method and apparatus for selectively combining particulate material

专利摘要:
METHODS AND APPLIANCES TO SELECTIVELY COMBINE PARTICULATED MATERIAL. A method and apparatus for selectively combining particulate material, including: (i) providing a layer of particulate material to a construction platform; (ii) providing radiation to sinter a portion of the layer material; (Hi) provide another layer of particulate material superimposed on the previous layer of particulate material including the previously sintered portion of the material; (iv) providing radiation to sinter another portion of the material within the other overlapping layer and to sinter said portion with the previously sintered portion of the material in the previous layer; (v) successively repeating blocks (ill) and (iv) to form a three-dimensional object; and in which at least some of the layers of the particulate material are preheated with a heater (51) before sintering a portion of the material of the respective layer, the heater being configured to move in relation to and near the particulate material.
公开号:BR112014002836B1
申请号:R112014002836-2
申请日:2012-08-01
公开日:2020-11-10
发明作者:Neil Hopkinson；Helen Rhiannon Thomas
申请人:Loughborough University；
IPC主号:

专利说明:

TECHNICAL FIELD
[001] Embodiments of the present invention relate to methods and apparatus for selectively combining particulate material. BACKGROUND
[002] The rapid prototype is widely used to form prototype components and a number of devices and methods are currently available for making rapid prototypes. In one method, a three-dimensional model generated by a component computer is initially produced using computer-aided design (CAD) software. The three-dimensional model is then cut into a number of virtual layers and a device is used to form the layers from particulate material and sinters the layers to create the three-dimensional object.
[003] When a three-dimensional object is formed, the particulate material normally needs to be in a relatively cold state in order to flow smoothly and be safely and uniformly deposited on the construction surface. If the particulate material is too hot when it is being deposited, it will flow poorly and may cause a construction failure or poor quality part. However, once deposited, the powder, if it is too cold, can cause the sintered overlapping material in the previous layer to cool down to a temperature, by which it will curl upwards and thus prevent construction progress.
[004] It will therefore be desirable to provide an alternative method and apparatus for selectively combining particulate material. BRIEF SUMMARY
[005] In accordance with several, but not necessarily all of the embodiments of the invention, a method is presented for selectively combining particulate material, which includes: (i) providing a layer of particulate material to a construction platform; (ii) providing radiation to sinter a portion of the layer material; (iii) providing another layer of particulate material superimposed on the previous layer of particulate material including the previously sintered portion of the material; (iv) providing radiation to sinter another portion of the material within the other overlapping layer and to sinter said portion with the previously sintered portion of the material in the previous layer; (v) successively repeat blocks (iii) and (iv) to form a three-dimensional object; and in which at least some of the layers of the particulate material are preheated with a heater before sintering a portion of the material in the respective layer, the heater being configured to move relative to and near the particulate material.
[006] The heater can be configured to move within 10mm of the particulate material.
[007] The heater can be parameterized to heat at least some of the layers of the particulate material in order to prevent at least one overlapping layer of the particulate material from cooling to a temperature under which it curls.
[008] A radiation source that provides radiation may include a reflection device that defines an elliptical configuration.
[009] The method may also include measuring a temperature of the particulate material and controlling the preheating of the layers of particulate material using the measured temperature.
[010] The heater may emit a series of wavelengths with a peak wavelength, which is different from that of the radiation source to provide the radiation that initiates sintering.
[011] The layers of particulate material can be substantially preheated simply by the heater.
[012] The method may also include determining the temperature in a sintered portion of the material and controlling the energy provided to the sintered portion using the established temperature.
[013] If the established temperature is below a threshold temperature, the energy provided to the sintered portion can be increased.
[014] If the established temperature is higher than a threshold temperature, the energy provided to the sintered portion can be reduced.
[015] A sensor can be used to determine the temperature of the sintered portion.
[016] The sensor can be an infrared camera, a simple pyrometer or a series of pyrometers.
[017] The method may also include determining the energy output at a radiation source to provide radiation and controlling the energy output from the radiation source in response to the determined energy output.
[018] A radiation source so that the radiation provided is different from the heater.
[019] The heater that preheats the layers of particulate material may include a radiation source to provide the radiation.
[020] A plurality of radiation sources can be configured to provide radiation.
[021] At least some of the plurality of radiation sources can provide radiation with different wavelength peaks.
[022] One or more filters can be configured to filter the radiation provided by at least some of the plurality of radiation sources.
[023] At least some of the plurality of radiation sources can be individually controllable to provide radiation to the particulate material.
[024] At least some of the plurality of radiation sources can form the heater.
[025] A support can be configured to receive the particulate material, and the support includes a plurality of walls, movable in relation to the support.
[026] At least some of the plurality of walls may include a heater to heat the particulate material.
[027] The method may further include providing a material for the particulate material to be sintered to change the properties of the particulate material to be sintered.
[028] The method may also include: varying the radiation absorption provided en bloc (ii) on a selected surface portion of the layer to sinter a portion of the layer material; and varying the radiation absorption provided en bloc (iv) on a selected surface portion of the additional layer to sinter an additional portion of the material within the other overlapping layer and to sinter said additional portion with the previously sintered portion of material in the previous layer
[029] The radiation absorption variation can be obtained by providing an amount of radiation absorbing material over the surface portion of the layer and the additional layer, respectively.
[030] The particulate material layers may be preheated substantially immediately after the particulate material layer is provided and substantially before the radiation-absorbing material is placed on the selected surface portion of the layer.
[031] The layers of particulate material may be preheated at least twice by the heater before the radiation-absorbing material is placed on the selected surface portion of the layer.
[032] The absorption radiation material may be provided by a printhead, which includes a thermal control device to control the temperature of the absorption radiation material.
[033] Infrared absorbent pigments or inks may be provided with the radiation absorbing material.
[034] The radiation-absorbing material may have a color other than black.
[035] A device may include a deposit, a printhead to provide a first radiation-absorbing material, a roll and a first radiation source.
[036] The first printhead can be positioned between the roller and the first radiation source.
[037] The device may also include a second radiation source in a position adjacent to the roller.
[038] The device may also include a second printhead to provide a second radiation-absorbing material.
[039] The method can also include measuring the energy output of the radiation absorbing material for a predetermined area and determining the extent to which the measured energy falls within a predetermined range.
[040] The particulate material may include at least one particle of a polymer, a ceramic and a metal.
[041] According to several, but not necessarily all, of the embodiments of the invention, a means of storing electronic support data encoded with instructions is presented which, when performed by a processor, generate the performance of the method as described in any previous paragraphs.
[042] According to several, but not necessarily all, of the realizations of the invention, an electronic program is presented that, when it runs on the computer, performs the method of any of the previous paragraphs.
[043] According to several, but not necessarily all of the embodiments of the invention, an apparatus is presented to selectively combine particulate material, which includes a controller configured to: (i) control the provision in a layer of particulate material to a platform of construction; (ii) controlling the provision of radiation to sinter a portion of the layer material; (iii) controlling the provision of another layer of particulate material superimposed on the previous layer of particulate material including the previously sintered portion of the material; (iv) controlling the provision of radiation to sinter another portion of the material within the other overlapping layer and to sinter said portion with the previously sintered portion of the material in the previous layer; (v) control the successive repetition of blocks (iii) and (iv) to form a three-dimensional object; and wherein at least some of the layers of particulate material are preheated with a heater before sintering a portion of the material in the respective layer, the heater being configured to move relative to and near the particulate material.
[044] The heater can be configured to move within 10mm of the particulate material.
[045] The heater can be parameterized to heat at least some of the layers of the particulate material in order to prevent at least one overlapping layer of the particulate material from cooling to a temperature under which it curls.
[046] The apparatus may also include a radiation source to provide the radiation, including a reflection device that defines an elliptical configuration.
[047] The device can also include a sensor configured to measure a temperature of the particulate material and the controller can be configured to control the preheating of the layers of particulate material using the measured temperature.
[048] The heater can be configured to emit a series of wavelengths with a peak wavelength, which is different from that of the radiation source to provide the radiation that initiates sintering.
[049] The layers of particulate material can be substantially preheated simply by the heater.
[050] The device can also include a sensor configured to determine the temperature of a sintered portion of the material and a controller can be configured to control the energy provided to the sintered portion using the specified temperature
[051] If the established temperature is less than a threshold temperature, the energy provided to the sintered portion can be increased.
[052] If the established temperature is higher than a threshold temperature, the energy provided to the sintered portion can be reduced.
[053] The sensor can be an infrared camera, a simple pyrometer or a series of pyrometers.
[054] The device can also include a sensor configured to determine the energy output of a radiation source to emit radiation and the controller can be configured to control the energy output of the radiation source in response to the determined energy output.
[055] The device may also include a radiation source configured to emit radiation, the radiation source being different from the heater.
[056] The heater that preheats the layers of particulate material may include a radiation source to provide the radiation.
[057] The device may also include a plurality of radiation sources configured to emit radiation.
[058] At least some of the plurality of radiation sources can provide radiation with different peak wavelengths.
[059] The device may also include one or more filters configured to filter the radiation provided by at least some of the plurality of radiation sources.
[060] At least some of the plurality of radiation sources can be individually controllable to provide radiation to the particulate material.
[061] At least some of the plurality of radiation sources can form the heater.
[062] The device may also include a support configured to receive particulate material, the support including a plurality of walls, movable in relation to the support.
[063] At least some of the plurality of walls may include a heater to heat the particulate material.
[064] The controller can also be configured to control the provision of a material for the particulate material to be sintered to change the properties of the particulate material to be sintered.
[065] The controller can be configured in order to control: vary the radiation absorption provided in block (ii) in a selected surface portion of the layer to sinter a portion of the layer material; and varying the radiation absorption provided en bloc (iv) on a selected surface portion of the additional layer to sinter an additional portion of the material within the other overlapping layer and to sinter said additional portion with the previously sintered portion of material in the previous layer
[066] The variation in radiation absorption can be obtained by providing an amount of radiation absorbing material over the selected surface portion of the layer and the additional layer respectively.
[067] The layers of the particulate material may be preheated substantially immediately after the layer of the particulate material is provided and substantially before the radiation-absorbing material is placed on the selected surface portion of the layer.
[068] The layers of particulate material may be preheated at least twice by the heater before the radiation-absorbing material is placed on the selected surface portion of the layer.
