GB2518044A - Improved method of additive manufacturing - Google Patents

Improved method of additive manufacturing Download PDF

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Publication number
GB2518044A
GB2518044A GB1411844.2A GB201411844A GB2518044A GB 2518044 A GB2518044 A GB 2518044A GB 201411844 A GB201411844 A GB 201411844A GB 2518044 A GB2518044 A GB 2518044A
Authority
GB
United Kingdom
Prior art keywords
support medium
layer
build platform
powdered material
fused
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Withdrawn
Application number
GB1411844.2A
Other versions
GB201411844D0 (en
Inventor
Robert Neil Burns
Andrew Mark Burns
Darren Travis
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
CROFT FILTERS Ltd
Original Assignee
CROFT FILTERS Ltd
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by CROFT FILTERS Ltd filed Critical CROFT FILTERS Ltd
Publication of GB201411844D0 publication Critical patent/GB201411844D0/en
Publication of GB2518044A publication Critical patent/GB2518044A/en
Withdrawn legal-status Critical Current

Links

Classifications

    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B22—CASTING; POWDER METALLURGY
    • B22F—WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
    • B22F10/00—Additive manufacturing of workpieces or articles from metallic powder
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B22—CASTING; POWDER METALLURGY
    • B22F—WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
    • B22F10/00—Additive manufacturing of workpieces or articles from metallic powder
    • B22F10/20—Direct sintering or melting
    • B22F10/28—Powder bed fusion, e.g. selective laser melting [SLM] or electron beam melting [EBM]
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B22—CASTING; POWDER METALLURGY
    • B22F—WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
    • B22F10/00—Additive manufacturing of workpieces or articles from metallic powder
    • B22F10/40—Structures for supporting workpieces or articles during manufacture and removed afterwards
    • B22F10/43—Structures for supporting workpieces or articles during manufacture and removed afterwards characterised by material
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B22—CASTING; POWDER METALLURGY
    • B22F—WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
    • B22F10/00—Additive manufacturing of workpieces or articles from metallic powder
    • B22F10/40—Structures for supporting workpieces or articles during manufacture and removed afterwards
    • B22F10/47—Structures for supporting workpieces or articles during manufacture and removed afterwards characterised by structural features
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C64/00—Additive manufacturing, i.e. manufacturing of three-dimensional [3D] objects by additive deposition, additive agglomeration or additive layering, e.g. by 3D printing, stereolithography or selective laser sintering
    • B29C64/10—Processes of additive manufacturing
    • B29C64/141—Processes of additive manufacturing using only solid materials
    • B29C64/153—Processes of additive manufacturing using only solid materials using layers of powder being selectively joined, e.g. by selective laser sintering or melting
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C64/00—Additive manufacturing, i.e. manufacturing of three-dimensional [3D] objects by additive deposition, additive agglomeration or additive layering, e.g. by 3D printing, stereolithography or selective laser sintering
    • B29C64/40—Structures for supporting 3D objects during manufacture and intended to be sacrificed after completion thereof
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B33—ADDITIVE MANUFACTURING TECHNOLOGY
    • B33Y—ADDITIVE MANUFACTURING, i.e. MANUFACTURING OF THREE-DIMENSIONAL [3-D] OBJECTS BY ADDITIVE DEPOSITION, ADDITIVE AGGLOMERATION OR ADDITIVE LAYERING, e.g. BY 3-D PRINTING, STEREOLITHOGRAPHY OR SELECTIVE LASER SINTERING
    • B33Y30/00—Apparatus for additive manufacturing; Details thereof or accessories therefor
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B22—CASTING; POWDER METALLURGY
    • B22F—WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
    • B22F2999/00—Aspects linked to processes or compositions used in powder metallurgy
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
    • Y02P—CLIMATE CHANGE MITIGATION TECHNOLOGIES IN THE PRODUCTION OR PROCESSING OF GOODS
    • Y02P10/00—Technologies related to metal processing
    • Y02P10/25—Process efficiency

