CN1347783A - Method and apparatus for producing three-dimensional objects - Google Patents

Method and apparatus for producing three-dimensional objects Download PDF

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Publication number
CN1347783A
CN1347783A CN01141161A CN01141161A CN1347783A CN 1347783 A CN1347783 A CN 1347783A CN 01141161 A CN01141161 A CN 01141161A CN 01141161 A CN01141161 A CN 01141161A CN 1347783 A CN1347783 A CN 1347783A
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Prior art keywords
layer
sinter
sinter layer
base portion
powder
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CN1283413C (en
Inventor
阿部谕
吉田德雄
东喜万
峠山裕彦
不破勋
上永修士
待田精造
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Panasonic Electric Works Co Ltd
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Matsushita Electric Works Ltd
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    • 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
    • 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
    • B22F10/25—Direct deposition of metal particles, e.g. direct metal deposition [DMD] or laser engineered net shaping [LENS]
    • 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
    • B22F10/30—Process control
    • B22F10/36—Process control of energy beam parameters
    • B22F10/364—Process control of energy beam parameters for post-heating, e.g. remelting
    • 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
    • B22F10/60—Treatment of workpieces or articles after build-up
    • B22F10/66—Treatment of workpieces or articles after build-up by mechanical means
    • 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
    • B22F3/00—Manufacture of workpieces or articles from metallic powder characterised by the manner of compacting or sintering; Apparatus specially adapted therefor ; Presses and furnaces
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B33—ADDITIVE MANUFACTURING TECHNOLOGY
    • B33Y—ADDITIVE MANUFACTURING, i.e. MANUFACTURING OF THREE-DIMENSIONAL [3-D] OBJECTS BY ADDITIVE DEPOSITION, ADDITIVE AGGLOMERATION OR ADDITIVE LAYERING, e.g. BY 3-D PRINTING, STEREOLITHOGRAPHY OR SELECTIVE LASER SINTERING
    • B33Y10/00—Processes of additive manufacturing
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B22—CASTING; POWDER METALLURGY
    • B22F—WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
    • B22F12/00—Apparatus or devices specially adapted for additive manufacturing; Auxiliary means for additive manufacturing; Combinations of additive manufacturing apparatus or devices with other processing apparatus or devices
    • B22F12/40—Radiation means
    • B22F12/44—Radiation means characterised by the configuration of the radiation means
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B22—CASTING; POWDER METALLURGY
    • B22F—WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
    • B22F12/00—Apparatus or devices specially adapted for additive manufacturing; Auxiliary means for additive manufacturing; Combinations of additive manufacturing apparatus or devices with other processing apparatus or devices
    • B22F12/40—Radiation means
    • B22F12/49—Scanners
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B22—CASTING; POWDER METALLURGY
    • B22F—WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
    • B22F12/00—Apparatus or devices specially adapted for additive manufacturing; Auxiliary means for additive manufacturing; Combinations of additive manufacturing apparatus or devices with other processing apparatus or devices
    • B22F12/80—Plants, production lines or modules
    • B22F12/82—Combination of additive manufacturing apparatus or devices with other processing apparatus or devices
    • B22F12/86—Serial processing with multiple devices grouped
    • 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
    • B22F3/00—Manufacture of workpieces or articles from metallic powder characterised by the manner of compacting or sintering; Apparatus specially adapted therefor ; Presses and furnaces
    • B22F3/24—After-treatment of workpieces or articles
    • B22F2003/247—Removing material: carving, cleaning, grinding, hobbing, honing, lapping, polishing, milling, shaving, skiving, turning the surface
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B22—CASTING; POWDER METALLURGY
    • B22F—WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
    • B22F2998/00—Supplementary information concerning processes or compositions relating to powder metallurgy
    • 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

To make a three-dimensional object, an optical beam is first irradiated on a predetermined portion of a powder layer to form a sintered layer, which is then covered with a new powder layer. The optical beam is again irradiated on a predetermined portion of the new powder layer to form another sintered layer that has been united with the underlying sintered layer. These processes are repeatedly carried out to form a plurality of sintered layers united together, which have a size greater than that of a target shape of the three-dimensional object. A surface region of a shaped object formed by then is removed during the formation of the plurality of sintered layers.