[069] The device may also include a printhead configured to provide the radiation-absorbing material, which includes an associated thermal control device to control the temperature of the absorbing radiation material.
[070] Infrared absorbent pigments or inks may be provided with the radiation absorbing material.
[071] The radiation-absorbing material may have a color other than black.
[072] The device may also include a device that includes a deposit, a first printhead to provide a first radiation-absorbing material, a roller and a first radiation source.
[073] The first printhead can be positioned between the roller and the first radiation source.
[074] The device may also include a second radiation source in a position adjacent to the roller.
[075] The device may also include a second printhead to provide a second radiation-absorbing material.
[076] The device may also include a sensor configured to measure the output of the radiation absorbing material to a predetermined area and the controller can be configured to determine the extent to which the measured output falls within a predetermined range.
[077] The particulate material may include at least one particle of a polymer, a ceramic and a metal. BRIEF DESCRIPTION
[078] For a better understanding of several examples of realizations of the present invention, reference will now be made, by way of example, only to the drawings accompanying this invention:
[079] Fig. 1 illustrates a schematic diagram of an apparatus according to various embodiments of the invention;
[080] Fig. 2 illustrates a plan view of a surface portion of a layer of particulate material;
[081] Fig. 3 illustrates a schematic diagram of another apparatus according to various embodiments of the invention;
[082] Fig. 4 illustrates a schematic diagram of another apparatus according to various embodiments of the invention;
[083] Fig. 5 illustrates a schematic diagram of another apparatus according to various embodiments of the invention;
[084] Fig. 6a illustrates a plan view of a surface portion of a layer of particulate material;
[085] Fig. 6b is a side view of the particulate material layer of Fig. 6a;
[086] Fig- 7 illustrates a schematic diagram for combining particulate material that θ is used to form a three-dimensional object; and
[087] Fig- 8 illustrates the apparatus of Fig. 1 which is used to combine different types of particulate material;
[088] Fig. 9 illustrates a flow chart of a method for selectively combining particulate material according to various embodiments of the invention;
[089] Fig. 10 illustrates a flow chart of a method for controlling the temperature of particulate material according to various embodiments of the invention;
[090] Fig. 11 illustrates a flow chart of a method for controlling the temperature of a sintered portion of particulate material according to various embodiments of the invention;
[091] Fig. 12 illustrates a flow chart of a method for controlling the energy output of a radiation source according to various embodiments of the invention;
[092] Fig. 13 illustrates a flow chart of a method for measuring the output of radiation absorbing material according to various embodiments of the invention;
[093] Fig. 14 illustrates a schematic diagram of a support for receiving particulate material according to various embodiments of the invention;
[094] Figs. 15A, 15B, 15C and 15D illustrate side schematic diagrams of devices for providing radiation absorbing material according to various embodiments of the invention;
[095] Figs. 16A, 16B, 16C illustrate schematic plant diagrams of devices for providing radiation absorbing material according to various embodiments of the invention; and
[096] Figs. 17A and 17B illustrate schematic plan diagrams of radiation sources according to various embodiments of the invention. DETAILED DESCRIPTION
[097] Referring to the figures, devices 11 are usually presented to combine particulate material, for example, by sintering. Apparatus 11 includes a controller 13 which is configured to allow the exposure of a surface portion of a layer 10 of particulate material to radiation, for example, infrared radiation provided by a radiation source 12. Controller 13 is also prepared for control the variation of radiation absorption in the surface portion.
[098] The implementation of controller 13 can be hardware alone (for example, a circuit, a processor etc.), have certain aspects in the software including firmware alone, or it can be a combination of hardware and software (including firmware). Controller 13 may be implemented using instructions that enable hardware functionality, for example, using computer program instructions executable 13s on a general purpose processor or a special purpose 13i that can be stored on an electronic data storage medium 132 (disk, memory, etc.) to be run by a 13i processor.
[099] Processor 13i is configured to read and write to memory 132. Processor 13i may also include an output interface through which data and / or commands are displayed by processor 13i and an input interface through which data and / or commands enter the 13i processor.
[100] Memory 132 stores a 13s computer program that includes instructions from the computer program that controls the operation of the device 11 when loaded into processor 13i. The computer program 13s establishes the logic and routines that allow the apparatus 11 to execute the methods described in the following paragraphs and also those illustrated in Figs. 9, 10, 11, 12 and 13. The processor 13i, when reading memory 132, is capable of loading and executing the computer program.
[101] Computer program 13s can reach device 11 via any suitable distribution mechanism 15. Distribution mechanism 15 may, for example, be an electronic data storage medium, a computer program product, a memory device, a recording medium such as a read-only compact disc (CD-ROM) or digital versatile disc (DVD), a production item that specifically incorporates the 13s computer program. The distribution mechanism may be a signal configured to securely transfer the 13s computer program. The apparatus 11 may propagate or transmit the computer program 13s as an electronic support data signal.
[102] Although it is illustrated with a single component, memory 132 can be implemented as one or more separate components, all or some of which components can be integrated / removable and / or can provide permanent / semi-permanent / dynamic / cache storage.
[103] References to “electronic data storage medium”, “computer program product”, “concretely incorporated computer program” etc. or a “controller”, “computer”, “processor”, etc. should be understood to cover not only computers with different architectures, such as single-processor or multi-processor architectures and sequential (Von Neumann) / parallel architectures, but also specialized circuits, such as programmable field gate arrays (FPGA), specific application (ASIC), signal processing devices and other processing circuits. Computer program references, instructions, code, etc. should be understood to encompass software for a programmable processor or firmware, such as, for example, the programmable content of a hardware device, be it instructions for a processor or configuration settings for a fixed function device, port array or device programmable logic, etc.
[104] As used in this application, the term “circuit” refers to all of the following: (a) hardware circuit implementations alone (such as analog and / or digital circuit implementations only) and (b) for a combination of circuits and software (and / or firmware), such as (as applicable): (i) for a processor (s) or (ii) for processor (s) / software parts (including processor (s)) digital signal), software, and memory (s) that work together to create a device, such as a cell phone or server, to perform various functions) and (c) for circuits, such as a microprocessor (s) or a part of a microprocessor (s), which requires software or firmware to function, even if the software or firmware is not physically present.
[105] This definition of "circuit" applies to all uses of this term in this application, including any of the claims. As an additional example, as used in this application, the term "circuit" would also cover an implementation of just one processor (or multiple processors) or part of a processor and its (or its) software and / or firmware. "would also cover, for example and if applicable to the particular element of the claim, a baseband integrated circuit or an application processor integrated circuit for a cell phone or a similar integrated circuit on the server, a cellular network device or other network device .
[106] Fig. 1 illustrates a first realization of apparatus for sintering particulate material in which a darker 14 (ie a mask) is displayed to selectively hide the radiation provided by source 12 on the surface portion of layer 10 to thereby vary the intensity of the radiation incident on the surface portion of layer 10. The most obscure 14 includes a transmissive radiation substrate 16, such as a glass plate, which carries a varying amount of reflective radiation material 18, such as oxide aluminum. The amount and pattern of material 18 deposited on the substrate may be varied to selectively vary the intensity of the radiation incident on the surface portion of layer 10, as described below.
[107] With reference still to Fig. 2, the surface portion of layer 10 is logically divided by the more obscure 14 in a number of areas including a combination portion 20, which is exposed to radiation to combine particulate material and a portion non-combination 22, which will be protected, or at least substantially protected, from radiation in order to prevent the combination of particulate material by sintering. The total protection of the non-combination portion 22 is not essential, considering that the intensity of radiation transmitted to the non-combination portion 22 is such that the particulate material is not heated to its sintering temperature. In some circumstances, transmission of low intensity radiation in the non-combination portion 22 to heat the material may be desired and may result in improved accuracy of the final component. This is because heating the material in the non-combining portion 22 reduces the thermal gradient between the material in the combining portion 20 and the non-combining portion 22.
[108] The combination portion 20 is logically divided by the more obscure 14 in a central portion 24 and a portion of the margin 26 and the reflective material 18 is deposited on the substrate 16 so that a greater amount of the material 18 is provided in the central portion 24 compared to the margin portion 26 where no reflective material may be provided 18. Consequently, the radiation intensity provided on the surface of the combination portion 20 increases from a minimum value in the central portion 24 to a maximum value in the margin portion 26, where the surface of layer 10 of the particulate material is completely exposed to radiation transmitted by the radiation source 12.
[109] The reflective material layer is illustrated schematically in Fig. 1. The variation in layer thickness in the figure does not illustrate the variation in layer thickness in practice but illustrates the variation in the amount of material. Where the layer is thick in the figure, in practice there will be a large amount of material.
[110] Although the combination portion 20 has been shown to have only a margin portion 26, so that the central portion 24 is located in the center of the combination portion 20, it is important to note that the combination portion 20 may, for example , be of an annular configuration so that the central position 24 is connected on both sides by portions of margin 26. Furthermore, it is not essential that the central portion 24 is located in the center of the surface portion of layer 10 of the particulate material.
[111] The controller 13 is prepared to control a motor 28 to move the substrate 16 from a hidden position, in which layer 10 overlaps, as shown in Fig. 1, to a non-hidden position, in which it does not overlap layer 10. Controller 13 is also prepared to control a deposition device, such as a printhead 30, to deposit reflective material 18 on substrate 16. Controller 13 controls the amount of material 18 deposited by printhead 30 in each part of substrate 16. In the embodiment shown in Fig. 1, the head 30 remains stationary and deposits reflective material 18 on the substrate 16 at the same time as the motor 28 moves the substrate 16 behind the head 30. In an alternative embodiment (not shown) ), substrate 16 can remain stationary, superimposed on layer 10 and the motor can move the printhead 30 on substrate 16 to deposit reflective material 18 there.
[112] In the illustrated embodiment, the reflective material 18 is simultaneously printed on the substrate 16 with the apparatus in operation. The amount of material 18 printed on the substrate 16 by the head 30 may be varied by the controller 13 according to the surface temperature of the layer 10. The apparatus 11 includes one or more sensors 31 to measure one or more characteristics of the apparatus 11. The temperature The surface of the layer 10 can be measured by a sensor 31, such as a temperature measurement device (for example, a pyrometer or a thermal imaging camera), and the surface temperature measurements are communicated in real time to the controller. 13. A cleaning scheme (not shown) may be provided to remove reflective material 18 from substrate 16 so that it can be reused. Different amounts of material 18 can be deposited on the substrate 16, depending on the desired radiation intensity profile on the substrate surface.
[113] Alternatively, the reflective material 18 can be pre-printed on substrate 16 before the apparatus is in operation and the same pre-printed substrate 16 or a number of pre-printed substrates 16 can be used, one for each layer 10 particulate material. In this case, measuring the surface temperature with a pyrometer may not be necessary. The use of pre-printed substrates 16 is particularly advantageous when there is a need to produce a large amount of the same component as it reduces the time spent sintering each layer of material and thus produces the prototype component, increases repetition and results in a reduction in the cost of component production
[114] It should also be considered that it is in the context of the present invention to use a plurality of pre-printed substrates 16 or simultaneously print different amounts of reflective material 18 on the same substrate 16 and use these to expose the same layer 10 of material to profiles different radiation intensity in multiple exposure phases.