Abstract

A method of additive manufacturing comprising providing a removable support medium 10 having a number of recesses or openings mounted securely on a build platform 22. Preferably, the support medium may be a woven wire mesh. The method includes depositing a first layer of powdered material 30 into at least some of the recesses; fusing predetermined portions of the first layer of powered material to the support medium; providing a second layer of powdered material and fusing predetermined portions of the second layer to the previously fused portions of the first layer; providing successive layers of powdered material and fusing predetermined portions of each successive layer to previously fused material in order to produce an article; removing the support medium and the article from the build platform; and removing the article(s) from the support medium. The support medium may be reusable or not. In use, preferably none of the powdered material is fused to the build platform; i.e. the article is fused to the support medium rather than the build platform.

Description

IMPROVED METHOD OF ADDITIVE MANUFACTURING
FIELD OF THE INVENTION
This invention relates to an improved method of additive manufacturing.
BACKGROUND TO THE INVENTION
Additive manufacturing (sometimes called "additive fabrication", "additive process", "additive layer manufacturing", layer manufacturing", "freeform fabrication", "3D printing" and "rapid prototyping") is a process for making three-dimensional solid articles from successive layers of material. In some additive is manufacturing methods a thin layer of powdered material is placed onto a build platform and fused into a structure of the desired form by a laser. A subsequent layer of powder is then added and the process repeated to build up the three-dimensional article. The powder may be a metal so that the resulting article is metallic, but other materials may also be used.
In other additive manufacturing methods a molten material is extruded at predetermined locations, the molten material hardening into a layer of the article prior to the extrusion of a subsequent layer of material.
The present invention is directed to those methods which utilise the fusing of a powder and the term "additive manufacturing" will hereafter be used exclusively to refer to such methods.
The build platform is typically a solid sheet of metal. The lowest layer of the article being manufactured by additive manufacturing is fused to the build platform by the laser. It is a necessary step of the additive manufacturing process that the article must be removed from the build platform after it has been manufactured.
Additive manufacturing is used to manufacture robust articles and fragile articles.
With fragile articles in particular, the step of removing the manufactured article from the build platform can damage the article, often irreparably, resulting in the article being scrapped. Care must also be taken to ensure that the build platform is not damaged during removal of the article, as the build platform is required to be re-used for the additive manufacturing of further articles.
SUMMARY OF THE INVENTION
The inventors have sought to reduce or avoid the likelihood of damaging articles which have been manufactured by additive manufacturing, so as to reduce the proportion of articles which have to be scrapped.
According to the invention there is provided a method of additive manufacturing comprising the steps of: providing an additive manufacturing machine having a build platform; providing a support medium having a large number of recesses or openings; mounting the support medium securely upon the build platform; filling at least some of the recesses or openings with a powdered material; fusing predetermined portions of the powered material to the support medium; providing a further layer of powdered material and fusing predetermined portions of the powdered material to the previously fused material; providing successive layers of powdered material and fusing predetermined portions of each layer to previously fused material in order to produce an article or articles; removing the support medium and the article(s) from the build platform; and removing the article(s) from the support medium.
According to the invention, therefore, the article (or articles if the method is used to make more than one article at the same time) is fused to the support medium rather than to the build platform. At the end of the manufacturing process the support medium may be removed from the build platform for subsequent processing (including the removal of the article(s) therefrom).
Since the support medium is not fused to the build platform its removal at the end of the manufacturing process will likely be considerably quicker than removing an article which has been fused to the build platform. The likelihood of damage to the build platform is therefore much reduced or eliminated.
Once the support medium has been removed from the build platform the build io platform can be cleaned ready for the manufacture of further articles. The rate at which articles can be manufactured is therefore increased, as is the utilisation of the additive manufacturing machine.
The retained powder within the article(s) can be removed, perhaps by way of the is openings in the support medium.
Another advantage is that the support medium and the fused article(s) are more readily portable when not attached to the build platform, and so can more easily be transported to the location where the article and support medium are separated. Also, the article and support medium can more easily be manipulated during the separation process.
The support medium may be reusable, but is preferably of sufficiently low cost to be "sacrificial", so that it is not intended to recover and re-use the support medium. It may for example be intended to damage or destroy the support medium during the separation of the article, it being recognised that destroying the support medium is preferable to damaging the article, and may reduce the likelihood that the article is damaged. The cost of a sacrificial support medium is known and can be incorporated into the cost of the article(s),. Also, the additional cost of the support medium is likely to be more than compensated for by the cost saved in reducing the time spent in removing the article(s).
The provision of openings or recesses in the support medium permits the introduction of powered material to be fused to the support medium.