Description

Make the method and the device of three-dimensional body
Technical field
The present invention relates to make the method and the device of three-dimensional body, it uses light beam sintering and hardening powder material to obtain target object.
Background technology
Japan Patent No.2620353 discloses a kind of method of making three-dimensional body, is called photograph setting method (photo-shaping).According to this patent, shown in Figure 21 A, light beam L at first is radiated on the predetermined position of one deck dusty material to form a sinter layer 11, and described dusty material can be an organic substance, also can be inorganic substances.The sinter layer 11 of Huo Deing has been capped the new dusty material of one deck then, and light beam L is radiated on the predetermined position of new layer to form a new sinter layer 11, and it will combine with following surface layer 11.Repeat these processes, many sinter layers 11 are stacked from level to level securely, form sintered article or three-dimensional body.According to this method, the model of the design data (data of CAD) of three-dimensional body is cut into the thin slice of desired thickness, make the irradiation that is used for guiding light beam L based on the segmented data of each layer that obtains.Therefore, do not have computer-aided manufacturing equipment, above mentioned method also can be used for making the three-dimensional body of arbitrary shape, and with respect to the method for using cutting operation, it can more promptly obtain the object of any required form.
Yet, shown in Figure 21 A,,, therefore will on shaped-article, form a low-density superficial layer 16 because wherein the heat transmission that produces can make unnecessary powder 15 stick on sintering and the sclerosis position according to this method.
Japanese Laid-Open Patent Application (uncensored) No.2000-73108 discloses the outside stair-stepping, that be overrided to form by sinter layer 11 shown in Figure 21 B has been removed.Yet shown in Figure 21 C, even removed stair-stepping outside, low-density superficial layer 16 still is being retained, and can therefore can't obtain smooth outer surface.
In addition, remove non-sintered layer and can in sintering process, have enough density (for example porosity is less than 5%), even otherwise after removing the outside,, remove stair-stepping outside and can't produce the smooth exterior surface face because the sinter layer surface still has micropore.
After being shaped, shaped-article being carried out fine finishining can the finisher of being determined by the profile of shaped-article be limited to some extent equally to remove low-density superficial layer.For example, because the instrument of minor diameter is restricted, can't cut darker and narrower groove relatively sometimes on length.In this case, need additional discharge processing, but the problem of this meeting generation time and cost aspect.
In addition, owing to adopt powder sintering to make whole three-dimensional body, or owing to adopt each powder bed of laser beam sintering, therefore the shape according to three-dimensional body to be made spends a large amount of time sometimes.
Summary of the invention
The present invention is used to overcome above-mentioned shortcoming.
An object of the present invention is to provide a kind of improved method and apparatus, it can make three-dimensional body at short notice.
Another object of the present invention provides a kind of method and apparatus of the above-mentioned type, and it can qurer, this body surface of fine finishining glossily, and irrelevant with its shape.
In order to finish the above and other purpose, method of the present invention comprise the following steps: (a) with a light beam irradiates on the predetermined position of a powder bed, form a sinter layer; (b) cover this sinter layer with new powder bed; (c) with light beam irradiates on the predetermined position of new powder bed, form another sinter layer that combines with following sinter layer; (d) repeating step (b) and (c) forms a plurality of sinter layers that combine, and their size is greater than the size of the target shape of three-dimensional body; And the surf zone of (e) removing the shaped-article that in step (d), forms.
Owing in the process of step (d), carried out step (e), can make the fine finishining of body surface can not be subjected to the restriction of fine finishining machine size, for example length of drill bit or similar factor.
Method of the present invention is placed on a base portion on the sintering platform at preceding also comprise the following steps: (a1) of step (a), and this base portion will constitute the substructure of three-dimensional body; (a2) process this base portion; And the position of (a3) the base portion alignment being shone.
The setting of base portion will need not to form and sintering is equivalent to the powder bed of the some of base portion thickness, can reduce so far through a plurality of sintering processing to make the required time of three-dimensional body.The setting of base portion has effective equally than the three-dimensional body of the narrow trenches of high-aspect-ratio for making.