[115] Fig. 3 illustrates a second embodiment of the apparatus for combining particulate material, in which the corresponding elements are assigned the respective reference numbers. The apparatus of Fig. 3 is similar to that shown in Fig. 1, except that instead of the reflective material 18 being deposited on the substrate, the reflective material 18 is deposited, using a printhead, directly on the surface portion of layer 10 of the particulate material.
[116] In the apparatus of this embodiment, the printhead 30 is once again controlled by controller 13, which controls both the movement of the printhead 30 along the surface of layer 10 and the rate of deposition of reflective material 18 in layer 10 Once again, the real-time measurement of the surface temperature of layer 10 can be conducted using a device for measuring temperature 31, for example, a pyrometer P or thermal imaging camera; the temperature measurement is used by the controller 13 to determine the amount of reflective material 18 to be printed by the head 30 on the surface portion of layer 10.
[117] The reflective material layer is illustrated schematically in Fig. 3. The variation in layer thickness in the figure does not illustrate the variation in layer thickness in practice but illustrates the variation in the amount of material. Where the layer is thick in the figure, in practice there will be a large amount of material.
[118] Fig. 4 illustrates a third embodiment of an apparatus for combining particulate material, which is similar to the first and second embodiments and in which the corresponding elements are assigned the corresponding reference numbers. In this embodiment, the controller 13 is prepared to selectively redirect the radiation provided by the source 12 and thus vary the incident of radiation intensity along the surface portion of layer 10. Selective redirection of radiation is obtained by means of control, using controller 13, a plurality of mirrors 34, which form a Digital Mirror Device (DMD) 36. Each mirror 34 is adjustable by the controller to an operative position, in which the radiation is totally directed towards the surface portion of layer 10 or to an inoperative position, in which the radiation is completely redirected away from the surface portion. When there is a series of mirrors 34, the surface portion of layer 10 can be effectively divided into a series of segments, as discussed below and the intensity of the radiation incident in each segment can vary according to a bitmap image, by varying selectively the frequencies at which individual mirrors 34 are moved between operating and inoperative positions.
[119] The use of a device to measure the temperature, such as a pyrometer, although optional, is particularly advantageous with the apparatus of this embodiment since each mirror 34 can be controlled instantly, in real time, by the controller 13 in response to instant temperature changes in the surface portion of layer 10.
[120] Fig. 5 illustrates a fourth embodiment of an apparatus for combining particulate material, which is similar to the embodiments described above and in which the corresponding elements are assigned the respective reference numbers.
[121] The apparatus in Fig. 5 is most similar to the apparatus in Fig. 3, in which the material is directly deposited on the surface portion of layer 10 of the particulate material. However, according to the fourth embodiment, the material is a radiation-absorbing material 50, for example, a material that includes powdered carbon black. In use, the radiation provided by the radiation source 12 is absorbed by the radiation absorbing material 50, where it is present on the surface, causing the radiation absorbing material 50 to heat up. The heat from the radiation-absorbing material 50 is transferred to the underlying particulate material by increasing the temperature of individual particles of the particulate material. As the particles are heated to a temperature close to the melting temperature, the neck particles bond with the adjacent heated particles. As the temperature subsequently decreases, the particles form a coherent mass of combined particulate material.
[122] The deposition of a radiation-absorbing material 50 directly on the surface portion of layer 10 allows the radiation-absorbing properties of the particulate material to be varied and carefully controlled, as desired. In various embodiments, a constant amount of radiation-absorbing material 50 is provided on the surface of the particulate material 10, which can be repeated for some or all of the layers 10 of particulate material to form a three-dimensional object. In other embodiments, varying the amount of radiation-absorbing material 50 on the surface allows the radiation-absorbing properties of the surface portion of the underlying layer 10 of the particulate material to vary. In areas where there is a greater amount of radiation absorbing material 50, a greater amount of radiation provided by the radiation source 12 is absorbed. This causes a greater amount of heat transfer to the adjacent particulate material, thereby heating said material to a higher temperature and making it combine more quickly. In areas where there is less radiation absorbing material 50, there is less radiation absorption and therefore less heat transfer to the adjacent particulate material, causing it to combine at a lower speed.
[123] In areas where there is no radiation-absorbing material 50 and where the pure particulate material is exposed to the radiation provided by the radiation source 12, there will not be sufficient absorption of radiation to heat the particulate material to its melting temperature. In this way, there will be no combination of particulate material in areas where radiation absorbing material is not provided 50.
[124] The radiation absorbing material layer 50 is illustrated schematically in Fig. 5. The variation in layer thickness in the figure does not illustrate the variation in layer thickness in practice but illustrates the variation in the amount of material. Where the layer is thick in the figure, in practice there will be a large amount of material.
[125] As with the achievements of Figs. 1 and 3, it may be desirable to provide a greater amount of radiation absorption in the margin portion 26 of the combination portion 20 than in the central portion 24. Consequently, the amount of radiation absorbing material 50 decreases from a maximum value in the portion of the combination. margin 26 to a minimum value in the central portion 24.
[126] As illustrated, no radiation-absorbing material 50 is provided on the surface portion of layer 10 of the particulate material in the non-combination portion 22. For the reasons explained above, there will be no combination of the particulate material in the non-combination portion 22 when layer 10 is exposed to radiation. However, there may be some heating of the particulate material in the non-combination portion 22, which can be advantageous to minimize the thermal gradient between the particulate material in the combination portion 20 and the non-combination portion 22, as already noted. discussed.
[127] As with Fig. 3, the printhead 30 is operable to deposit desired amounts of the radiation absorbing material 50 on the surface portion of layer 10 and the movement of the printhead 30 and the amount of material 50 deposited by the head 30 is controlled by the controller 13. Once again the pyrometer or a thermal imaging camera can be used to measure the surface temperature of layer 10, the amount of deposited radiation absorbing material 50 that is varied by the controller 13 according to temperature measurements.
[128] The applicant understood that when the particulate material is combined when sintering at a slow rate, the combined material has good material properties, for example, high strength, but with little definition in the margin portion 26. The weak definition of the margin it increases because as the particulate material is combined, there is a certain contraction that causes unwanted movements of the unmatched particulate material of the non-combination portion 22 in relation to the combination portion 20. On the other hand, when the particulate material is combined by sintering at an accelerated rate, the combined material has lower properties, but with good margin definition considering that the particulate material in the margin portion 26 is quickly combined and locked in position, thereby minimizing unwanted movements of the surrounding unmatched particulate material.
[129] In order to create a layer 10 of combined particulate material with good material properties and good definition in the margin portion 26, it is then desirable to make the particulate material in the combination portion 20 be combined at a slow rate to to obtain good properties of the material and to make the particulate material in the margin portion 26 combine quickly to obtain a good margin definition.
[130] One method of achieving this result is to use an apparatus according to the different embodiments of the invention described above to achieve greater radiation absorption in the margin portion 26 than in the remainder of the combination portion 20. It can be obtained this result by varying the intensity of the radiation incident on the selected surface portion of layer 10 using the apparatus according to the first, second and third embodiments or by varying the radiation absorption on the selected surface portion by providing a variable amount of radiation-absorbing material 50 on the surface portion. In all the aforementioned cases, radiation in layer 10 is provided in a single exposure phase.
[131] Using the apparatus according to the fourth embodiment of the invention, similar results can be obtained by providing radiation in layer 10 of particulate material in multiple exposure phases, as we will now discuss.
[132] According to a first method, a first constant amount of radiation absorbing material 50 is provided over the combination portion 20, and the radiation is then provided in layer 10, using the radiation source 12 to create underlying particulate material in the combining portion 20 for combining purposes. The first amount of radiation-absorbing material 50 is selected so that it is a relatively low amount so that the underlying particulate material combines at a slow rate and has good material properties.
[133] After the particulate material has been combined, additional particulate material is added to layer 10 in the portion of margin 26, where a contraction will have occurred. A second amount of the same radiation-absorbing material 50, which is greater than the first amount, is then provided in the margin portion 26 and the radiation is again provided using the radiation source 12. The second amount of material is selected so to be a relatively large amount so that the underlying particulate material combines at a rapid rate. Due to the large amount of radiation-absorbing material 50 present in the margin portion 26 and the consequent rapid combination of the underlying particulate material, the reduction of the material is minimized, thereby providing the resulting layer 10 of the combined material with a good definition in the portion of margin 26.
[134] According to a second method, a constant amount of a first radiation absorbing material 50 is provided with a first absorption of natural radiation on the combination portion 20, and the radiation is then provided in layer 10, using the source of radiation 12 to create underlying particulate material in the combining portion 20 for combining purposes. The first radiation-absorbing material 50 is selected to have a low natural radiation absorption so that a relatively low amount is absorbed and the underlying particulate material combines at a slow rate and has good material properties.
[135] After the particulate material has been combined, additional particulate material is added to layer 10 in the portion of margin 26, where a contraction will have occurred. A second different radiation-absorbing material 50, with a second absorption of natural radiation, is then provided in the margin portion 26 and the radiation is again provided to layer 10 using the radiation source 12. Second radiation-absorbing material 50 is selected to have a high natural radiation absorption, which is superior to the absorption of the first radiation absorbing material 50 so that a high amount of radiation is absorbed and so that the underlying particulate material in the margin portion 26 matches at a rapid rate.
[136] According to a third method, a first radiation-absorbing material 50 with the ability to absorb a first wavelength or spectral range of radiation is provided on the combination portion 20, and radiation of a first wavelength or spectral variety is then provided in layer 10, using the radiation source 12 to create underlying particulate material in the combining portion 20 for combining purposes.
[137] After the particulate material has been combined, additional particulate material is added to layer 10 in the portion of margin 26, where a contraction will have occurred. A second radiation-absorbing material 50, capable of absorbing a second wavelength or spectral range of radiation is then provided over the margin portion 26, and radiation of a second wavelength or spectral range is then provided in layer 10, using the radiation source 12.
[138] In order to provide the desired material properties in the combination portion 20, radiation in the first wavelength or spectral variety can be selected to obtain a relatively low intensity so that the first radiation absorbing material 50 is heated at a slow rate, thus causing the underlying particulate material to combine at a slow rate. In order to provide good definition in the margin portion 26, the radiation in the second wavelength or spectral variety may be selected because it has a relatively high intensity so that the second radiation-absorbing material 50 is heated quickly, in this way , causing the underlying particulate material to combine at a rapid rate.
[139] Alternatively, a quantity of the second radiation-absorbing material 50 may be provided greater than the quantity of the first radiation-absorbing material 50, as described above with reference to the first method, and the radiation of the first and second wavelengths or spectral variety is provided by the radiation source 12 selected to have the same intensity.