The support medium may have recesses which do not communicate with the build platform. Alternatively the support medium has openings which communicate with the build platform, whereby some of the first layer of powered material lies upon the build platform. It is nevertheless not necessary (or desired) to fuse the powered material to the build platform. Thus, the support medium provides a base upon which the article(s) is(are) manufactured, and the build platform merely io provides a flat surface upon which the support platform is mounted. Importantly therefore, the laser ideally does not fuse any of the powdered material to the build platform, and it is not difficult (or damaging) to remove the article(s) and support medium from the build platform at the end of the manufacturing process. Such a method will therefore minimise the likelihood of damage to the build platform. It is will also minimise the delay between the production of one article and the subsequent production of another article, thereby allowing maximum utilisation of the additive manufacturing machine.
Preferably the support medium is a mesh material, desirably a woven mesh material. In preferred embodiments the support medium comprises a plurality of woven wire strands. A woven mesh made from thin wires provides a very large number of openings for the powdered material.
The first layer of powdered material ideally covers the support medium, with none of the support medium exposed. In the case of a mesh material the mesh will have peaks and troughs, and also openings between the wire strands. The first layer of powdered material will ideally be level with the high points of the mesh, with the powdered material filling the openings between the wire strands, and also lying upon the wire strands in the troughs of the mesh. The additive manufacturing machine can then fuse selected portions of the powder to the adjacent portions of the mesh.
If desired, a substantially continuous layer of fused material and mesh can be provided as the first layer of powdered material is fused. Alternatively, the first layer of powdered material can be fused into a grid of fused material interspersed with unfused material. In any event, the portions where the powdered material is s fused are joined to the other fused portions by the support medium, the fused portions being located at predetermined positions so as to provide a basis for the article(s) to be formed from the subsequent layers of fused material.
BRIEF DESCRIPTION OF THE PREFERRED EMBODIMENTS
The invention will now be described in more detail, by way of example, with reference to the accompanying drawings, which show: is Fig.1 a perspective view of a part of the support medium of the present invention; Fig.2 a side view of the support medium of Fig.1 mounted upon a build platform of an additive manufacturing machine; Fig.3 a perspective view of the support medium and build platform of Fig.2; and Fig.4 a view similar to Fig.2, but showing the addition of a first layer of powdered material.
DETAILED DESCRIPTION
The support medium 10 in the embodiment shown comprises a woven mesh of metal wires 12, 14. In this embodiment the wires 12, 14 are identical, and of steel. In other embodiments the material and dimensions of the wires 12 may differ from the wires 14, for example. Also, each of the wires 12 is substantially parallel to the other wires 12, and substantially perpendicular to the wires 14, but in other embodiments the wires 12 are other than perpendicular to the wires 14.
The mesh 10 comprises a series of peaks 16 and troughs 18, the peaks being at the locations where one of the wires 12, 14 passes over another wire 14, 12, the troughs being at locations where one of the wires 12, 14 passes under another wire 14, 12. Also, between the wires 12, 14 are openings 20.
Figs.2 and 3 show the support medium 10 mounted upon the build platform 22 of io an additive manufacturing machine (not shown). Those skilled in the art will understand that the build platform 22 is a horizontal flat rigid plate. The support medium 10 is secured to the build platform by suitable fastenings (not shown), the securement being such that the support medium 10 is held substantially immovable, and substantially flat.
It will be understood that when the support medium 10 is secured to the build platform 22, respective parts of each of the wires 12, 14 engage the build platform whilst other parts of the wires 12, 14 are held above the build platform. The build platform 22 is visible and accessible through each of the openings 20.
In order to manufacture an article (not shown), the additive manufacturing machine deposits a series of layers of powdered material onto the build platform.
A laser (not shown) is then directed at predetermined portions of the powdered material in order to fuse the portions of powder to the previously fused layers.
In known additive manufacturing machines and methods, portions of the first layer of powdered material are fused to the build platform. In the present invention, however, portions of the first layer of powdered material are fused to the support medium 10.
The first layer of material 30 is shown in Fig.4. The layer 30 is considerably thicker than the first layer of powdered material deposited in the known methods, since it is not necessary to fuse any of the powdered material to the build platform 22. In tact, it is desired not to fuse any of the powdered material 30 to the build platform 22. Thus, notwithstanding that the powdered material 30 will fill up all of the openings 20 as well as the troughs 18, the layer of powdered material 30 is too thick to permit the laser to fuse any of the powder to the build platform 22, and the laser is not directed to do so.
The laser is instead directed to fuse portions of the powdered material 30 to the wires 12, 14 adjacent to the peaks 16 of the mesh. In this embodiment the first layer of powdered material 30 is of a depth d which is equal to the thickness t of io the support medium 10, so that the peaks 16 are level with the top surface of the first layer of powdered material.
In addition, the whole of the top surface of the powdered material 30, i.e. including that overlying the openings 20, can be fused together to form a continuous layer is of fused material adjacent to the level of the peaks 16, and upon which successive layers of the article can be built. Alternatively, only part of the top surface of the powered material 30 may be fused together, so that prior to the deposition of the next layer of powdered material the first layer presents a surface which is partly fused and partly unfused. Whichever of these options is adopted will depend upon the requirements for successive layers of the article(s) which is to be manufactured.
It will be understood that the precise form of the support medium may differ from that shown in the drawings, without departing from the invention. In particular, the support medium may be formed as a grid of material without discrete peaks.
Also, since the powdered material is not fused to the build platform 22 it is not necessary that any of the powdered material engage the build platform. Instead of openings therefore, the support medium may have an array of recesses which can accommodate powdered material but which are each closed at the bottom so that they do not communicate with the build platform.