In step (a1) before, the processing base portion required time many sinter layer required times the same with formation and base shape are compared, the required time be shorter than the latter, then should make base portion if can determine the former.
If base portion has a recess that wherein forms some sinter layers or forms the plane of sinter layer of the end on it, can increase the bond strength between base portion and the sinter layer.
Preferably, the thickness of removed surf zone is greater than the thickness that sticks to the low-density superficial layer that dusty material produced on the sinter layer.This way fine finishining object surfaces smoothly.
Can expose sinter layer if remove surf zone, the superficial density of this exposure is with higher, and therefore meeting become level and smooth.
The preferred approach that surf zone is removed in cutting is, light beam irradiates waited to remove on the position so that it is softening in that step (e) is preceding.The irradiation of light beam will reduce cutting force, can reduce the cutting time and prolong service life of cutting element.
Available laser removes surf zone.
Advantageously, after step (e) with light beam irradiates on the part of the shaped-article of removing surf zone, increase the density of this part by this.
Advantageously another, in the process of step (e), remove sinter layer not sintered powder or the removal smear metal that surf zone produced on every side.This way can make the new powder bed that after this forms can not be subjected to the adverse effect of these smear metals.
(e) is preceding in step, can remove sinter layer not sintered powder on every side.In this case, do not sneak into not sintered powder, therefore can reuse not sintered powder owing to do not have smear metal.
After step (e), resin or wax are inserted in the space of removing sintered powder not or smear metal.Powder quantity when using resin or wax to reduce to form subsequently a new powder bed.
(e) is preceding in step, and available freezing method or use resin or wax solidify not sintered powder.In this case, need not to insert again dusty material, only need remove smear metal simply and get final product.
On the other hand, the inventive system comprises: a powder bed that is used to form powder bed forms the sinter layer that parts, are used to form sinter layer and forms parts, it with light beam irradiates on the predetermined position of powder bed, one be used to regulate range adjuster and that described sinter layer forms the distance between parts and the sinter layer and be used to remove the superficial layer removing component of superficial layer that density is lower than the density of sinter layer.
The device of above-mentioned structure helps to improve the quality of body surface.
This device can comprise that also one forms the discharge member of parts near described powder bed, and it can be used for discharging the smear metal that sintered powder not or superficial layer removing component produce.This discharge member can prevent that new powder bed is subjected to the adverse effect of smear metal.
This discharge member can have an actuator, and it can move discharge member along the outline line on each plane to be formed.
Description of drawings
Below in conjunction with accompanying drawing preferred embodiment is described, this will make above-mentioned and other purpose of the present invention and feature more clear, and identical label indicates identical part all the time, wherein:
Fig. 1 shows the stereogram of device of the making three-dimensional body of the first embodiment of the present invention;
Fig. 2 shows the front view of creating three-dimensional body;
Fig. 3 is a data flow of representing how to make three-dimensional body;
Fig. 4 shows the front view of the model with high density surface zone;
Fig. 5 A is the vertical sectional view of many sinter layers;
Fig. 5 B is after removing surf zone, the vertical sectional view of many sinter layers;
Fig. 6 A is the vertical sectional view with shaped-article of identical unnecessary thickness;
Fig. 6 B is the schematic diagram similar to Fig. 6 A, has described another shaped-article with different unnecessary thickness;
Fig. 7 is the schematic diagram similar to Fig. 6 A, has described the vertical interval of cutting when target object has mild slope;
The stereogram of the shaped-article when Fig. 8 is a part of object before light beam irradiates is being located in cutting element;
Fig. 9 is similar to Fig. 8, is the stereogram on the part of light beam irradiates after instrument passes through the time;
Figure 10 shows device shown in Figure 1 through amended stereogram;
Figure 11 shows device shown in Figure 1 through another amended stereogram;
Figure 12 A shows the front view of being located at the suction nozzle on the above-mentioned shaped-article;
