CROSS-REFERENCE TO RELATED APPLICATIONS

This application claims priority to U.S. Application Serial No. 62/650,218, filed on March 29, 2018, the disclosure of which is incorporated by reference. TECHNICAL FIELD

This specification relates to additive manufacturing, also known as 3D printing.

BACKGROUND

Additive manufacturing (AM), also known as solid freeform fabrication or 3D printing, refers to a manufacturing process where three-dimensional objects are built up from successive dispensing of raw material (e.g., powders, liquids, suspensions, or molten solids) into two- dimensional layers. In contrast, traditional machining techniques involve subtractive processes in which objects are cut out from a stock material (e.g., a block of wood, plastic or metal).

A variety of additive processes can be used in additive manufacturing. Some methods melt or soften material to produce layers, e.g., selective laser melting (SLM) or direct metal laser sintering (DMLS), selective laser sintering (SLS), fused deposition modeling (FDM), while others cure liquid materials using different technologies, e.g., stereolithography (SLA). These processes can differ in the way layers are formed to create the finished objects and in the materials that are compatible for use in the processes.

Conventional systems use an energy source for sintering or melting a powdered material. Once all the selected locations on the first layer are sintered or melted and then re- solidified, a new layer of powdered material is deposited on top of the completed layer, and the process is repeated layer by layer until the desired object is produced.

SUMMARY

In one aspect, an additive manufacturing apparatus for forming an object includes a platen to support the object being formed, a dispensing system to deliver a plurality of layers of a powder to the platen, a housing to enclose the platen and dispensing system in a sealed chamber, a powder transfer system to deliver powder to the dispensing system, and an energy source to apply energy to the powder dispensed on the top surface of the platen to form a fused portion of the powder. The powder transfer system includes a mechanical interface to engage a canister positioned exterior to the housing. The mechanical interface is configured to form a sealed connection to an interior volume of the canister that contains a supply of the powder, and the mechanical interface has a projection to engage and open a valve in the canister.

Implementations may include one or more of the following features.

The mechanical interface may include a front operated user port. The mechanical interface may be disposed on a side of the housing. The dispensing system may include a hopper to hold powder, and the dispensing system and the hopper may be horizontally movable relative to the platen. The powder transfer system may include a reservoir coupled to the mechanical interface to receive powder from a canister engaged to the mechanical interface, and a valve to deliver powder from the reservoir to the hopper. The reservoir and valve may be stationary, and the hopper may be movable to a position beneath the valve. The valve may be a ball valve.

In another aspect, a method of measuring a characteristic of a powder includes rotating a cylinder holding a powder for use in additive manufacturing so as to cause a portion of the powder to flow onto a surface, monitoring powder that flows onto the surface with a metrology system, and collecting the powder from the surface into a canister.

Implementations may include one or more of the following features.

The powder may flow onto the surface in a layer not more than about three times thicker than a mean diameter of the particles of the powder. The metrology system may include a camera. Monitoring the powder may include one or more of determining powder size distribution, determining powder morphology, and detecting contamination, based on an image from the camera. The powder may flow onto the surface, be monitored by the metrology system, and be collected in the canister, in a vacuum. The powder may be collected from the surface with a wiper blade. The powder may be placed in a hopper, and the hopper may be rotated such that the powder flows into the cylinder. A record may be stored in a database associating an identification number for the canister with data from the metrology system.

Advantages of the foregoing may include, but are not limited to, the following. Whether a given batch of new or recycled powder meets process required can be determined more easily or reliably. Old and new powder can be blended to provide a blended batch of powder for dispensing, thereby reducing waste of powder. The blended powder can be homogenized, thereby improving process and layer uniformity. Powder can be monitored as it is depleted from this blended batch, and whether a new batch of blended powder is needed can be determined. Contamination of powder can be reduced, thereby improving part quality and yield.

The details of one or more implementations of the subject matter described in this specification are set forth in the accompanying drawings and the description below. Other potential features, aspects, and advantages will become apparent from the description, the drawings, and the claims.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a schematic cross-sectional view of an example additive manufacturing apparatus.

FIG. 2 A is a schematic side view of an example of a printhead for an example additive manufacturing apparatus.

FIG. 2B is a schematic top view of the printhead of FIG. 2 A.

FIG. 3 is a schematic side view of a front operated user port and a canister.