[140] As an additional alternative, the Second radiation-absorbing material 50, may be selected to have a natural absorption greater than that of the first radiation-absorbing material 50, as described above with reference to the Second method and the radiation of the first and second lengths waveform or spectral variety is provided by the radiation source 12 selected to have the same intensity.
[141] If desired, the third method could be adapted so that the first and second radiation absorbing material 50 were simultaneously applied to the surface of the particulate layer and the radiation of the first and second wavelengths provided in separate phases.
[142] It is possible that the first, second and third methods described above could be modified to cause the particulate material in the margin portion 26 of layer 10 to be initially combined at a rapid rate to lock the margin portion 26 and to make causing the particulate material in the remainder of the combination portion 20 to be subsequently combined at a slow rate to obtain the desired material properties.
[143] With reference to Figs. 6a and 6b, the apparatus according to the invention allows the surface portion of layer 10 of the particulate material to be logically divided into a series of segments 32. Controller 13 can control the amount of radiation absorption in each segment 32 independently and can a bitmap image can be used to specify the amount that should be absorbed in the surface portion. The gray scale of each segment 32 of the bitmap image is individually adjustable and in the case of the first and second realizations of the device, the amount of reflective material 18 deposited on each segment of the substrate 16 or surface portion of layer 10 is individually adjustable, according to the bitmap image, to provide any desired radiation intensity profile on the surface portion of layer 10. When the apparatus of the third embodiment is employed, mirrors 34 are adjusted to vary the intensity of the radiation incident in each segment 32 from the series. When the apparatus of the fourth embodiment is used, the amount of radiation absorbing material 50 deposited on each segment of the surface portion of layer 10 is individually adjustable, according to the bitmap image to provide any desired radiation absorption profile in the portion surface layer 10.
[144] In Figs. 6a and 6b, a first amount of reflective material 18 was deposited per print head 30 in segments 32 defining the central portion 24 of the combination portion 20. Consequently, a first radiation intensity, which is less than the maximum intensity, is incident on the surface portion of layer 10 located under these segments 32. The first radiation intensity is high enough to increase the temperature of the particulate material for combining purposes.
[145] No reflective material 18 was provided in segments 32, which define the margin portion 26 of the combination portion 20, thereby allowing maximum radiation intensity to reach the surface portion of layer 10 located under these segments 32 The maximum radiation intensity makes the particulate material located under the segments 32 that define the margin portion 26 match more quickly than the particulate material in the central portion 24.
[146] A second quantity of reflective material 18, which is higher than the first quantity, is deposited per print head 30 in segments 32 which defines the non-combination portion 22. Sufficient quantity of material 18 may be provided to prevent transmission of any radiation to the surface portion of layer 10 located below these segments. Consequently, the particulate material located under these segments 32 does not match.
[147] While the variation in radiation intensity in each individual segment 32 has been described with respect to the second embodiment of the apparatus, it should be understood that the same effect can be obtained using an apparatus according to the first embodiment, in which the material reflector 18 is printed on a substrate 16, according to the third embodiment, in which mirrors 34 are used to vary the intensity of the radiation incident in each segment 32, or according to the fourth embodiment, in which the radiation absorbing material 50 is printed on the surface portion of layer 10 of the particulate material.
[148] The layer of reflective material is illustrated schematically in Fig. 6b. The variation in layer thickness in the figure does not illustrate a variation in layer thickness in practice but illustrates a variation in the amount of material. Where the layer is thick in the figure, in practice there will be a large amount of material.
[149] With reference to Fig. 7, a diagram of the apparatus of Fig. 3 in use to form a three-dimensional object 38 is shown. Once again, the elements of the apparatus which have already been designated previously are identified with the corresponding reference numbers.
[150] The apparatus is used to form a three-dimensional object 38 by combining layers 10a to 10e of particulate material. A batch of particulate material, for example Nylon powder, is placed in a feed tank 40 and the controller 13 is arranged to control an M motor, which can move the particulate material from tank 40 to a construction device 42, which includes a platform with vertical displacement 44.
[151] The movement of platform 44 is controlled by controller 13, so that platform 44 moves vertically downward in discrete steps after the formation of each layer 10.
[152] Initially, with platform 44 in the highest position, controller 13 drives motor M to provide a first layer 10a of particulate material on platform 44. Controller 13 then drives printhead 30 to deposit a pattern reflective material 18 on the surface portion of layer 10 of the material. Alternatively, the reflective material 18 can be deposited by the printhead 30 on a substrate 16 as previously discussed, or the density incident to the surface can be controlled with digital mirrors.
[153] Controller 13 then activates radiation source 12 to provide radiation on the selected surface portion of layer 10, as defined by reflective material 18. As shown in fig. 7, the radiation is supplied with varying intensity by the combination portion 20 and the material in this portion is combined. The reflective material 18 prevents, or at least substantially prevents, the transmission of radiation to the surface portion of the material in the n-combination portion 22, where the material is not combined and remains in the form of particles. The variable amount of reflective material 18 thus provides radiation of varying intensity throughout the combination portion 20 of layer 10.
[154] After combining the material in the combining portion 20 of the first layer 10a has been performed, the controller 13 deactivates the radiation source 12 and lowers the platform 44 a space approximately equivalent to the desired layer thickness. Controller 13 then drives motor M to provide a second layer 10b of particulate material superimposed on the first layer 10a, including a previously combined portion of material. The controller 13 then drives the printhead 30 to deposit the reflective material 18 on the surface portion of the second layer 10b. The amount and pattern of reflective material 18 deposited on the surface portion of the second layer 10b may be the same as that indicated in the first layer 10a or it may be different, for example in response to the design or measurements of the surface temperature performed using the pyrometer.
[155] Controller 13 then activates radiation source 12 to supply radiation through the surface portion of the second layer 10b, providing the reflective material 18 with radiation of varying intensity by the surface portion. The material in the combining portion 20 of the second layer 10b is thus required to combine and further combine with the previously combined portion of the material in the first layer 10a. Adjacent layers 10a, 10b are thus combined to form part of a coherent object 38.
[156] Controller 13 continues to function in this way to provide more layers 10c to 10e of particulate material and combine them until the formation of object 38 is completed. As soon as coherent object 38 has been formed, platform 44 is raised by controller 13 to eject the combined object 38 and any remaining unmatched particulate material around the object 38 of the device 42.
[157] Once again it should be appreciated that the apparatus according to any of the embodiments of the invention can be used to form a three-dimensional object 38.
[158] Fig. 8 illustrates the use of the apparatus of Fig. 1 to combine different particulate materials P1 and P2, which are located adjacent to each other in a layer 10. As an illustration, material P1, for example copper, can it has a lower melting point than that of material P2, for example steel and can thus combine by sintering at a lower temperature. The concentration of material P2 decreases from right to left across the transition gradient region 19. The concentration of material P1 decreases from right to left across the transition gradient region 19.
[159] In order to ensure optimum material characteristics and minimize thermal stress throughout the gradient region 19, between materials P1 and P2, substrate 18 can be provided with a high amount of reflective material 18 in the portion on the material P1 of layer 10, a low amount of reflective material in the portion on the material P2 and a quantity of reflective material on the gradient region 19 which decreases from left to right in the figure.
[160] By varying the radiation intensity in this way, the materials P1 and P2 are heated to different temperatures using a radiation source of fixed intensity 12 and are simultaneously combined to form a coherent layer.
[161] The reflective material layer 18 is schematically illustrated in Fig. 8. The variation in layer thickness in the figure does not illustrate a variation in layer thickness in practice but illustrates a variation in the amount of material. Where the layer is thick in the figure, in practice there will be a large amount of material.
[162] While the first embodiment of the apparatus has been described for use in combining the dissimilar particulate materials P1 and P2, it will be readily appreciated that the second embodiment of the apparatus may be used as an alternative on which reflective material 18 is directly printed on the surface portion of the layer 10, the third embodiment of the apparatus using mirrors 34 to selectively redirect radiation, or the fourth embodiment of the apparatus in which the radiation absorbing material 50 is directly printed on the surface portion of layer 10.
[163] If any of the achievements described above, it may be desirable to add radiation-absorbing material to the particulate material to increase radiation absorption. For example, a material such as carbon black can be used for this purpose.
[164] Other particulate materials, such as ceramic fillers, can be added to the particulate material to improve the material properties of the resulting component.
[165] When different radiation-absorbing materials are employed, for example as described above in relation to Fig. 5, they can be of different colors to produce the resulting component with the desired aesthetic properties. For example, radiation-absorbing materials may have a color other than black.
[166] Fig. 9 illustrates a flow chart of a method for selectively combining particulate material according to various embodiments of the invention; The method illustrated in figure 9 can be implemented by any device that is configured to selectively combine particulate material through sintering. For example, the method can be implemented through a selective laser sintering device, a selective inhibition device, a selective mask device, a sintering device that uses radiation absorbing material and through various devices 11 illustrated in figures 1 to 8.
[167] In block 52, the method includes the presentation of a layer of particulate material on a support (which can also be designated as a construction platform). Then, in block 54, the method includes presenting radiation from a radiation source to sinter a portion of the material in the layer. The radiation source can be any suitable source that is configured to emit electromagnetic waves at any suitable wavelength (s). For example, the radiation source can be a laser.
[168] In block 56, the method includes presenting another layer of particulate material over the previous layer of particulate material, including the previously sintered portion of material. Then, in block 58, the method includes presenting radiation to sinter an additional portion of the material within the other overlapping layer and to sinter said additional portion with the previously sintered portion of material in the previous layer. The method then repeats blocks 56 and 58 to form a three-dimensional object in block 60.
[169] It should be noted that in blocks 52 and 54, the method may also include the provision of a radiation-absorbing material, a reflective material or a reflective mask after the layers of particulate material have been presented.
[170] And at least some of the layers of particulate material a heater (such as heater 51 shown in Figure 5) preheats the particulate material before the apparatus sinters a portion of the material in the respective layer. For example, in block 52 and / or block 54, the method may also include controlling the heater to preheat the already presented layer of particulate material.
[171] It should be borne in mind that the layers of the particulate material can be substantially preheated, immediately after the layer of the particulate material is provided and before the radiation to start sintering the particulate material is applied on the selected surface portion layer. In some embodiments, the layers of particulate material may be preheated at least twice by the heater before radiation is applied to start sintering the particulate material on the selected surface portion of the layer.
[172] The heater can be any source of radiation and can be configured to move relative to the particulate material and in the vicinity of the particulate material. The heater can be considered as being close to the particulate material if it is less than 100 mm from the particulate material. This may involve a heating lamp that crosses the surface of the construction platform following the device for depositing particulate matter at a height of 100 mm or less above the surface of the construction platform. The heater can be the same device as the radiation source or it can be a different device. Whenever the apparatus includes a device for providing particulate material and / or reflective material or radiation-absorbing material, the heater can be housed within the device housing and can thus move with the device.