Figure 12 B shows the front view of being located at another suction nozzle on the above-mentioned shaped-article;
Figure 13 A shows the front view of the suction nozzle that communicates with powder container;
Figure 13 B is similar to Figure 13 A, is the front view at the suction nozzle that communicates with the smear metal container;
The vertical sectional view of shaped-article when Figure 14 A shows resin or wax inserted the space of removing sintered powder not;
Figure 14 B is similar to Figure 14 A, is the schematic diagram when forming new powder bed on the shaped-article of Figure 14 A;
Figure 14 C is the schematic diagram similar to Figure 14 A, but has described the not situation of sintered powder cryocoagulation;
Figure 15 shows and is installed on the actuator to drive the front view of the suction nozzle of smoothing blade;
Figure 16 A is mounted in the stereogram of the special-purpose suction nozzle on the XY actuator;
Figure 16 B is the schematic diagram similar to Figure 16 A, has described the suction nozzle on the XY actuator that is installed in the superficial layer removing component;
Figure 17 shows the stereogram of device of the making three-dimensional body of the second embodiment of the present invention;
Figure 18 A to 18D shows how description forms many sinter layers on base portion front view;
Figure 19 is the plan view from above of base portion when needing the position of the actual irradiation of position alignment light beam of light beam irradiates;
Figure 20 shows the front view of a three-dimensional body example;
Figure 21 A is the vertical sectional view of many sinter layers, has described it and has adhered to the state of unnecessary powder;
Figure 21 B is the vertical sectional view with many sinter layers of stepped outside; And
Figure 21 C is after removing stepped outside, the vertical sectional view of many sinter layers.
The specific embodiment
The application is respectively based on Japanese No.2000-306546 that applies on October 5th, 2000 and the application text that applies for the Japanese No.2001-192121 in June 26 calendar year 2001, and the full content that hereinafter will quote them as a reference.
Please refer to accompanying drawing now, shown in Fig. 1 is the device of the making three-dimensional body of the first embodiment of the present invention.Shown device comprises that a powder bed that is used to form powder bed 10 forms the sinter layer that parts 2, are used to form sinter layer 11 and forms the superficial layer removing component 4 that parts 3 and are used to remove the low-density superficial layer.Supplying organic or inorganic powder material on the vertical sintering platform 20 that moves in the space that cylinder surrounds, using smoothing blade 21 with the dusty material smoothing, can make powder bed form parts 2 formation desired thicknesses is the powder bed 10 of Δ t1.Actuator 5 orders about sintering platform 20 and moves up and down.The laser that laser beam generator 30 sends is radiated on the powder bed 10 by scanning optics, makes sinter layer form parts 3 and forms sinter layer 11, and described scanning optics comprises deflecting plates 31 and similar device.One laser oscillator can be preferably as laser beam generator 30.Superficial layer removing component 4 comprises that one is installed in XY actuator 40 and on its base portion and is installed in fine finishining machine 41 on the XY actuator 40.Preferable XY actuator 40 can use a linear motor to come high-speed driving.Can be with a current mirror preferably as deflecting plates 31.One cutter (such as end mill bed or drilling machine) thereby, laser beam generator or by blow facing to object sintered powder relatively the object sand-blasting machine that carries out plastic working can preferably be used as fine finishining machine 41.An available polar coordinates actuator replaces XY actuator 40.
Fig. 2 has described how to use device making three-dimensional body above-mentioned.As shown in the figure, the organic or inorganic dusty material at first is applied on the base portion 22 that is installed on the sintering platform 20, and described sintering platform can be used as regulates the range adjuster that sinter layer forms the distance between parts 3 and the sinter layer.Then, smoothing blade 21 will be applied to the dusty material smoothing on the base portion 22, forming on the desired area that first powder bed, 10, one light beams (laser beam) L is radiated at first powder bed 10 with its sintering, thereby the sinter layer 11 that combines with base portion 22 of formation.
After this, sintering platform 20 has been lowered a predetermined length and has applied dusty material once more and with smoothing blade 21 with its smoothing, to form second powder bed 10.Light beam L is radiated on the desired area of second powder bed 10 once more with its sintering, thereby another sinter layer 11 of combining with following sinter layer 11 of formation.