Like reference numbers and designations in the various drawings indicate like elements. DETAILED DESCRIPTION

Additive manufacturing (AM) apparatuses can form an object by dispensing and fusing successive layers of a powder on a build platform. This powder, particular in the case of metal powders, can be very expensive. Consequently it is desirable to recycle powder when possible. However, recycled powder may not meet process specifications, e.g., purity or particle size. Even if new powder is used, the powder may not meet process specifications. The powder can be qualified, i.e., confirmed that it meets necessary process specification, by a qualification system.

In addition, if powder is exposed to the environment, it can become contaminated. Powder can be loaded into an additive manufacturing system using a front operated user port (FOUP) that keeps the powder in a sealed environment.

Additive Manufacturing Apparatuses

FIG. 1 illustrates a schematic side view of an example additive manufacturing (AM) apparatus 100 that includes a printhead 102 and a build platform 104 (e.g., a build stage). The printhead 102 dispenses a powder 106 and, optionally, fuses the powder 106 dispensed on the platform 104. Optionally, as described below, the printhead 102 can also dispense and/or fuse a second powder 108 on the platform 104.

The printhead 102 and a build platform 104 can both be enclosed in a housing 180 that forms a sealed chamber 186, e.g., a vacuum chamber, that provides a controlled operating environment. The chamber 180 can include an inlet 182 coupled to a gas source, e.g. Ar, or N2, and an outlet 184 coupled to an exhaust system, e.g., a pump. This permits the pressure and oxygen content of the interior of the housing 180 to be controlled. For example, oxygen gas can be maintained below 50 ppm when dealing with Ti powder particles.

Referring to FIGS. 1 and 2B, the printhead 102 is configured to traverse the platform 104. For example, the apparatus 100 can include a support, e.g., a linear rail or pair of linear rails 119, along which the printhead can be moved by a linear actuator and/or motor. This permits the printhead 102 to move across the platform 104 along a first horizontal axis. In some

implementations, the printhead 102 can move along a second horizontal axis perpendicular to the first axis.

The printhead 102 can also be movable along a vertical axis. In particular, the printhead

102 can be lifted by an amount equal to the thickness of the deposited layer of powder. This can maintain a constant height difference between the dispenser on the printhead and the top of the powder on the platform 104. A drive mechanism, e.g., a piston or linear actuator, can be connected to the printhead or support holding the printhead to control the height of the printhead. Alternatively, the printhead 102 can be held in a fixed vertical position, and the platform 104 can be lowered after each layer is deposited.

Referring to FIGS. 1 and 2A, the printhead 102 includes at least a first dispensing system 116 to selectively dispense powder 106 on the build platform 104. Referring to FIGS. 1 and 2A, the first dispensing system 116 includes a hopper 131 to receive the powder 106. The powder 106 can travels through a channel 136 having a controllable aperture, e.g., a valve, that controls whether the powder is dispensed onto the platform 104.

Returning to FIGS. 2A and 2B, the apparatus 100 also includes an energy source 114 to selectively add energy to the layer of powder on the build platform 104. The energy source 114 can be incorporated into the printhead 102 (as shown in FIGS. 2 A and 2B), be mounted on a support that holds the printhead, or be mounted separately, e.g., on a separate support is independently movable relative to the printhead 102, or on a frame supporting the build platform 104 or on chamber wall that surrounds the build platform 104.

In some implementations, the energy source 114 can include a scanning laser that generates a beam of focused energy that increases a temperature of a small area of the layer of the powder. In some cases, the energy source 114 can include an ion beam or an electron beam. The energy source 114 can fuse the powder by using, for example, a sintering process, a melting process, or other process to cause the powder to form a solid mass of material. The energy source 114 can be positioned on the printhead 102 such that, as the printhead 102 advances in a forward direction, the energy source can selectively heat regions of powder dispensed by the dispensing system 116.

Optionally, the apparatus can include a heat source 112 to direct heat to raise the temperature of the deposited powder. The heat source 112 can heat the deposited powder to a temperature that is below its sintering or melting temperature. The heat source 112 can be, for example, a heat lamp array. The energy source 114 can be incorporated into the printhead 102, be mounted on a support that holds the printhead, or be mounted separately, e.g., on a separate support is independently movable relative to the printhead 102, or on a frame supporting the build platform 104 or on chamber wall that surrounds the build platform 104. The heat source 112 can be located, relative to the forward moving direction of the printhead 102, behind the first dispensing system 116. As the printhead 102 moves in the forward direction, the heat source 112 moves across the area where the first dispensing system 116 was previously located.