[173] In various embodiments, the heater may be configured to emit a series of wavelengths with a peak wavelength different from that of the radiation source to provide the radiation (for example, the radiation source 12 shown in the figure 1) and the layers of particulate material can be substantially preheated by only one heater (i.e., it may not be preheated by the radiation source).
[174] The method illustrated in fig. 9 can provide several advantages. For example, the heat from the nearby heater can be quickly transferred to the deposited particulate material so that the underlying sintered material is less likely to cool to a temperature that causes it to curl. In addition, the heat from the nearby heater can be efficiently transferred to the newly deposited powder and may not heat other parts of the machine. In addition, the nearby heater will allow the deposited powder to reach a temperature at which it is ready to be sintered quickly, thus leading to a more globally rapid production process.
[175] Fig. 10 illustrates a flow chart of a method of controlling the temperature of the particulate material according to various embodiments of the invention. The method illustrated in fig. 10 can be performed with the method illustrated in fig. 9. In block 62, the method includes measuring a temperature of the particulate material. For example, one or more of the sensors 31 may include an infrared camera, a simple pyrometer or a series of pyrometers for measuring the temperature of the particulate material. In block 64, the method includes controlling the preheating of the layers of particulate material using the measured temperature. For example, controller 13 can control the heater to increase or decrease the thermal energy supplied by the heater. The method can then return to block 62 and be repeated.
[176] The method illustrated in fig. 10 can advantageously help to prevent the underlying sintered material from cooling to a temperature that causes it to curl.
[177] Fig. 11 illustrates a flow chart of a method of controlling the temperature of the sintered portion of the particulate material according to various embodiments of the invention. The method illustrated in figure 11 can be implemented by any device that is configured to selectively combine particulate material through sintering. For example, the method can be implemented through a selective laser sintering device, a selective inhibition device, a selective mask device, a sintering device that uses radiation absorbing material and through various devices 11 illustrated in figures 1 to 8. The method illustrated in fig. 11 can be performed with the methods illustrated in figs. 9 and 10 and can be performed independently of the methods illustrated in figs. 9 and 10.
[178] In block 66, the method includes determining the temperature of a sintered portion of the particulate material. For example, one or more of the sensors 31 (eg an infrared camera, an individual pyrometer or a series of pyrometers) can measure and determine the temperature of the sintered portion of the particulate material.
[179] In block 68, the method includes controlling the energy applied to the sintered portion using the established temperature. For example, if the established temperature is below a threshold temperature, controller 13 controls the radiation source so that the energy provided to the sintered portion is increased. Another example, if the established temperature is higher than a threshold temperature, the controller 13 controls the radiation source so that the energy supplied to the sintered portion is decreased. The method can then be returned to block 66 and repeated.
[180] The thermal camera can record the temperatures generated at specific locations where sintering takes place (ie, where a laser has passed laser sintering or where the radiation-absorbing material has been printed and lamp energy has been applied). Using the 2D profile information for a given layer, it will be possible to record the temperature in the sintered regions of only one work surface.
[181] If the peak temperatures recorded in these regions are too low, a warning (eg an audible alarm) can be issued indicating a possible weakness in the parts due to insufficient heating. In addition, the device can add more energy, for example by increasing the temperature set for the construction platform or the sintering energy applied. Similarly, if the peak temperature recorded in these regions is too high, a warning can be issued indicating the possible weakness of the parts due to degradation caused by too much thermal energy. In addition, the device can reduce energy, for example by reducing the temperature set for the construction platform or the sintering energy applied.
[182] The thermal control of a sintered area allows the determination of the properties of the part (where research determines the minimum temperature required in the sintered area to achieve the necessary or desired properties of the part). This operation can be carried out by comparing the 2D profile (eg bitmap image) of the layer in question with the result recorded by the infrared camera in the same region. This process thus ensures that the part has reached the minimum temperature and that the parts will have the desired mechanical properties. If an area of the printed image has too low a temperature, overheated heaters may increase temperatures in that area or the sintering energy source (s) (eg lamp or laser) may apply more energy or more ink can be printed on that area including radiation-absorbing material.
[183] The method illustrated in fig. 11 can provide an advantage in that it can allow the reduction of energy provided on the construction platform. Reducing the energy provided on the construction platform can have several advantages. For example, it can help to ensure that powder that has not been sintered does not aggregate too firmly, so it is easy to separate from the sintered material (ie in the part or parts) after construction is complete. If the temperature of the sintered area is too high (again, verified by investigation), the applied energy (sintering energy source, upper heaters, heating lamp, volume of radiation absorbing material) can be reduced to reduce the hardness of the powder platform and / or the applied power. Corresponding to the temperatures measured by increasing or decreasing the sintering energy (eg the energy supplied by the laser in laser sintering or by increasing the volume of radiation absorbing material) it is possible to increase the energy applied at some points and at the same time reducing the energy applied elsewhere in the same layer.
[184] The cost of apparatus 11 can be advantageously reduced if an individual pyrometer or series of pyrometers is used instead of an infrared camera. The pyrometers can be calibrated for different materials contained in the construction platform.
[185] Fig. 12 illustrates a flow chart of a method of controlling the energy applied from the radiation source according to various embodiments of the invention. The method illustrated in figure 12 can be implemented by any device that is configured to selectively combine particulate material through sintering. For example, the method can be implemented through a selective laser sintering device, a selective inhibition device, a selective mask device, a sintering device that uses radiation absorbing material and through various devices 11 illustrated in figures 1 to 8. The method illustrated in fig. 12 can be performed with the methods illustrated in figs. 9 and 10 and / or 11 or can be performed independently of the methods illustrated in figs. 9, 10 and 11.
[186] In block 70, the method includes determining the applied energy from a radiation source. For example, one or more sensors 31 may include an infrared measurement sensor that is positioned inside the construction chamber to measure the records of an infrared emitter 12 during construction. The sensor 31 is configured to measure the degradation or other changes in the register of the infrared emitter 12. In block 72, the method includes controlling the energy application of the radiation source 12 in response to the determined energy application. Consequently, the application of the radiation source can be adjusted to the level necessary for the construction in progress. Various sensors 31 can be employed in the event of a drop in the applied energy at any point along the radiation source 12.
[187] The method can then return to block 70 and be repeated.
[188] Fig. 13 illustrates a flow chart of a method of measuring the flow rate of radiation absorbing material according to various embodiments of the invention. The method illustrated in fig. 13 can be used in any device that sinters particulate material using radiation-absorbing material. The method illustrated in fig. 13 can be performed with the methods illustrated in figs. 9 and 10 and / or 11 and / or 12 or can be performed independently of the methods illustrated in figs. 9, 10, 11 and 12.
[189] In block 74, the method includes measuring the flow rate of the radiation absorbing material in a predetermined area. For example, controller 13 can measure the rate of radiation absorbing material by measuring a change in the volume of stored radiation absorbing material (detected by one of the sensors 31).
[190] In block 76, the method includes determining whether the measured radiation absorbent material flow rate falls within a predetermined range. For example, apparatus 11 can provide radiation-absorbing material (at steady state) for an image with a known number of pixels and therefore a known amount of ink (for example, where 1 pixel = 80 picoliters, therefore, 1.25,109 pixels = 0.1 liters of ink). Controller 13 can then determine whether the amount of radiation absorbing material used is within the predetermined range of the calculated amount. If the amount of radiation absorbing material used is outside the predetermined range, controller 13 can control an alarm to alert the user. In addition, if the amount of radiation absorbing material used is outside the predetermined range, controller 13 can change the amount of radiation absorbing material applied later, so that an amount of radiation absorbing material provided later is located within the predetermined range.
[191] The method illustrated in fig. 13 has the advantage of being able to allow the application of a relatively consistent volume of radiation-absorbing material since a user is informed if the apparatus 11 is inconsistent in providing radiation-absorbing material.
[192] Fig. 14 illustrates a perspective view of a support 78 for receiving particulate material according to various embodiments of the invention. Support 78, which can also be called a construction platform, defines a container to receive particulate material intended for sintering (eg that can be deposited from a pendant funnel or can be dragged to support 78 through a material container particulate). The support 78 comprises several walls 80 which are movable relative to the support 78 and within the support 78. Some or all of the walls 80 include one or more heaters 82 intended for heating the particulate material on the support 78. The heaters 82 can be controlled by the controller 3 in response to various sensors that measure the temperature of the particulate material in the holder 78.
[193] It should be noted that, while in fig. 14 the various walls 80 are vertical, the various walls 80 can be found in different orientations in other embodiments.
[194] The support 78 has the advantage that the various walls 80 allow the segmentation of a large construction platform into a series of smaller construction platforms with a more controllable temperature. The inner walls of the construction platform 80 can be moved to different points in order to create construction platforms of different sizes. When displaced, the internal walls of the construction platform 80 fit into plugs (not shown) in order to allow the use of heaters 82 within the walls. The support 78 can also have the advantage of being able to process different particulate materials simultaneously, in different segments of the support 78. In addition, the use of support 78 can increase the throughput of the device 11 without subjecting it to thermal pressures derived from the control relatively large support.
[195] Figs. 15A, 15B, 15C and 15D illustrate side schematic diagrams of devices 84 for providing absorbing radiation material in accordance with various embodiments of the invention; The devices 84 can be used in any apparatus that uses radiation-absorbing material to sinter the particulate material.
[196] Regarding fig. 15A, device 84 includes a first roll 86, a first printhead 88, a first radiation source 90 and a box 92 in which at least partially housed and / or connected the first roll 86, the first printhead 88 and the first radiation source 90. The first printhead 88 is positioned between the first roll 86 and the first radiation source 90. Controller 13 is configured to control the position and movement of device 84 relative to the particulate material deposited on the platform of construction through one or more engines.
[197] The first roller 86 is arranged to distribute particulate material on a construction platform, so that the particulate material forms a substantially level surface. The first printhead 88 is configured to provide the first radiation absorbent material, and may include an associated thermal control device for controlling the temperature of the absorption radiation material. The first radiation source 90 can be any suitable radiation source and can be configured to function as the heater previously described in relation to figures 9 and 10 and also the radiation source that provides radiation for sintering the particulate material. In various embodiments, the first radiation source 90 may include a reflector device 93 that defines an elliptical configuration and is configured to reflect radiation from the first radiation source 90 with a desired pattern.
[198] Concerning Fig. 15B, device 842 is similar to device 84i shown in fig. 15A and whenever the characteristics are similar, the same reference numbers are used. Device 842 differs from device 84i in that it further comprises a second radiation source 94 positioned adjacent to the first roll 86, on the opposite side of the printhead 88.