Carry out reducing the back repeatedly and form the process of a new powder bed 10 and desired area that light beam L is radiated at new powder bed 10, make three-dimensional body by this to form the process of new sinter layer 11 at the sintering platform.Have generally average diameter be about 20 microns spheric iron particle powder can be preferably as dusty material, carbon dioxide laser can be preferably as light beam.The preferred thickness Δ t1 of each powder bed 10 is about 0.05 millimeter.
Fig. 3 has schematically described a data flow example of the present invention.This data flow makes desirable three-dimensional computer aided design models that two kinds of data be arranged, a kind of path of data representation laser irradiation, the path of another kind of data representation cutting.From the data of the auxiliary design of three-dimensional computer, design these paths in advance, so that desired shapes to be shown.
The path of laser irradiation is identical with traditional manufacturing process basically, and wherein the outline data that the STL data that produce from the three-dimensional computer aided design models is carried out resulting each part of layering (slicing) with equidistant (being 0.05 millimeter in the present embodiment) defines target shape.Outline data is added that laser irradiation condition (sweep speed, spot diameter, power and conditions of similarity) to produce new data, makes them pass to the fine finishining process again.
Factors such as the diameter of the machining tool that the cutting path that is obtained uses in considering that three-dimensional computer is auxiliary and making, kind, feed speed, rotary speed.The data of representing this path also will be delivered to the fine finishining process.
Use the data of expression laser exposure pathways in the laser sintered process, then use the data of expression cutting path in the high-speed machining process.Carry out these two processes repeatedly to finish target object.
Preferably guide the irradiation of light beam so that be sintered to high density (for example porosity is less than 5%) to the surf zone of major general's three-dimensional body.This reason is: even if superficial layer removing component 4 is removed superficial layer, if surf zone density is lower, the surface of exposing after the surface removal processing remains loose.Therefore, as shown in Figure 4, model data is divided into surf zone S and interior zone N two parts, and light beam shines under following state: interior zone N is for what loosen, and surf zone S becomes high density under the situation that most of dusty material is melted.
In Fig. 5 A, label 12 expression high-density regions, label 16 expression low-density superficial layers, as discussed above, the low-density superficial layer is that the adhesion by dusty material produces.The density that is positioned at the inside of high-density region 12 the insides is lower than the density of high-density region 12, but is higher than the density of low-density superficial layer 16.
In the forming process of many sinter layers 11, for example when its gross thickness reached the particular value that the tool length of milling head 41 is scheduled to, superficial layer removing component 4 began to cut the surface of the three-dimensional body that had been shaped at that time.For example, the cutter of milling head 41 (ball end milling cutter) diameter is 1 millimeter, and effectively blade lengths is 3 millimeters, and they can finish the degree of depth is 3 millimeters cutting.Therefore, if the thickness deltat t1 of powder bed 10 is 0.05 millimeter, when forming 60 layers of sinter layer 11, can make superficial layer removing component 4 begin to drive.
As Fig. 5 A, this superficial layer removing component 4 can be removed the low-density superficial layer 16 that surface produced of powder adherence at shaped-article, simultaneously can cut away a part of high-density region 12, high-density region 12 is exposed at outside the whole surface of shaped-article, shown in Fig. 5 B.For this reason, the geomery of sinter layer 11 is slightly larger than ideal form M.
By example, when shining under the condition given below along the light beam L of desirable outline line, the horizontal size of each sinter layer 11 (width) can reach about 0.3 millimeter, greater than the horizontal size of ideal form M.
Laser power: 200 watts
Laser spot diameter: 0.6 millimeter
Sweep speed: 50 mm/second
Unnecessary thickness on the vertical direction can equal or be different from the unnecessary thickness on the horizontal direction.The initial data of revising the vertical dimension of expression ideal form M can obtain the vertical dimension of the profile of sinter layer 11.
Fig. 6 A described the unnecessary thickness on the horizontal direction basically with vertical direction on unnecessary thickness identical situation, and Fig. 6 B has described the situation that the unnecessary thickness on the horizontal direction is different from the unnecessary thickness on the vertical direction.In Fig. 6 A and 6B, dotted line is represented the shape of sinter layer 11, and solid line is represented ideal form M.
