METHOD AND APPARATUS FOR ADDITIVE MANUFACTURING OF GLASS

Abstract

This relates to an additive manufacturing method for producing a three-dimensional component made of glass, the method including the steps of: feeding continuously a glass filament having a flame retardant or self-extinguishing protective film applied to the surface thereof, from a filament feeding nozzle to a heating source for removing the flame retardant or self-extinguishing protective film and softening the glass fiber, applying the softened glass filament to a surface of a substrate or object, wherein the flame retardant or self-extinguishing protective film is made of polyimide-based material having a thickness in the range of 1 m to 50 m, wherein the fed glass filament length is less than 5 millimeters. The invention is also related to a glass filament and the use of the same.

Claims

1. An additive manufacturing method for producing a three-dimensional component/object made of glass, said method comprising the steps of: a. feeding continuously a single glass filament from a filament feeding nozzle, wherein the glass filament has a single flame retardant or self-extinguishing protective film applied to the surface thereof, to a heating source for removing said flame retardant or self-extinguishing protective film and softening said glass filament, b. applying said softened glass filament to a surface of a substrate or object, wherein said single flame retardant or self-extinguishing protective film is made of polyimide-based material and has a thickness in the range of 1 m to 50 m, c. wherein the fed glass filament length is the distance between the filament feeding nozzle and said surface of the substrate or object, and is less than 5 millimeters.

2. The method according to claim 1, wherein said glass filament is a glass fiber having a diameter in the range of 100-500 m.

3. The method according to claim 1, wherein said heating source is at least one laser source.

4. The method according to claim 1, wherein the glass filament is hollow, and wherein the method further comprises the step of providing a gas pressure inside the hollow filament for producing a three-dimensional component having said hollow feature.

5. A single glass filament for additive manufacturing of a three-dimensional component of glass, the glass filament provided with a single flame retardant or self-extinguishing protective film applied to the surface thereof, wherein the film is made of polyimide-based material and has a thickness in the range of 1 m to 50 m.

6. The glass filament according to claim 5, wherein said glass filament is a glass fiber having a diameter in the range of 100-500 m.

7. The glass filament according to claim 6, wherein said glass filament is an optical fiber.

8. The glass filament according to claim 6 or 7, wherein said glass filament is hollow.

9. The glass filament according to claim 8, wherein the volume of said hollow portion is between 10-70% of a volume of said glass content in said glass filament.

10. (canceled)

11. The method according to claim 2, wherein said heating source is at least one laser source.

12. The method according to claim 2, wherein the glass filament is hollow, and wherein the method further comprises the step of providing a gas pressure inside the hollow filament for producing a three-dimensional component having said hollow feature.

13. The method according to claim 3, wherein the glass filament is hollow, and wherein the method further comprises the step of providing a gas pressure inside the hollow filament for producing a three-dimensional component having said hollow feature.

14. The method according to claim 11, wherein the glass filament is hollow, and wherein the method further comprises the step of providing a gas pressure inside the hollow filament for producing a three-dimensional component having said hollow feature.

15. The glass filament according to claim 7, wherein said glass filament is hollow.

16. The glass filament according to claim 15, wherein the volume of said hollow portion is between 10-70% of a volume of said glass content in said glass filament.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

[0037] A more complete understanding of the abovementioned and other features and advantages of the present invention will be apparent from the following detailed description of preferred embodiments in conjunction with the appended drawings, wherein:

[0038] FIG. 1 depicts a schematic side view of an example embodiment of an apparatus for manufacturing a three-dimensional component made of glass which may be used for performing the method according to the present invention.

[0039] FIG. 2 depicts a schematic side view of a glass filament and a filament feeding nozzle.

[0040] FIG. 3a-c depict various example embodiments of a glass filament with protective coating.

DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS OF THE INVENTION

[0041] The process invention here refers to a new Additive Manufacturing (AM) process where using a digital model, a component geometry is built by fusing together glass filaments layer-by-layer, freestanding or localized deposition using an energy source such as a laser beam through localized melting.

[0042] This invention is about a direct manufacturing process by integrating a flame retardant and/or self-extinguishing protective film/coating and its removal from the glass filament within the printing process. This means, that the new process will be able to manufacture fully or near-fully dense glass component/object using glass filaments and will overcome all the shortcomings of the prior art glass manufacturing methods.

[0043] The new process will enable direct manufacturing of three-dimensional glass components without toxic bi-products, which may avoid a health risk.

[0044] Here we have identified polyimide-based coatings as a suitable filament coating for laser-based 3D printing. Polyimides are inherently resistant to flame combustion. Polyimides exhibit flame retardant and self-extinguishing properties. Experiments have shown that when initiating combustion, using open flame or CO.sub.2-laser heating, polyimide coated fused silica and fused quartz fibers with a diameter of approximately 200 m do not ignite or show sustained combustion once the heat source has been removed or turned off.

[0045] A further benefit of polyimide-based coatings is that they can be applied to the glass filament with techniques commonly used in standard optical fiber draw towers. Typical coating thickness of polyimide coatings range from 1 m to 50 m, typically 5 m to 25 m.

