plurality of fusing lamps 24 could be used.
  • any suitable variable energy source can be used to provide energy to a build layer to create the object portions, and these could include lasers, lamps, microwaves, or combinations of these or other sources in which the energy per unit area applied to build layers during a build operation can be altered. This may be achieved by adjusting the length of time for which energy is applied to a build layer, portions of a build layer, or by adjusting the power output of the variable energy source, or a combination of these.
  • variable energy source is variable so that the energy that it applies to a build layer can be altered, for example changing the energy per unit area applied to the build layer.
  • This altering of the energy applied to a build layer may be achieved by changing the power output of the variable energy source, and/or may be achieved by altering the time for which the energy is applied.
  • the carriage 16 moves across every build layer at a substantially constant rate which means that the time for which energy is applied to each region of every build layer is substantially constant.
  • the variability of the energy applied in this example is achieved by varying the power output of the fuse lamp 24.
  • the power output of the fuse lamp 24 is not changed as the carriage moves over a build layer, but can be changed between layers.
  • the energy applied across a build layer is substantially constant, but may be changed between build layers.
  • the energy that the variable energy source applies to a build layer can be altered across a layer, for example as the carriage moves over the build layer.
  • the variable energy source could be moved at a variable speed over the build layer while emitting a constant power output, thus altering the energy supplied per unit area per carriage pass.
  • the power output of the variable energy source may be varied, for example by altering the intensity of the output.
  • a build chamber 26 above the build platform 6 has been created by the incremental lowering of the build platform 6 during the build operation and the build chamber 26 contains a plurality of build layer, two test objects 28 and a partly completed test object 30.
  • the object portions of several sets of adjacent build layers which overlie one another and have been solidified together to create each of the test objects 28.
  • the sets of adjacent build layers that form each of the test objects 28 and partly completed test object 30 do not overlap, and the sets of layers that form the test objects 28 and partly completed test object 30 are separated by gaps comprising a plurality of layers.
  • the power output of the energy source is the same for each of the set of layers forming a test object, and is different for each test object.
  • the carriage also includes thermal sensors 32 which can measure, for example during building, the temperature of a region 34 of an object portion of the most recently created build layer.
  • thermal sensors 32 can measure, for example during building, the temperature of a region 34 of an object portion of the most recently created build layer.
  • a single thermal sensor 32 can be used, or there may be a plurality of thermal sensors 32.
  • a thermal sensor 32 may be mounted in the carriage as shown in this example, but a thermal sensor could be mounted anywhere, static or movable, from which it can measure the temperature of the appropriate region.
  • An example of a suitable temperature sensor is a thermal camera.
  • the additive manufacturing system 1 includes a controller 78 which includes instructions executable by the additive manufacturing system to carry out a method.
  • the controller 78 will be discussed in more detail with reference to Figure 7.
  • Figure 3 shows a method 36 comprising initiating 38 a test build in an additive manufacturing system, for example the additive manufacturing system 1 of Figure 1.
  • the test build comprises building 40 a plurality of test objects.
  • all of the test objects are substantially identical and each of the test objects is formed in a non-overlapping sets of build layers.
  • the test objects may not be identical and may be formed in at least partially overlapping sets of build layers.
  • the test objects may be any shape, for example they may have a cross section perpendicular to the layers which is a regular shape such as square or circular, or they may have an irregularly shaped cross section.
  • the test objects specified in the test build may have a substantially constant area in a plane parallel to a plane of the build layers.
  • Each test object may, for example, comprise 50 layers, 70 layers, or 100 layers of build material. The number of layers may depend upon the thickness of the build layers from which the object is built.
  • the build layer thickness may be substantially consistent during a test build.
  • the test build specifies that the test objects are be spaced apart from one another by gaps which are perpendicular to the plane of the build layers so that the test objects comprise object portions formed in non-overlapping sets of build layers.
  • the gaps may comprise a plurality of layers of build material in which no portion is solidified.
  • the gaps may comprise, for example, 20 layers, 50 layers, or 100 layers of build material.
  • the number of layers in the gaps may depend upon the thickness of the build layers. In other examples the gaps may be parallel to the plane of the layers of build material.
  • the gaps may assist in thermally separating the test objects from one another.
  • the test build is a build operation in which the additive manufacturing system is controlled to carry out a test build to produce a plurality test objects.
  • the test objects have intended dimensions, but the actual dimensions of the test objects produced may differ from the intended dimensions due to, for example thermal bleed or contraction.
  • the test build operation may be terminated before all of the plurality of test objects specified in the test build have completed.