Optionally, the printhead 102 can also include a first spreader 118, e.g., a roller or blade, that cooperates with first the dispensing system 116 to compact and spread powder dispensed by the dispensing system 116. The spreader 118 can provide the layer with a substantially uniform thickness. In some cases, the first spreader 118 can press on the layer of powder to compact the powder.

The printhead 102 can also optionally include a first sensing system 120 and/or a second sensing system 122 to detect properties of the apparatus 100 as well as powder dispensed by the dispensing system 116.

In some implementations, the printhead 102 includes a second dispensing system 124 to dispense the second powder 108. The second dispensing system 116, if present, can be constructed similarly with a hopper 134 and channel 135. A second spreader 126 can operate with the second dispensing system 124 to spread and compact the second powder 108.

The first powder particles 106 can have a larger mean diameter than the second particle particles 108, e.g., by a factor of two or more. When the second powder particles 108 are dispensed on a layer of the first powder particles 106, the second powder particles 108 infiltrate the layer of first powder particles 106 to fill voids between the first powder particles 106. The second powder particles 108, being smaller than the first powder particles 106, can achieve a higher resolution, higher pre-sintering density, and/or a higher compaction rate.

Alternatively or in addition, if the apparatus 100 includes two types of powders, the first powder particles 106 can have a different sintering temperature than the second particle particles. For example, the first powder can have a lower sintering temperature than the second powder. In such implementations, the energy source 114 can be used to heat the entire layer of powder to a temperature such that the first particles fuse but the second powder does not fuse.

In implementations when multiples types of powders are used, the first and second dispensing systems 116, 124 can deliver the first and the second powder particles 106, 108 each into different selected areas, depending on the resolution requirement of the portion of the object to be formed.

Materials for the powder include metals, such as, for example, steel, aluminum, cobalt, chrome, and titanium, alloy mixtures, ceramics, composites, and green sand. In implementations with two different types of powders, in some cases, the first and second powder particles 106,

108 can be formed of different materials, while, in other cases, the first and second powder particles 106, 108 have the same material composition. In an example in which the apparatus 100 is operated to form a metal object and dispenses two types of powder, the first and second powder particles 106, 108 can have compositions that combine to form a metal alloy or intermetallic material.

The processing conditions for additive manufacturing of metals and ceramics are significantly different than those for plastics. For example, in general, metals and ceramics require significantly higher processing temperatures. Thus 3D printing techniques for plastic may not be applicable to metal or ceramic processing and equipment may not be equivalent. However, some techniques described here could be applicable to polymer powders, e.g. nylon, ABS, polyetheretherketone (PEEK), polyetherketoneketone (PEKK) and polystyrene. If the apparatus 100 dispenses two different types of powders having different sintering temperatures, the first and second heat sources 112, 125 can have different temperature or heating set points. For example, if the first powder 106 can be sintered at a lower temperature than the second powder 108, the first heat source 112 may have a lower temperature set point than the second heat source 125.

Referring to FIG. 1, after the dispensing system 116 dispenses one or more layers of powder, the hopper 131 can eventually run out of powder. In this case, the hopper 131 may need to be recharged. The printhead 102 can be moved to position the hopper 131 below a recharging dispenser 150. The recharging dispenser 150 includes a reservoir 152 to hold powder, and controllable nozzle 158 to controllably deliver powder from the reservoir 152 by gravity feed into the hopper 131 of the powder dispenser 116.

A mechanical interface 160 that provides a front operated user port 160 is coupled to the reservoir 152 by a passage 154 through which powder can flow, e.g., by gravity, or be directed, e.g., by an augur system. The user port 160 is accessible from the outside of the housing 180 so that an operator can place a canister 170 into the user port 160.

Referring to FIG. 3, the user port 160 is configured to receive a canister 170 that holds new or recycled powder in an internal volume 174. The canister 170 can include a valve 172, e.g., a ball valve, that is biased into a shut position to isolate the internal volume 174 of the canister from the outside environment.

The front operated user port 160 includes a mounting plate 162 configured to hold the canister 170. The user port 160 also includes a projection 164, e.g., extending from the mounting plate 162. The projection 164 can be a bayonet feature. The projection 164 is configured to engage the valve 172 when the canister is mated to the mounting plate 162 so as to open the valve 172. The combination of the biased valve 172 and projection 164 helps prevent the valve from opening on the user port 160 unless it is connected to the mounting plate 162. In addition, an O-ring 166 can form seal between the user port 160 and the canister 170 when the canister is mated to the mounting plate 162. Both of these reduce the likelihood of

contamination of the powder in the internal volume 174.