[0046] Additional benefits is that in general the combustion by-products of polyimide burned in air (or oxygen) atmosphere is carbon-dioxide, water and nitrogen-oxide, i.e., combustion produces non-toxic fumes.

[0047] It is therefore crucial that the glass filament film/coating is resistant to flame combustion, should be flame retardant and/or show self-extinguishing properties in order to protect the feeding nozzle, filament and filament cassette, 3D printer as well as physical safety of operator and surroundings.

[0048] Polyimide decomposition occurs at temperatures above 400 C, typically above 600 C. This high temperature is advantageous as the coating is then removed very close to the hot-zone, enabling a shorter distance between the tip of feeding nozzle and the hot-zone thereby allowing for a shorter length of filament extruding from the nozzle. The fed glass filament length L shall be less than 5 millimeters. By using a shorter length of filament extruding from the nozzle, the mechanical properties of the filament (stiffness) enables significantly improved printing accuracy and resolution during printing. Suitable length of extruding filament with a diameter of around 200 m is typically less than 5 mm with the polyimide coating being removed typically within 1 mm of the hot-zone.

[0049] FIG. 1 depicts a schematic side view of an example embodiment of an additive manufacturing apparatus 100 according to the present invention which is configured to manufacture three-dimensional components in glass. Said apparatus 100 comprises a stage/substrate 130, a laser source 110 and a filament feeding nozzle 120. The filament feeding nozzle 120 may be configured to move in an x-y plane relative to said stage 130 so that said filament feeding nozzle 120 is covering a predetermined area of said stage 130. The relative movement may be that said stage 130 is fixed and said filament feeding nozzle 120 is moving in x-y-z direction. Alternatively, the stage 130 may be movable in x-y whereas said filament feeding nozzle is fixed. One or both of said filament feeding nozzle 120 and/or said stage 130 may be movable in Z direction in order to allow for additively manufacture the three-dimensional component and keeping a distance between the filament feeding nozzle and a top surface of the component to which a new layer is to be attached at a constant distance, i.e., for every new applied layer the stage 130 may be moved downwards in Z-direction with a distance corresponding to the thickness of new applied layer or the filament feeding nozzle 120 may be moved upwards in Z-direction with a distance corresponding to the thickness of new applied layer or a combination of movement of said stage downwards in Z-direction and said filament feeding nozzle upwards in Z-direction in order to keep a distance between the filament feeding nozzle and a top surface of the component to which a new layer is to be attached at a constant distance. Filament 160 may be fed to the filament feeding nozzle 120 via a guide tube 170. The laser source 110 may be a CO.sub.2-laser, CO-laser, Nd:YAG laser, fiber laser, excimer laser, nitrogen laser or the like. The laser beam 150 may be continuous or pulsed. The laser beam softens or melts the filament in a hot-zone 140 in vicinity to the stage onto which said softened or molten glass is to be attached.

[0050] The filament feeding nozzle 120 and/or the stage 130 may be arranged on at least one motorized support. A control unit may control the relative movement of said filament feeding nozzle with respect to said stage 130. Said control unit may also control laser and laser optics.

[0051] In FIG. 1 the filament feeding nozzle 120 is providing feedstock material 160 onto a stage 130 for forming a layer of the three-dimensional component. A build plate may be provided on the stage 130 onto which the three-dimensional component is to be formed. The build plate may be made of any material, e.g., the same material as the final three-dimensional component, ceramic material or any other metallic material which is different to the material in the three-dimensional component. The thickness of the build plate may be in the range of a few tenth of a mm to several cm's.

[0052] The first step is the fusion and deposition of feedstock material onto the stage 130. The filament feeding nozzle locally deposits the feedstock material along a predefined path. The filament feeding nozzle may heat the feedstock material before it leaves the nozzle on its way towards the stage 130. The nozzle may be adapted to the size and shape of the feedstock material.

[0053] A three-axes kinematic may position the filament feeding nozzle 120 in the machine's work envelope and generates the three-dimensional component layer by layer. The feedstock material 160 is a glass filament. The glass filament 160 is provided with a flame retardant and/or self-extinguishing protective coating or protective film 169 applied to the surface thereof.

[0054] In FIG. 1 only one filament feeding nozzle 120 is shown to be used. In various example embodiments multiple filament feeding nozzles maybe used in series or in parallel. In various example embodiments multiple strings of feedstock material 160 may be provided on the stage 130 simultaneously in order to speed up the deposition of feedstock material onto the stage 130.

[0055] One feedstock feeding nozzle may provide feedstock material or filament 160 at a first predetermined layer area of the three-dimensional component and two or more nozzles may be used for a second predetermined layer area of the three-dimensional component, i.e., the layer formation may alter between one, two, three or more nozzles depending on the shape of the layer to be formed and/or type of material to be added. In various example embodiments a plurality of nozzles for providing feedstock/filament onto the substrate may have the same diameter or different diameter. A plurality of filament feeding nozzle may provide feedstock material of different glass materials. In various example embodiment one feedstock feeding nozzle may comprise a plurality of different feedstock material, e.g., a plurality of fibers of the same material, different materials and/or different diameters.