  • each test object comprises an object portion of a nonoverlapping set of a plurality of adjacent layers of build material in the additive manufacturing system.
  • the object portion of each layer is solidified as a result of irradiation by a variable output energy source, for example the fusing lamp 24 of the additive manufacturing system 1 of Figures 1 and 2.
  • the variable energy source is set to provide a constant power output across each build layer, to provide the same constant power output across each build layer of a test object and to provide a different power output for each test object.
  • the variability of the energy source comprises using one of a plurality of pre-set, or predetermined, power output levels for the energy source between a lowest and a highest.
  • the power output may be substantially continuously variable.
  • the method 36 comprises measuring, for example by measuring using the sensors 32 of the additive manufacturing system 1 of Figure 1 , during building of each test object, the temperature of a region of the object portion of a set of the plurality of adjacent layers which form the test object.
  • the set of the plurality of adjacent layers may comprise all the build layers that make up the test object, the set may comprise a random sample of some of the build layers, or may comprise a predetermined subset of the adjacent layers, for example every other layer, or every fifth layer.
  • the set of the plurality of adjacent layers may exclude an initial plurality of layers. For example the initial 10 to 20 layers in which object portions are solidified at the start of the creation of a test object may be excluded as there may be transient temperature effects that may hinder later analysis of the temperature results.
  • the temperature of a region of the object portion may be measured at a consistent stage in the build process for each layer, for example the temperature may be measured immediately prior to a recoating operation being carried out by the additive manufacturing system. This is a stage at which a direct measurement of the temperature of the object portion can be obtained as the object portion has not yet been covered in a new layer of build material.
  • the method 36 further comprises determining 42 during building of each test object, based on the measured temperatures of layers in the object portion, a trend in the measured temperature of the region of the object portion in a test object.
  • the method comprises determining 44, based on the temperature trend determined, a setting for the variable energy source to be used for a subsequent build in the additive manufacturing system.
  • An object being built in an additive manufacturing system may experience a phenomenon known as thermal bleed.
  • An object which has experienced thermal bleed has build material adhered to the object which was not identified in the build instructions. This can happen when build material surrounding an object is affected by diffusion of heat energy from an object being built and adheres to that object.
  • the amount of energy applied to the object by the variable energy source has a direct impact on amount of energy absorbed by the object and thus the temperature of the object, and on the amount of energy that diffuses from the object.
  • the amount of energy diffused by the object may depend upon the build material being used, the additive manufacturing apparatus and the fusing and detailing agent used.
  • the temperature trend in the object portion during an additive manufacturing build process depends upon the energy provided to the object portion by the energy source. If it is determined that there is an upward temperature trend in the object portions of subsequent layers during a build then a reduction in the energy applied per unit area of the object portion of a build layer by the energy source for a subsequent build can reduce the rate of, or prevent, an upward trend in the temperature.
  • the material properties of the object being built will also depend upon the energy applied per unit area of the object portion of a build layer by the energy source. Material properties may be adversely affected if too little energy is applied.
  • the additive manufacturing system may be set so that the energy source applies a substantially constant, preset, energy per unit area of the object portion of a build layer during the building of an object in a non-test build.
  • the test build initiated in the method includes building 40 a plurality of test objects, and the variable energy source is set to provide a consistent amount energy per unit area for each object portion of a test object and to provide a different amount of energy per unit area for each test object.
  • the variable energy source is set to a first power output
  • the variable energy source is set to a second or subsequent power output which differs from previous power settings.
  • the temperature of a region of the object portion of a set of the plurality of adjacent layers which create the test object is measured and a temperature trend is determined.
  • the temperature trend may depend upon the energy per unit area provided by the variable energy source.
  • Figure 4 shows a graph 46 of layer number against temperature for a test build comprising six test objects.
  • the temperature of a portion of every layer has been measured, including those which do not form part of the test objects.
  • the temperature of build layers not forming part of a test object is measured in a region which substantially corresponds with the region of the object portion in which the temperature is measured in layers forming part of the test objects.
  • the graph of Figure 4 shows temperature in °C on the vertical axis and layer number on the horizontal axis. Due to pre-heating of the layers by the additive manufacturing apparatus, the non-object layers are stabilised at about 120°C and the non-overlapping sets of layers which form the test objects can be clearly identified by the increase in temperature to raised peaks 48,50,52,54,56,58 at over about 134°C.
  • the six test objects created during this test build were created with the energy per unit area provided by the variable energy source highest for peak 50 and reducing so that the energy per area for peak 50 > peak 54 > peak 58 > peak 48 > peak 52 > peak 56.