Although shown on the side of the housing 180, the front operated user port could be on the top of the housing 180, and the canister can be oriented with the opening and valve on the bottom such that powder can flow by gravity into the reservoir 152. Although unillustrated, if the printhead 102 includes a second powder dispenser 124, the apparatus 100 can include a second recharging dispenser and a second mechanical interface for receiving a canister with the second powder, otherwise constructed and operated as described above.

A controller 128 controls the operations of the apparatus 100, including the operations of the printhead 102 and its subsystems, such as the heat source 112, the energy source 114, and the first dispensing system 116. The controller 128 can also control, if present, the first spreader 118, the first sensing system 120, the second sensing system 122, the second dispensing system 124, and the second spreader 126. The controller 128 can also receive signals from, for example, user input on a user interface of the apparatus or sensing signals from sensors of the apparatus 100. The controller 128 can operate the dispensing system 116 to dispense the powder 106 and can operate the energy source 114 and the heat source 112 to fuse the powder 106 to form a workpiece 130 that becomes the object to be formed.

The controller 128 can include a computer aided design (CAD) system that receives and/or generates CAD data. The CAD data is indicative of the object to be formed, and, as described herein, can be used to determine properties of the structures formed during additive manufacturing processes. Based on the CAD data, the controller 128 can generate instructions usable by each of the systems operable with the controller 128, for example, to dispense the powder 106, to fuse the powder 106, to move various systems of the apparatus 100, and to sense properties of the systems, powder, and/or the workpiece 130. In some implementations, the controller 128 can control the first and second dispensing systems 116, 124 to selectively deliver the first and the second powder particles 106, 108 to different regions.

The controller 128, for example, can transmit control signals to drive mechanisms that move various components of the apparatus. In some implementations, the drive mechanisms can cause translation and/or rotation of these different systems, including dispensers, rollers, support plates, energy sources, heat sources, sensing systems, sensors, dispenser assemblies, dispensers, and other components of the apparatus 100. Each of the drive mechanisms can include one or more actuators, linkages, and other mechanical or electromechanical parts to enable movement of the components of the apparatus. Powder Qualification

A technique to qualify powder is to place new or used sieved powder in a hopper. The hopper is placed in a vacuum chamber. The hopper is rotated under vacuum, and a portion of the powder allowed to flow at a controlled rate to fill a cylinder held on a rotating pedestal. The pedestal is rotated at a constant velocity and a spring loaded gap between the pedestal and fixed cylinder maintained. Rotation of the pedestal induces a precise amount of powder to flow from the cylinder and form a thin layer (about one or two powder diameters thick). A metrology sensor is positioned over the pedestal and used to monitor the presented powder. This metrology sensor may include a camera that can be used to measure powder size distribution, necked powder, and the presence of non-powder particles or contamination. Alternative sensors may also be employed in place or in addition to the camera. For example, an FTIR, MBIR or other surface inspection tools which may be used to evaluate various surface properties. The analyzed powder is then directed off the rotating pedestal using a wiper blade that collimates the powder into a stream and a receiving canister also within the vacuum environment. The analyzed powder is then closed in the receiving canister under vacuum and the metrology data captured during the run maintained in a computer database that tracks powder properties with the receiving canister.

Conclusion

The controller and other computing devices part of systems described herein can be implemented in digital electronic circuitry, or in computer software, firmware, or hardware. For example, the controller can include a processor to execute a computer program as stored in a computer program product, e.g., in a non-transitory machine readable storage medium. Such a computer program (also known as a program, software, software application, or code) can be written in any form of programming language, including compiled or interpreted languages, and it can be deployed in any form, including as a standalone program or as a module, component, subroutine, or other unit suitable for use in a computing environment.

While this document contains many specific implementation details, these should not be construed as limitations on the scope of any inventions or of what may be claimed, but rather as descriptions of features specific to particular embodiments of particular inventions. Certain features that are described in this document in the context of separate embodiments can also be implemented in combination in a single embodiment. Conversely, various features that are described in the context of a single embodiment can also be implemented in multiple

embodiments separately or in any suitable subcombination. Moreover, although features may be described above as acting in certain combinations and even initially claimed as such, one or more features from a claimed combination can in some cases be excised from the combination, and the claimed combination may be directed to a subcombination or variation of a subcombination.

A number of implementations have been described. Nevertheless, it will be understood that various modifications may be made.

Accordingly, other implementations are within the scope of the claims.