[199] In some embodiments, the first radiation source 90 is configured to provide radiation for sintering and the second radiation source 94 is configured to function as a heater and heat the particulate material. In other embodiments, the second radiation source 94 can be further configured to provide radiation for sintering in addition to preheating. In other additional embodiments, the first and second radiation sources 90, 94 can both be configured to function as a heater and to preheat the particulate material. The apparatus 11 can thus have greater control of the temperature of the particulate material on the construction platform.
[200] Regarding fig. 15C, device 84s is similar to device 842 shown in fig. 15B and whenever the characteristics are similar the same reference numbers are used. Device 84s differs from device 842 in that it further comprises a second printhead 96, positioned between the second radiation source 94 and the first roll 86. The second printhead 96 can be configured to apply a second radiation absorbing material , which differs from the first radiation absorbing material or can be configured to apply the first radiation absorbing material as well.
[201] With reference to fig. 15D, device 844 is similar to device 842 shown in fig. 15B and whenever the characteristics are similar the same reference numbers are used. Device 844 differs from device 842 in that it further comprises a second roll 98, positioned between the first radiation source 90 and the first printhead 88.
[202] Devices 84a and 844 may have the advantage of being able to allow the application of radiation absorbing material to the layer of particulate material when the devices move along the interior-exterior courses (that is, they can apply radiation absorbing material during the shift between right and left). In particular, device 84 can be advantageous in that it can allow the deposition of particulate material followed by immediate printing followed by immediate sintering from left to right and right to left with only one printhead.
[203] Since the printheads are relatively expensive, the 844 device can be relatively inexpensive as it comprises a single printhead.
[204] Device 84 may also have the advantage that box 92 allows the user to exchange parts (eg the first roll 86, the first printhead 88, the first radiation source 90, the second radiation source 94, the second printhead 96 and the second roll 98) and the sequence of processing steps can also be changed. Users thus enjoy flexibility thanks to the adjustment of the process according to different needs, such as the use of different particulate materials. Part exchange can be achieved by incorporating fittings or other means of fixing components in a variety of arrangements within box 92.
[205] Figs. 16A, 16B, 16C illustrate side schematic diagrams of devices 84 for providing radiation absorbing material according to various embodiments of the invention;
[206] With reference to fig. 16A, device 845 is similar to device 84s and whenever the characteristics are similar, the same reference numbers are used. The device 84s differs from the device 84i in that the first printhead 88 comprises several printheads arranged parallel to the first roll 86. The various printheads are arranged in two vertical columns and there is a space between at least some of the printheads. each column. The first radiation source 90 comprises a single elongated lamp, which is oriented parallel to the first roller 86.
[207] With reference to fig. 16B, device 84e is similar to device 84s and whenever the characteristics are similar the same reference numbers are used. The 84ε device differs from the 84s device in that the first radiation source 90 comprises two elongated lamps, which are arranged in two vertical columns and with an offset from each other so that they overlap in only a portion of their respective lengths . The lamps can be arranged so that they overlap in a region at the end of each lamp where the emitted dust is reduced, so that combined the two lamps provide a more uniform emission of energy than with a single lamp with a reduction in power close the end.
[208] With reference to fig. 16C, device 84 it is similar to 84s and 84Θ devices and whenever the characteristics are similar the same reference numbers are used. Device 84 it differs from devices 84s and 84Θ in that the first radiation source 90 comprises several elongated lamps arranged in two vertical columns and there is a space between at least some of the elongated lamps in each column.
[209] Figs. 17A and 17B illustrate plant schematic diagrams of radiation sources 12, 90, 94 according to various embodiments of the invention. The radiation sources can be used in any sintering apparatus and can also be used in any of the devices 84, illustrated in figs. 15A, 15B, 15C, 15D, 16A, 16Be16C.
[210] With reference to fig. 17A, the radiation source comprises several elongated electromagnetic radiation emitters 100 which are arranged so that they are oriented parallel to each other and overlap substantially over their entire length. Some or all of the elongated electromagnetic radiation emitters 100 can be individually controlled by controller 13 and can be used to preheat particulate material and / or apply radiation to sinter particulate material.
[211] Regarding fig. 17B, the radiation source comprises several emitters of electromagnetic radiation 102, which are arranged in a matrix with seven columns and three rows (it should be noted that the radiation source can have any number of columns and rows in other embodiments) . Some or all of the emitters of electromagnetic radiation 102 can be individually controlled by controller 13 and can be used to preheat particulate material and / or apply radiation to sinter particulate material.
[212] The radiation sources illustrated in figs. 17A and 17B can have the advantage of allowing individual control of the sintering energy applied in different areas of the construction platform if they are controlled through the thermal measurements of a sensor (such as a thermal camera or various thermal measuring devices, such as pyrometers or thermocouples).
[213] In various embodiments, several devices emitting electromagnetic radiation (EMR) can be used without being laser at the radiation source. Each EMR device may have a similar or significantly different peak spectral emission (that is, they may have a similar or significantly different peak wavelength). Based on the spectral emission, each EMR emitting device can be selected either to sinter (directly or indirectly) different particulate materials on the construction platform or to heat any particulate material (s) deposited with the feed (s) and construction platform (s). Multiple EMR emitting devices can be used on the same device. The selection of more than one device thus allows sintering and / or heating of more than one type of particulate material / radiation absorbing material / deposited material.
[214] In various embodiments, the radiation source may include one or more filters to reduce and concentrate the EMR energy in a desired spectral emission / energy density. A range of EMR emitters can be used to create a series of emitters (single or multiple lines) that are individually controlled to sinter or heat specific regions or materials on the powder platform.
[215] The use of printing devices within a sintering apparatus allows for the selective and precise deposition of a radiation-absorbing material on a construction platform. The presence of these printing devices within the process also allows the deposition of other radiation-absorbing materials or, alternatively, the deposit of other materials in the printing region. The use of these printing devices thus allows selective, precise deposition of secondary materials.
[216] For example, a secondary printhead (as in fig. 15C) can be configured to deposit a secondary radiation-absorbing material to sinter different areas on the construction platform.
[217] As an additional example, a secondary printhead can be configured to deposit secondary material that does not significantly enhance sintering with the part layer, but changes local properties in the printed region. These materials can provide additional properties to the sintered parts, such as flame retardancy, UV protection, a change in the visible color of the parts or improvement of the mechanical properties through the addition of fillers. With regard to flame retardancy, the addition of flame retardants includes chlorine, bromine and phosphorus compounds, alumina trihydrate, hydrated magnesium, sulphates and boron. For UV protection, the materials include carbon black, metal oxides. As for cargo, the materials include sawdust, silica flour, clay, powdered mica, short cellulose fibers, grass, carbon black, graphite, talc, metal oxides and asbestos. As for dyes, the materials include organic (dyes) or inorganic (pigments) dyes. The advantage of this approach is that it is only the material that forms the part that will contain the desirable added material, so you can save money compared to adding these additive (s) to the entire material in the machine. It also means that the standard particulate fed material can be modified with all flexibility, from construction to construction or even from part to part or even locally in subsections of a part.
[218] In certain embodiments where a printhead is used, these additional materials may need to be nanoscale to allow projection from the printhead holes. In these embodiments, additional fluid materials (solvents, resins, pigments, colorants, petroleum fractions (hydrocarbons), alcohols, oils, plasticizers, waxes, photoinitiators) can be combined with additives to produce a projectable fluid. These support fluids / materials can be designed either to remain inside the 3D part after printing or to evaporate, leaving only the desired additive in the selected position.
[219] Evaporation can either occur naturally due to localized heat or forced through exposure to a heating device.
[220] In various embodiments, additional materials can be added using an alternative deposition device, such as a funnel that can be controlled by the controller 13 to move across the construction platform, depositing material in the specified regions of a part. The use of a funnel can allow the deposition of larger materials (greater than the nanometer scale) and still negate the need for any additional liquid supports.
[221] The inventors of the present patent application have determined that the visual color of radiation-absorbing material is not significant for the mechanical properties resulting from the three-dimensional piece produced. Consequently, radiation-absorbing materials other than carbon black can be used in the sintering process and it is thus possible to produce white parts in device 11. Color parts (red, green, blue) can be produced in device 11 by combining infrared absorbent pigments with color pigments and colorants (eg red, green and blue). The pigments can be provided in different radiation absorbing materials, they can be combined in the same radiation absorbing material or they may not be found in the radiation absorbing material.
[222] A three-dimensional colored piece can also be produced using a series of colored particulate materials (since the visible color of the particulate material does not necessarily significantly increase the absorption of infrared energy by the particulate material).
[223] The blocks illustrated in figs. 9 to 13 can represent phases in a method and / or sections of code in computer software 133. The illustration of a particular order of the blocks does not necessarily imply that there is a mandatory or preferential order of the blocks and the order and arrangement of the block may vary. In addition, it is possible to omit some blocks.
[224] Although the embodiments of the present invention have been described in the preceding paragraphs with reference to several examples, it should be noted that modifications can be made to the examples without departing from the scope of the invention according to the claims. For example, although the use of infrared radiation has been described, other radiation than infrared radiation can be employed, as long as it has the capacity to raise the temperature of the particulate material to a level that allows the combination by sintering. The radiation source can be of any type, for example, LED, a laser or a halogen source. The particulate material that is combined through the above-described embodiments can be any suitable material, such as metal, ceramic, etc. A device other than the M motor can be used to move the particulate material from the supply tank 40 to the combining device 42. The combining device 42 can have a different configuration than the one shown. Layer 10 can include any number of different types of particulate material. Alternatively, the adjacent layers can include different types of particulate material. The reflective material 18 can be deposited on a lower surface of the substrate 16 instead of an upper surface, as illustrated. Different materials can be used for the reflective material 18 and the substrate 16. Any material suitable for the radiation absorbing material 50 can be used. For example, a liquid suspension and / or a gas, for example, carbon dioxide, can be used. employed instead of a powder material. The digital mirror described in relation to fig. 4 can be replaced by a series of diffractive optical devices, one per layer.
[225] Whenever the term “sintering” is used, it should be taken into account that it includes the total melting of the particulate material.
[226] The features described in the preceding description can be used in combinations other than the combinations explicitly described.
[227] Although functions have been described with reference to certain characteristics, these functions can be performed by other features, described or not.
[228] Although features have been described with reference to certain outputs, these features may also be present in other outputs, described or not.
[229] While trying to draw attention, in the previous specification, to these features of the invention that are thought to be of fundamental importance, it should be borne in mind that the applicant claims protection with respect to any feature or combination of patentable features referred to previously and / or represented in the figures, whether or not particular emphasis was placed on them.