Claims (15)

  1. CLAIMS1. A method of additive manufacturing comprising the steps of: providing an additive manufacturing machine having a build platform; providing a support medium having a number of recesses or openings; mounting the support medium securely upon the build platform; depositing a first layer of powdered material into at least some of the recesses or openings; fusing predetermined portions of the first layer of powered material to the io support medium; providing a second layer of powdered material and fusing predetermined portions of the second layer to the previously fused portions of the first layer; providing successive layers of powdered material and fusing predetermined portions of each successive layer to previously fused material in order to produce an article; removing the support medium and the article from the build platform; and removing the article(s) from the support medium.
  2. 2. The method according to claim 1 in which the support medium is reusable.
  3. 3. The method according to claim 1 in which the support medium is not reusable.
  4. 4. The method according to any one of claims 1-3 in which the support medium has recesses which do not communicate with the build platform.
  5. 5. The method according to any one of claims 1-3 in which the support medium has openings which communicate with the build platform.
  6. 6. The method according to claim 5 in which none of the first layer of powered material is fused to the build platform.
  7. 7. The method according to claim 5 or claim 6 in which the support medium is a mesh material.
  8. 8. The method according to claim 7 in which the support medium is a woven mesh material.
  9. 9. The method according to claim 8 in which the support medium comprises a plurality of woven wire strands.
  10. 10. The method according to claim 9 in which the wire strands have a number of peaks and a number of troughs, and in which, during the step of depositing the first layer of powdered material, sufficient powdered material is deposited so that the top of the first layer is level with the peaks.
  11. 11. The method according to claim 10 in which the openings are located between adjacent wire strands, and in which, during the step of depositing the first layer of powdered material, the powdered material fills the openings and the troughs.
  12. 12. The method according to any one of claims 1-11 in which, during the step of depositing the first layer of powdered material, sufficient powdered material is deposited so that the first layer of powdered material covers the support medium.
  13. 13. The method according to any one of claims 1-12 in which, during the step of fusing predetermined portions of the first layer of powered material to the support medium, a substantially continuous layer of fused material is provided.
  14. 14. The method according to any one of claims 1-12 in which, during the step of fusing predetermined portions of the first layer of powered material to the support medium, the first layer is fused into a grid of fused material interspersed with unfused material.
  15. 15. The method according to any one of claims 1-14 in which the support medium is made of metal.
GB1411844.2A 2013-07-02 2014-07-02 Improved method of additive manufacturing Withdrawn GB2518044A (en)