  • Figure 5 shows the graph 46 of Figure 4 with temperature trends 60 marked.
  • the setting determined may be indicated to a user using any suitable indicator, for example visually, using lights, or a graphical user interface, audibly using a speaker, or in any other suitable manner.
  • This indication allows a user to manually set the variable energy source appropriately, or choose to use a higher or lower setting if desired.
  • the variable energy source may be automatically set to the setting determined as this may be easier for a user.
  • the user may have the option of overriding the automatic setting of the variable energy source.
  • variable energy source By carrying out this trend analysis it is possible to set the variable energy source appropriately without the need to wait several hours, or even days, for the object to cool and be cleaned before the object can be analysed to determine whether it exhibits thermal bleed.
  • a test build in which multiple test objects are built using different settings of a variable energy source it may be possible to determine the variable output energy source for future builds on the basis of the analysis of the temperature trends in object regions as the test objects are built so that the risk of thermal bleed is eliminated, or at least reduced.
  • variable energy source determining the appropriate setting for the variable energy source needs to be carried out based upon the additive manufacturing system, including any fluids used, the build mode being used and the build material being used, so each time a change is made to the additive manufacturing system, build mode and/or build material being used the variable energy source may need to be reset.
  • FIG 6 flow chart for another example of a method 62 which comprises initiating 64 a test build in an additive manufacturing system, for example the additive manufacturing system 1 of Figure 1.
  • the test build is similar to that of the method 36, in that it comprises instructions for building a plurality of test objects, however in the method 62 a test object is built 66 and the temperature trend of the measured temperature of the region of the object portion in a test object is determined 68 and is used to determine whether or not to end 70 the test build at that stage.
  • the temperature trend may be indicative that an appropriate setting has been identified for the variable output energy source and so the test build can be halted at that stage.
  • the test build may be stopped if a test object is built in which the temperature trend indicates a temperature increase trend which is below a predetermined threshold, for example less than 1°C per 100 layers, or less than 0.5°C per 100 layers.
  • the test build may be stopped if a test object is built in which the temperature trend indicates that the temperature is substantially stable and not increasing. Stopping the test build once a suitable setting has been identified can significantly shorten the time required to identify a suitable setting.
  • Stopping the test build early may not be suitable if the test build is being carried out with the variable energy source being set at random levels, rather than gradually decreasing, as a higher energy setting which still produces an upward temperature trend below a predetermined threshold, or a level trend.
  • the test build may be ended when the test build is complete and all test objects have been built.
  • the test build of the method may start using a highest energy setting of the variable output energy source in which a highest energy per unit area is applied to each build layer to create the first test object. Second and subsequent test objects may be built using sequentially lower energy settings until a lowest energy setting is used for the final test object of the test build.
  • the highest energy setting that provides a temperature trend which meets the required threshold is a suitable setting to reduce risk of thermal bleed and starting with the highest energy and reducing it for each subsequent test object provides an efficient way to identify a suitable setting.
  • the energy source is set 72 for the building of the new object.
  • the new energy setting may be based on a predetermined sequence of settings, for example from a highest to a lowest in predetermined steps.
  • the new energy setting may be randomly selected from a plurality of predetermined, or calculated, settings that have not yet been used to build a test object during the test build.
  • the new energy setting may be based on the determined temperature trend of the previous test object and the energy setting used for that test object. This may allow the method to not use some energy settings which are unlikely to produce an acceptable temperature trend.
  • the method 62 repeats the building of a test object until the test build is ended because the test build has completed, or because the test build was ended early.
  • a suitable setting for the variable energy source is determined 74 based upon the energy trends determined during the test build.
  • the variable output energy source is then set 76 based upon the determined suitable setting so that it can be used for subsequent build operations.
  • FIG. 7 shows a schematic diagram of a controller 78.
  • the controller 78 comprises a non-transitory computer-readable storage medium 80 comprising instructions 82 executable by a processor.
  • the machine-readable storage medium 68 comprising:
  • Instructions 84 to carry out a test build an additive manufacturing system for example the additive manufacturing system 1 of Figure 1 , the test build comprising a plurality of test objects.
  • Each test object comprises a plurality of adjacent layers of build material, each layer comprising an object portion which is solidified as a result of irradiation by a variable output energy source and the variable output energy source operating at a different output for each test object.
  • the instructions 82 may also comprise setting the variable energy source for subsequent build operations.

