Selective laser solidification apparatus and method

Abstract

A method of selecting a scanning sequence of a laser beam in a selective laser solidification process, in which one or more objects are formed layer-by-layer by repeatedly depositing a layer of powder on a powder bed and scanning the laser beam over the deposited powder to selectively solidify at least part of the powder layers, includes determining an order in which areas should be scanned by: projecting a debris fallout zone that would be created when solidifying each area based on a gas flow direction of a gas flow passed over the powder bed; determining whether one or more other areas to be solidified fall within the debris fallout zone; and selecting to solidify the one or more other areas that fall within the debris fallout zone before solidifying the area from which the debris fallout zone has been projected.

Claims

1. A method of controlling an additive manufacturing process, in which a laser beam is used to selectively melt powder of a powder bed to form, in the presence of gas-borne debris generated by the melting of the powder, an object layer-by-layer, the method comprising: determining a map of the gas-borne debris; and controlling the laser beam to melt the powder based on the map.

2. The method according to claim 1, further comprising generating a gas flow across the powder bed.

3. The method according to claim 2, further comprising using a gas inlet on one side of the powder bed and a gas outlet on another side of the powder bed to generate the gas flow.

4. The method according to claim 1, further comprising remelting debris that falls within a zone when solidifying powder of a successive layer.

5. The method according claim 1, wherein the map includes zones effected by the gas-borne debris, and the laser beam is controlled to avoid intersecting the zones.

6. The method according to claim 1, wherein the map changes with time as areas of the powder bed are progressively melted within a layer.

7. The method according to claim 1, wherein the map is determined from islands of powder to be solidified by melting.

8. The method according claim 1, further comprising determining a different map of the gas-borne debris for each layer.

9. The method according to claim 1, further comprising melting a downwind area downwind of an upwind area after melting the upwind area if the map identifies the downwind area as outside of gas-borne debris created during melting of the upwind area.

10. A method of controlling an additive manufacturing process, in which a laser beam is used to selectively melt powder of a powder bed to form, in the presence of a gas flow across the powder bed, an object layer-by-layer, the method comprising: determining at least one lane across the powder bed in a direction debris is carried by the gas flow; and controlling the laser beam to melt the powder of the powder bed outside the at least one lane.

11. The method according to claim 10, wherein a width of the at least one lane is based on areas to be solidified in a layer.

12. The method according to claim 10, further comprising: for a layer, determining a plurality of lanes across the powder bed in a direction debris is carried by the gas flow; and controlling the laser beam to melt the powder of the powder bed outside the plurality of lanes.

13. The method according to claim 12, wherein a width of a first one of the plurality of lanes is different than a width of a second one of the plurality of lanes.

14. The method according to claim 10, further comprising determining at least one lane for each layer of a plurality of layers, the at least one lane of each layer extending across the powder bed in a direction debris is carried by the gas flow; and controlling the laser beam to melt the powder of the powder bed outside the at least one lane for each layer.

15. The method according to claim 14, wherein a width of the at least one lane is smaller for a first one of the layers than a width of the at least one lane for a second one of the layers.

16. The method according to claim 10, wherein the at least one lane is associated with an upwind area upwind of a downwind area, and the method comprises melting the downwind area after melting the upwind area if the downwind area is outside of the at least one lane.

17. The method according to claim 10, further comprising using a gas inlet on one side of the powder bed and a gas outlet on another side of the powder bed to generate the gas flow.

18. A method of controlling an additive manufacturing process, in which a laser beam is used to selectively melt powder of a powder bed to form, in the presence of gas-borne debris generated by the melting of the powder, an object layer-by-layer, the method comprising: ordering melting of areas of the powder to control creation of the gas-borne debris such that scanning of the laser beam across the layer does not interact with the gas-borne debris, wherein a downwind area, which is (i) downwind of an upwind area and (ii) outside of a zone of gas-borne debris created by melting the upwind area, is melted after melting the upwind area.

19. The method according to claim 18, wherein scanning of the downwind area does not interact with the gas-borne debris created during melting of the upwind area.

20. The method according to claim 18, further comprising generating a gas flow across the powder bed.

21. The method according claim 20, further comprising using a gas inlet on one side of the powder bed and a gas outlet on another side of the powder bed to generate the gas flow.

Description

DESCRIPTION OF THE DRAWINGS

(1) Embodiments of the invention will now be described, as examples only, with reference to the accompanying drawings, in which:—

(2) FIG. 1 is a schematic view of a laser solidification apparatus according to one embodiment of the invention;

(3) FIG. 2 is a schematic view of the laser solidification apparatus from another side;

(4) FIG. 3 is a flowchart showing the steps of a method according to the invention;

(5) FIG. 4 is a plan view of islands to be solidified on a build platform of the apparatus, wherein debris fallout zones have been projected; and

(6) FIG. 5 is a plan view of islands to be solidified on a build platform of the apparatus, wherein debris fallout zones according to a different embodiment of the invention have been projected.

DESCRIPTION OF EMBODIMENTS

(7) Referring to FIGS. 1 and 2, a laser solidification apparatus according to an embodiment of the invention comprises a build platform 102 for supporting an object 103 built by selective laser melting powder 104. The platform 102 can be lowered in the chamber 101 as successive layers of the object 103 are formed. Layers of powder 104 are formed as the object 103 is built by dispensing apparatus 108 and a wiper 109. For example, the dispensing apparatus 108 may be apparatus as described in WO2010/007396. A laser module 105 generates a laser for melting the powder 104, the laser directed as required by optical module 106 under the control of a computer 130. The laser enters the build chamber via a window 107.