Applications Claiming Priority (1)

Application Number Priority Date Filing Date Title
GBGB1311796.5A GB201311796D0 (en) 2013-07-02 2013-07-02 Improved method of additive manufacturing

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GB201411844D0 GB201411844D0 (en) 2014-08-13
GB2518044A true GB2518044A (en) 2015-03-11

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Cited By (5)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
WO2017045542A1 (en) * 2015-09-17 2017-03-23 珠海天威飞马打印耗材有限公司 Three-dimensional printing platform, three-dimensional shaping base, three-dimensional printer and three-dimensional printing method
WO2017196230A1 (en) * 2016-05-09 2017-11-16 Blb Industries Ab A table system for an additive manufacturing machinery for plastic components
NL2017161B1 (en) * 2016-07-13 2018-01-18 Additive Ind Bv Apparatus for producing an object by means of additive manufacturing and method of using the apparatus
WO2018129525A1 (en) * 2017-01-09 2018-07-12 Sabic Global Technologies B.V. Method of making multi-part article
WO2019224016A1 (en) * 2018-05-25 2019-11-28 Sabic Global Technologies B.V. Process for shaping a polymeric object

Citations (1)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
WO2010049696A2 (en) * 2008-10-30 2010-05-06 Mtt Technologies Limited Additive manufacturing apparatus and method

Patent Citations (1)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
WO2010049696A2 (en) * 2008-10-30 2010-05-06 Mtt Technologies Limited Additive manufacturing apparatus and method

Cited By (11)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
WO2017045542A1 (en) * 2015-09-17 2017-03-23 珠海天威飞马打印耗材有限公司 Three-dimensional printing platform, three-dimensional shaping base, three-dimensional printer and three-dimensional printing method
WO2017196230A1 (en) * 2016-05-09 2017-11-16 Blb Industries Ab A table system for an additive manufacturing machinery for plastic components
NL2017161B1 (en) * 2016-07-13 2018-01-18 Additive Ind Bv Apparatus for producing an object by means of additive manufacturing and method of using the apparatus
WO2018012974A1 (en) 2016-07-13 2018-01-18 Additive Industries B.V. Apparatus for producing an object by means of additive manufacturing and method of using the apparatus
CN109689252A (en) * 2016-07-13 2019-04-26 添加剂工业有限公司 For the equipment by increasing material manufacturing next life product body and the method using the equipment
JP2019521023A (en) * 2016-07-13 2019-07-25 アディティブ インダストリーズ ビー．ブイ． Device for manufacturing an object by additive manufacturing and method of using the device
US11192208B2 (en) 2016-07-13 2021-12-07 Additive Industries B.V. Apparatus for producing an object by means of additive manufacturing and method of using the apparatus
WO2018129525A1 (en) * 2017-01-09 2018-07-12 Sabic Global Technologies B.V. Method of making multi-part article
WO2019224016A1 (en) * 2018-05-25 2019-11-28 Sabic Global Technologies B.V. Process for shaping a polymeric object
US20210129428A1 (en) * 2018-05-25 2021-05-06 Sabic Global Technologies B.V. Process for shaping a polymeric object
US11919232B2 (en) * 2018-05-25 2024-03-05 Sabic Global Technologies B.V. Process for shaping a polymeric object

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Publication number Publication date
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