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  • Automation & Control Theory (AREA)
  • Health & Medical Sciences (AREA)
  • Toxicology (AREA)
  • Plasma & Fusion (AREA)
  • General Health & Medical Sciences (AREA)
  • Analytical Chemistry (AREA)
  • General Physics & Mathematics (AREA)

Abstract

L'invention concerne un procédé comprenant le lancement d'une construction de test dans un système de fabrication additive. La construction de test comprend la construction d'une pluralité d'objets de test. Chaque objet de test comprend une partie objet d'une pluralité de couches adjacentes de matériau de construction. La partie objet de chaque couche est solidifiée à la suite d'une irradiation par une source d'énergie à sortie variable qui est réglée pour fournir une énergie de quantité constante par unité de surface pour chaque partie objet d'un objet de test et pour fournir une quantité différente d'énergie par unité de surface pour chaque objet de test. Pendant la construction de chaque objet de test, la température d'une région de la partie objet d'un ensemble de la pluralité de couches adjacentes est mesurée et une tendance dans la température mesurée est déterminée pour chaque objet de test. Sur la base des tendances de température déterminées, un réglage pour la source d'énergie variable à utiliser pour une construction ultérieure dans le système de fabrication additive est déterminé.
PCT/US2020/015069 2020-01-24 2020-01-24 Réglage de source d'énergie Ceased WO2021150248A1 (fr)

Priority Applications (1)

Application Number Priority Date Filing Date Title
PCT/US2020/015069 WO2021150248A1 (fr) 2020-01-24 2020-01-24 Réglage de source d'énergie

Applications Claiming Priority (1)

Application Number Priority Date Filing Date Title
PCT/US2020/015069 WO2021150248A1 (fr) 2020-01-24 2020-01-24 Réglage de source d'énergie

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WO2021150248A1 true WO2021150248A1 (fr) 2021-07-29

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Citations (5)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US20040251242A1 (en) * 2001-11-17 2004-12-16 Jeong-Hun Suh Method and system for real-time monitoring and controlling height of deposit by using image photographing and image processing technology in laser cladding and laser-aided direct metal manufacturing process
WO2018075033A1 (fr) * 2016-10-19 2018-04-26 Hewlett-Packard Development Company, L.P. Fabrication additive
WO2018127429A1 (fr) * 2017-01-03 2018-07-12 L3F Sweden Ab Procédé d'impression d'un produit 3d et dispositif d'impression 3d
US20190047226A1 (en) * 2017-08-11 2019-02-14 David Masayuki ISHIKAWA Temperature control for additive manufacturing
US20190054699A1 (en) * 2016-02-08 2019-02-21 Hewlett-Packer Development Company ,L.P. Build layer temperature control

Patent Citations (5)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US20040251242A1 (en) * 2001-11-17 2004-12-16 Jeong-Hun Suh Method and system for real-time monitoring and controlling height of deposit by using image photographing and image processing technology in laser cladding and laser-aided direct metal manufacturing process
US20190054699A1 (en) * 2016-02-08 2019-02-21 Hewlett-Packer Development Company ,L.P. Build layer temperature control
WO2018075033A1 (fr) * 2016-10-19 2018-04-26 Hewlett-Packard Development Company, L.P. Fabrication additive
WO2018127429A1 (fr) * 2017-01-03 2018-07-12 L3F Sweden Ab Procédé d'impression d'un produit 3d et dispositif d'impression 3d
US20190047226A1 (en) * 2017-08-11 2019-02-14 David Masayuki ISHIKAWA Temperature control for additive manufacturing

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