As previously mentioned, cutting path and laser exposure pathways are determined by the data of the auxiliary design of three-dimensional computer.Although can determine cutting path based on so-called outline line processing method, the vertical interval of cutting path always do not require with sintering process in to laminate spacing identical.As shown in Figure 7, if target object has mild slope, just can reduce vertical interval to obtain level and smooth surface.
Using diameter is under 1 millimeter the ball end milling cutter situation of cutting, preferably cutting depth, feed speed and the rotary speed of instrument is set in respectively 0.1-0.5 millimeter, 5-50 rice/minute and 20,000-100,000 rev/min.
Cutting will be carried out in mode shown in Figure 8.Light beam (laser beam) the L irradiation and the heating that especially will have less energy density are located in instrument 44 preceding object parts so that the former the softening latter.Cut softening part to reduce cutting force with instrument 44, can reduce the service life of cutting time and prolongation instrument 44.
Also as shown in Figure 9, light beam L can shine just on instrument 44 warps part later.This way is fusible and solidify or this part of heat treatment, thereby increases its density.
Figure 10 has described the modification of device shown in Figure 1.Device shown in Figure 10 comprises that one is installed in the irradiation head 35 on the XY actuator 40 of superficial layer removing component 4, and it forms light beam that the laser beam generator 30 of parts 3 receive with output from sinter layer by an optical fiber 36.This is configured with the quantity that helps reduce part.
Figure 11 has described another modification of device shown in Figure 1.Device shown in Figure 11 comprises that one is positioned at a near suction nozzle 51 and the air pump 50 that links to each other with suction nozzle 51 the fine finishining machine 41.Suction nozzle 51 as tapping equipment is used for and will emits with produced simultaneously not sintered powder of cutting or smear metal.Because not only sintered powder or smear metal meeting do not stop the removal operation of superficial layer removing component 4, and smear metal is once in a while can be by smoothing blade 21 entrained and hinder smoothing blade 21 to form smooth powder beds 10, so the setting of suction nozzle 51 is highly effective.Smear metal is sandwiched between smoothing blade 21 and the shaped-article, can make smoothing blade 21 be stuck in this place once in a while.
Figure 12 A has described and has been arranged side by side the suction nozzle 51 that connects air pump 50 and the situation of milling head 41, and Figure 12 B has described the situation that suction nozzle 51 and milling head 41 are set with one heart.In both cases, suction nozzle 51 all abut against milling head 41 near.
Shown in Figure 13 A and 13B, suction nozzle 51 can be designed to selectively communicate with powder container 52 or smear metal container 53.In this case, suction nozzle 51 is passed to mutually with powder container 52 before cutting guide not sintered powder, and be that suction nozzle 51 passes to directs chips mutually with smear metal container 52 in cutting.This way can not make smear metal sneak into not sintered powder, so that reuse not sintered powder.
Meanwhile, if sintered powder is not inhaled into mouth 51 and removes, after removing not sintered powder, will need a large amount of powder on the sinter layer (or multilayer) 11 so to form new powder bed 10.Repeatedly remove repeatedly under the situation of the process of sintered powder not, before each sintering, powder must be inserted whole spaces of the not sintered powder of having removed, cause losing the plenty of time.
In order to address this problem, resin or wax can be filled up these spaces, shown in Figure 14 A, they will be solidified with formation solidifies part 18.As shown in Figure 14B, in this case, at uppermost sinter layer 11 with solidify and form next powder bed 10 on the part 18, make it can reduce the quantity of required powder and prevent that smear metal from sneaking into not in the sintered powder.
Perhaps, shown in Figure 14 C, sintered powder can not solidify with freezing method, for example blows out liquid nitrogen from nozzle 54.If necessary, containing wetly gas can use jointly with liquid nitrogen.
Although in the above-described embodiments, superficial layer removing component 4 is used a cutting instrument, also can use superpower laser.By example, one has peak power output can remove low-density superficial layer 16 greater than 10 kilowatts Q-switch YAG laser instrument (Q-switch YAG laser) apace by it is evaporated immediately.In addition, be removed part and be not limited to low-density superficial layer 16.Or even depend on target object shape produced, originally unnecessary part also can be removed.