(8) An inlet 112 and outlet 110 are arranged for generating a gas flow across the powder bed formed on the build platform 102. The inlet 112 and outlet 110 are arranged to produce a laminar flow having a flow direction from the inlet to the outlet, as indicated by arrows 118. Gas is re-circulated from the outlet 110 to the inlet 112 through a gas recirculation loop 111. A pump 113 maintains the desired gas pressure at inlet 112 and openings 5, 6. A filter 114 is provided in the recirculation loop 111 to filter from the gas condensate that has become entrapped in the flow. It will be understood that more than one inlet 112 may be provided in the build chamber 101. Furthermore, rather than extending outside of the build chamber 101, the recirculation loop 111 may be contained within the build chamber 101.

(9) Computer 130 comprises a processor unit 131, memory 132, display 133, user input device 134, such as a keyboard, touch screen, etc, a data connection to modules of the laser sintering unit, such as optical module 106 and laser module 105, and an external data connection 135. Stored on memory 132 is a computer program that instructs the processing unit to carry out the method described with reference to FIGS. 3 to 5.

(10) Referring to FIG. 3, geometric data of objects to be built, such as in the form of an STL file, are received 201 by the computer 130, for example over the external data connection 135. The processing unit 131 receives 202 information on the location of the objects on the build platform 102. This location information may already be defined in the STL or the user may the select, using the user input device 135, where each object should be located on the build platform 102. For each layer, the processing unit 131 identifies areas of the layer that are to be solidified and determines 203 an order in which these areas should be scanned by the laser beam. An example of how this may be done is shown in FIG. 4.

(11) FIG. 4 shows five separate areas (islands) 122 to 126 to be solidified for a particular layer. For each island 122 to 126, the processing unit projects a debris fallout zone 122a to 126a in a gas flow direction from the island. The processing unit 131 then determines, for each island 122 to 126, if any other island falls within the debris fallout zone. If so, the processing unit selects to form this other island before forming the island for which the debris fallout zone was determined. For example, in FIG. 4, islands 125 and 126 fall within the fallout zone of island 122 and therefore, are selected to be scanned before island 122. Island 126 also falls within the fallout zone of island 125 and therefore, should be formed before island 125.

(12) Rather than restricting ordering of the build to a complete island, the processing unit 131 may be arranged to select to form, in between forming different parts of the island, at least part of another island. FIG. 4 illustrates two examples of this. In the first example, island 123 is completely surrounded by island 124. Accordingly, island 124 comprises parts that are both upwind and downwind of island 123. In such a scenario, the processing unit 131 selects to process the part of the island that is located downwind of island 123 before scanning island 123 and then scans the part of the island 124 that is upwind of island 123. The part of island 124 that is neither upwind nor downwind of island 123 may be scanned before or after island 123 and the selection of the scanning order of these parts may be based on other criteria, such as scan speed. The different parts of island 124 are illustrated by the dotted lines. In the second example, rather than scanning all of island 125 after scanning island 126, the part of island 125 that is not upwind of island 126 may be scanned before island 126. There may be reasons for scanning part of island 125 ahead of island 126, such as to optimize scan speed, variations in material composition and/or focal position.

(13) In this embodiment, the processing unit 131 carries out this process for each layer. However, in another embodiment, rather than calculating a scanning order for each layer, it may be possible to determine an order for multiple layers from a single analysis. For example, a fallout zone could be determined from a footprint of each object on the build platform 102, the order being determined based upon whether other objects fall within a debris fallout zone calculated based on this footprint. Even though for some layers the debris fallout zone may be smaller than that calculated from the footprint, such a method may provide a reasonable generalization that reduces the amount of processing required in determining an order in which the parts should be built.

(14) The selected order of scanning the parts may be displayed to the user and the user may be able to change the order. The user can then activate the build to cause the processing unit to control 204 the optical module 106 and laser module 105 to scan the powder layers to form the islands in the selected order.

(15) In the embodiment shown in FIG. 4, the debris fallout zones are projected by extending straight lines in the gas flow direction from edges of the islands. However, other projections of the fallout zones could be used. Two examples are shown in FIG. 5. For island 127, a fallout zone 127a is projected as diverging straight lines at a slight angle to the gas flow direction to take into account slight turbulence in the gas flow that may cause the debris to be deposited beyond the outmost edges of the island in a direction perpendicular to the gas flow direction. A similar principal is embodied by island 128 and fallout zone 128a, where an initially curved border to the fallout zone is used to model that locally debris may be thrown out by the impact of the laser beam on the powder layer but further from the island the debris is more likely to be carried away along a straighter path by the gas flow.

(16) In a further embodiment, rather than the processing unit selecting the order in which islands are scanned, a user may select an order in which islands are built. This may be achieved by the processing unit 131 causing the display 133 to display images similar to those shown in FIGS. 4 and 5 so that the user can select the order islands are scanned based upon this visualisation of the fallout zones. The processing unit 131 then receives user inputs from the user input device of the order in which islands should be scanned.

(17) It will be understood that in the above description, the islands may come together in earlier or later layers so as to form a single object or may remain separate so as to form one or more separate objects.

(18) It will be understood that alterations and modifications may be made to the invention without departing from the scope of the invention as defined herein. For example, the invention could be applied to a single island, wherein it is desirable to scan a downwind part of the island ahead of scanning an upwind part of the island.