权利要求:
Claims (14)
[0001]
1. Method for selectively combining particulate material, characterized by including: (i) using a particulate material deposition device to provide a layer of particulate material to a construction platform; (ii) providing radiation to sinter a portion of the layer material; (iii) using a particulate material deposition device to provide another overlapping layer of particulate material overlapping the previous layer of particulate material, including the previously sintered portion of material; (iv) providing radiation to sinter another portion of the material within the other overlapping layer and to sinter said other portion with the previously sintered portion of material in the previous layer; (v) successively repeat blocks (iii) and (iv) to form a three-dimensional object; and in which at least some of the layers of the particulate material are preheated with a radiant heater before and independently of sintering a portion of the material of the respective layer, the radiant heater being separated from the particulate material depositing device and configured to move in relation to the particulate material crossing over the construction platform surface, following the particulate material deposition device to transfer heat, by radiation, to the deposited particulate material.
[0002]
2. Method according to claim 1, characterized in that the radiant heater is configured to move within 100 mm of the particulate material.
[0003]
Method according to claim 1 or 2, characterized in that the preheater of at least some of the layers of particulate material with the radiant heater is controlled in order to prevent the underlying particulate material from cooling to a temperature under which it curls .
[0004]
Method according to any one of claims 1 to 3, characterized in that it further comprises measuring a temperature of the particulate material; and controlling the preheating of the layers of particulate material using the measured temperature.
[0005]
Method according to any one of claims 1 to 4, characterized in that the radiant heater emits a range of wavelengths with a peak wavelength that is different from that of a radiation source to provide radiation from the block ( ii) and block (iv).
[0006]
Method according to any one of claims 1 to 5, characterized in that it further comprises: the variation in the absorption of radiation supplied in the block (ii) through a part of the selected surface of the layer to sinter a part of the layer material; and the variation of the absorption of the radiation provided in the block (iv) through a part of the selected surface of another layer to sinter another part of the material within the other superimposed layer and to sinter said other part with the previously sintered part of the material in the previous layer.
[0007]
Method according to claim 6, characterized in that the variation in radiation absorption is obtained by supplying a quantity of radiation absorbing material on the selected surface part of the layer and the other overlapping layer respectively.
[0008]
Method according to claim 6, characterized in that a device comprises a housing that houses: a first print head to provide a first radiation-absorbing material, a roll configured as the particulate material depositing device, and a first radiation source configured to provide radiation from block (ii) and block (iv).
[0009]
Method according to claim 8, characterized in that the device further comprises a second radiation source positioned adjacent the roller, and configured as the radiant heater, in which the second radiation source is housed within the housing.
[0010]
10. Apparatus for selectively combining particulate material, characterized by comprising (i) device for depositing particulate material; a radiation source for sintering particulate matter; a radiant heater for preheating of particulate material, in which the radiant heater is separated from the particulate material deposition device and is configured to move in relation to the particulate material crossing over a surface of a construction platform, following the device of deposition of particulate material to transfer heat, via radiation, to deposited particulate material; and a controller configured to: (ii) control the delivery of a layer of particulate material to the construction platform using the particulate material deposition device; (iii) controlling the radiation supply to sinter a part of the layer material; (iv)) control the supply, to the construction platform, of another overlapping layer of particulate material overlapping the previous layer of particulate material including the previously sintered part of the material using the particulate material deposition device; (v)) controlling the radiation supply to sinter another portion of the material within the other overlapping layer and to sinter said other portion with the portion of material previously sintered in the previous layer; (vi) control the successive repetition of blocks (iii) and (iv) to form a three-dimensional object; and controlling the radiant heater to preheat at least some of the layers of the particulate material before and independently of sintering a part of the material of the respective layer.
[0011]
Apparatus according to claim 10, characterized in that the controller is configured to control: the variation of radiation absorption provided in the block (ii) through a part of the selected surface of the layer to sinter a part of the layer material; and the variation of the absorption of the radiation supplied in the block (iv) through a part of the selected surface of another overlapping layer to sinter another part of the material within the overlap of another layer and to sinter said part with the previously sintered part of the material the previous layer.
[0012]
Apparatus according to claim 11, characterized in that the variation in radiation absorption is obtained by supplying an amount of radiation absorbing material on the selected surface part of the layer and the other superimposed layer respectively.
[0013]
Apparatus according to claim 12, characterized in that it further comprises a device that includes a housing that houses: a first print head for providing a first radiation-absorbing material, a roll configured as the particulate material depositing device, and the radiation source for sintering, and a second radiation source positioned adjacent to the roller and configured as the radiant heater.
[0014]
Apparatus according to any one of claims 10 to 13, characterized in that a common component provides both the radiation source for sintering and the radiant heater, or in which different components provide, respectively, the radiation source for sintering and the radiant heater.