As shown in figure 15, preferably suction nozzle 51 can be installed on the actuator, this actuator can be used to drive the smoothing blade 21 that powder bed forms parts 2.This structure does not need to use any driving mechanism that is specifically designed to suction nozzle 51, but the structure of simplification device.
On the other hand, shown in Figure 16 A, suction nozzle 51 can be installed on the special-purpose XY actuator 55, perhaps shown in Figure 16 B, is installed on the XY actuator 40 of superficial layer removing component 4.XY actuator 40 or 55 is designed to the suction nozzle that moves previously 51 at fine finishining machine 41, and moves suction nozzle 51, make suction nozzle 51 siphon away not sintered powder around the sinter layer (or multilayer) 11 along the outline line on each plane to be formed.This structure can prevent superficial layer removing component 4 not sintered powder clamp, can obtain the surface of high precision.
Figure 17 has described the device that is used for making three-dimensional body of the second embodiment of the present invention.Device shown in it comprises that a powder bed that is used to form a powder bed 10 forms the sinter layer that parts 2, are used to form sinter layer 11 and forms the superficial layer removing component 4 that parts 3 and are used to remove the low-density superficial layer.Apply organic or the inorganic powder material on the vertical mobile sintering platform 20 in the space that a cylinder centers on, use smoothing blade 21 with the dusty material smoothing, can make powder bed form parts 2 formation desired thicknesses is the powder bed 10 of Δ t1.Actuator 5 orders about sintering platform 20 and moves up and down.The laser that laser beam generator 30 sends is radiated on the powder bed 10 by scanning optics, makes sinter layer form parts 3 and forms sinter layer 11, and described scanning fibre system comprises deflecting plates 31 and similar device.Superficial layer removing component 4 comprises XY actuator 40 that is installed on its base portion and the fine finishining machine 41 that is installed on the XY actuator.Device shown in Figure 17 comprises that further one is used to control the controller 60 of above-mentioned parts and equipment, comprises that also one has the alignment member 62 of camera 64, and this camera can obtain the view data on the sintering platform 20, and controller 60 can carry out alignment procedure.
State device in the use and make in the process of three-dimensional body of ideal form, at first form a base portion 22 with shape, this shape is corresponding to whole substructure or its a part of structure of three-dimensional body.Base portion 22 can be any material that can combine with the sinter layer of formation on it.
Shown in Figure 18 A, base portion 22 places on the sintering platform 20, carries out required machined as requested by fine finishining machine 41.Data based on the shape after the expression machined are carried out this machined, in advance predetermined condition are added on the computer-aided design data of three-dimensional body, can obtain described data.
Shown in Figure 18 B, after processing, connect camera 64, by obtaining its view data and survey the outline line seen from the top to determine the position of the base portion 22 on the sintering platform 20, make the laser irradiation the position can with the surface of base portion 22 on will begin the position consistency of sintering.After this, the light beam L with less energy density marks on the surface of base portion 22, and camera 64 can obtain the view data of mark position.At this moment, as shown in figure 19, if light beam L wishes the position B of the actual irradiation of position A off-beams L of shining with respect to base portion 22, controller 60 will be realized the deviation between the coordinate of the coordinate of this base portion 22 and light beam irradiates system, and be proofreaied and correct.
Shown in Figure 18 C, finishing in the above-mentioned aligning, on sintering platform 20, apply dusty material, this dusty material is smoothed blade 21 smoothings, to form the powder bed 10 that a thickness is Δ t1.Then, light beam L shines powder bed 10, in order to the sintering desired zone.After the sintering of the formation of carrying out powder bed 10 repeatedly and light beam L, can obtain the superstructure that the substructure made by base portion 22 and many sinter layers 11 are overrided to form mutually, shown in Figure 18 D.
The setting of base portion 22 will no longer need to laminate and sintering is equivalent to the powder bed 10 of the some of base portion 22 thickness, and this time-consuming job can be exempted.
Form the required time of many sinter layers identical with base portion 22 shapes 11 if the 22 required times of machined base portion are longer than, then the setting of base portion 22 will cause increasing the time of making three-dimensional body.Therefore, with the process of the base portion 22 of analog machine processing in advance and the process of formation sinter layer 11,, can use base portion 22 if the former required time is shorter than latter's required time.