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同族专利:

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公开号 | 公开日

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KR20140050093A|2014-04-28|

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CA2843188A1|2013-02-14|

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JP6784730B2|2020-11-11|

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KR101695300B1|2017-01-12|

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JP2014527481A|2014-10-16|

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JP2019001171A|2019-01-10|

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EP2739457B1|2019-06-19|

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US10933581B2|2021-03-02|

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CN103842157A|2014-06-04|

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ZA201400857B|2015-11-25|

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BR112014002836A2|2017-03-07|

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JP2017105196A|2017-06-15|

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AU2012293491A1|2014-02-27|

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EP3539752A1|2019-09-18|

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US20140314613A1|2014-10-23|

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KR20170007525A|2017-01-18|

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AU2012293491B2|2015-09-03|

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GB2493398A|2013-02-06|

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US20210162658A1|2021-06-03|

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WO2013021173A1|2013-02-14|

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GB201113612D0|2011-09-21|

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CN103842157B|2016-08-17|

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GB2493398B|2016-07-27|

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KR101861531B1|2018-05-28|

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EP2739457A1|2014-06-11|

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CA2843188C|2020-02-04|

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JP6062940B2|2017-01-18|

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法律状态:
2018-03-27| B06F| Objections, documents and/or translations needed after an examination request according [chapter 6.6 patent gazette]|

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2019-09-10| B06U| Preliminary requirement: requests with searches performed by other patent offices: procedure suspended [chapter 6.21 patent gazette]|

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2020-07-07| B09A| Decision: intention to grant [chapter 9.1 patent gazette]|

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2020-11-10| B16A| Patent or certificate of addition of invention granted [chapter 16.1 patent gazette]|Free format text: PRAZO DE VALIDADE: 20 (VINTE) ANOS CONTADOS A PARTIR DE 01/08/2012, OBSERVADAS AS CONDICOES LEGAIS. |

优先权:

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申请号 | 申请日 | 专利标题

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GB1113612.4|2011-08-05|

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GB1113612.4A|GB2493398B|2011-08-05|2011-08-05|Methods and apparatus for selectively combining particulate material|

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PCT/GB2012/051866|WO2013021173A1|2011-08-05|2012-08-01|Methods and apparatus for selectively combining particulate material|

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