The use of base portion 22 further is discussed according to structure as shown in figure 20.
Only when the required time of portion C of making this structure of machined was shorter than stacked multi-layer sintering layer 11 and makes required time of portion C, the structure of Figure 20 just can be used as base portion 22.On the contrary, be longer than the stacked 11 making required time of portion C of multi-layer sintering layer, will carry out machined does not have portion C with formation base portion 22 part D if make the required time of portion C with machined.
Although by way of example the present invention is carried out detailed narration in conjunction with the accompanying drawings, have multiple variation and modification yet should be noted in the discussion above that person skilled in the art will know.Therefore, unless these variations and modification have broken away from the spirit and scope of the present invention, all they can be interpreted as being included among the present invention.

Claims (18)

1. method of making three-dimensional body, it comprises the following steps:
(a) with a light beam irradiates on the predetermined position of a powder bed, form a sinter layer;
(b) cover this sinter layer with new powder bed;
(c) with light beam irradiates on the predetermined position of new powder bed, form another sinter layer that combines with following sinter layer;
(d) repeating step (b) and (c) to form a plurality of sinter layers that combine, their size is greater than the size of the target shape of three-dimensional body; And
(e) surf zone of removal shaped-article of formation in step (d).
2. the method for claim 1 is characterized in that, also comprises the following steps: in that step (a) is preceding
(a1) base portion is placed on the sintering platform, described base portion will constitute the substructure of three-dimensional body;
(a2) process this base portion; And
(a3) position that the base portion alignment is shone.
3. method as claimed in claim 2 is characterized in that, also comprises the following steps: in that step (a1) is preceding
The many sinter layers required time identical with base shape with the formation time that the machined base portion is required compares; And
The required time be shorter than the latter if can determine the former, then should make base portion.
4. the method for claim 1 is characterized in that, the thickness of removed surf zone is greater than the thickness that sticks to the superficial layer that dusty material produced on the sinter layer, and the density of this superficial layer is lower than sinter layer.
5. method as claimed in claim 4 is characterized in that, removes surf zone and will expose sinter layer.
6. the method for claim 1 is characterized in that, removes surf zone with the method for cutting.
7. the method for claim 1 is characterized in that, uses the laser ablation surf zone.
8. the method for claim 1 is characterized in that, in the preceding step that also comprises of step (e): with light beam irradiates on position to be removed, with softening this position.
9. the method for claim 1 is characterized in that, also comprises step after step (e): light beam irradiates has been removed on the position of surf zone at shaped-article, thereby can have been increased the density of this part.
10. the method for claim 1 is characterized in that, removes sinter layer not sintered powder or the removal smear metal that surf zone produced on every side in the process of step (e).
11. the method for claim 1 is characterized in that, in the preceding step that also comprises of step (e): remove the not sintered powder around the sinter layer.
12. method as claimed in claim 10 is characterized in that, also comprises step after step (e): resin or wax are inserted the space of removing sintered powder not or smear metal.
13. the method for claim 1 is characterized in that, in the preceding step that also comprises of step (e): solidify not sintered powder.
14. method as claimed in claim 13 is characterized in that, solidifies not sintered powder with freezing method.
15. method as claimed in claim 13 is characterized in that, uses resin or wax to solidify not sintered powder.
16. a device of making three-dimensional body comprises:
One powder bed that is used to form powder bed forms parts;
One sinter layer that is used to form sinter layer forms parts, it with light beam irradiates on the predetermined position of powder bed;
One is used to regulate the range adjuster that described sinter layer forms distance between parts and the sinter layer; And
One is used to remove the superficial layer removing component of superficial layer that density is lower than the density of sinter layer.
17. device as claimed in claim 16 is characterized in that, comprises that also one forms the discharge member of parts near described powder bed, it can be used for discharging the smear metal that sintered powder not or superficial layer removing component are produced.
18. device as claimed in claim 16, it is characterized in that, also comprise a discharge member, it can be used for discharging the smear metal that sintered powder not or superficial layer removing component are produced, described discharge member has an actuator, and this actuator can move described discharge member along the outline line on each plane to be formed.
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