[0056] In synchronization to filament extrusion, a tip of the filament 180 is positioned according to a predefined path. This path is derived by slicing the geometry of the work piece into layers and calculating a time-efficient trajectory for the extrusion of the filament 160. The positioning may be done by a three-axes positioning unit. It is intended to extend the manufacturing flexibility with a five-axes kinematic in order to further realign the work piece with reference to the gravity field of Earth.

[0057] In a first option simultaneous processing with a travelling laser beam, sintering/melting the deposited glass filament 160, following in close proximity to the filament deposition.

[0058] Alternatively, sintering/melting a thin layer/s of the glass filament with high power laser beam through selective laser scanning of the latest printed layer/s. The process may require a controlled heat input and timing. To ensure geometric accuracy, in-situ measurements may be made which enable the direct compensation of the process variance. Imperfections in the material may require a quality inspection of the sintered/melted glass layers. In-situ quality control ensuring geometric accuracy, appropriate temperature, and gas content and pressure in the printing environment.

[0059] To verify and validate the process capability, the following aspects may require further testing such as evaluation of the achievable manufactured layer, fulfilment of minimum geometric accuracy requirements, quantification of material shrinkage from the nominal design, quantification of the achievable layer adhesion and/or ensuring defect-free 3D printing.

[0060] One or a plurality of laser beams may be used simultaneously for melting/softening the glass filament.

[0061] The inventive idea concerns glass filaments, for use in laser-based glass 3D printers. Bare glass filaments possess poor mechanical properties, and thus are susceptible to breakage. In order for mechanical and chemical protection of the glass filament during storage and handling, a protective coating is required. For increased safety during machine operation the coatings needs to be of flame retardant and self-extinguishing type to avoid self-sustained open flame spreading. The flame retardant and self-extinguishing protective coating can be applied during filament fabrication, using, e.g., a fiber draw tower used to produce optical fibers. A furnace heats the preform (large version of filament in both shape and composition). The softened glass is then pulled using a capstan in combination with a diameter gauge and a tension meter for the correct filament dimensions. As the filament is being pulled, the preform is fed further into the furnace. Typically, a coating resin may be introduced into a coating cup, which the filament is passing through. The coating may then be subsequently cured, either thermally or using e.g., UV lamps, prior to winding the filament onto storage and transport spools. Polyimides are inherently resistant to flame combustion. Polyimides exhibit flame retardant and self-extinguishing properties. Curing temperatures for polyimide-based coatings on optical fibers may typically be performed in the temperature range of about 100 to 400 C.

[0062] Polyimide based coatings on optical fibers can survive operating temperatures of around 300 C and are commonly used for higher-temperature (sensing) applications. Here coating thickness of 10 to 15 m is typically used. Thicker coatings can be applied by repeating the coating procedure, adding multiple coating layers.

[0063] For glass filaments the coating thickness should be as thin as possible, while ensuring sufficient mechanical and chemical protection of the fiber. The filaments we have evaluated that gave good results have a single layer polyimide coating thickness of approximately 5 m.

[0064] Suitable outer diameters of glass filaments are in the range 100 m to 500 m. The diameter has a large impact on the mechanical properties of the filament with increased diameter resulting in more stiff filaments. The translation of the nozzle and filament relative to the printed structure, during printing, results in a lateral force on the filament. A deviation of the filament position depends on viscosity and surface tension of the liquid glass in the hot-zone 140, as well as printing speed. A schematic of a printing nozzle and extruding filament is shown in the FIG. 2. With a stiffer filament, the distance between the filament feeding nozzle and hot-zone 140 can be increased. The filament diameter, nozzle design, and distance to the hot-zone 140 therefore has a large effect on the print resolution, accuracy and quality. A large filament diameter and short extruding filament length will reduce the filament deviation during printing. Increasing the filament diameter reduces the resolution of the printer. If the extruding filament length is too short the filament feeding nozzle can be damaged by the hot-zone that may reach temperatures in excess of 2000 C.

[0065] The total deflection/deviation of the filament is given by:

[00001]$=\frac{4{\mathrm{FL}}^3}{4E{r}^4},$

where F is the retention force applied by the relative movement during printing process, L is the extruding filament length, E is the Young's modulus of the filament material, r is the radius of the filament. Theoretically, under the same processing conditions the filament with a diameter of 200 m deflects one quarter to that of the filament having a diameter of 125 m. Using a filament diameter of 200 m and an extruding filament length smaller than 5 mm, the deflection results in sub-m and can be considered negligible.

[0066] During glass 3D printing, the glass filament is continuously fed to a hot-zone at 1800 to 2200 C. One common method is to feed using uncoated glass optical fibers. However, since most optical fibers are produced with coating, removal of the coating 169 is required to produce pure glass filament prior to printing. Stripping off the coating 169 can be performed using mechanical or chemical means (e.g., using sulfuric acid, dichloromethane). The striping process limits the total length of the printable glass filament i.e., maximum mechanical stripping of a few meters, maximum chemical stripping of a few 10's of meters, which severally damages the continuity and capability (volume) of the 3D printing process. As the filament can become brittle without coating and stripping the coating may further weaken the mechanical strength of the filament, this brings extra risks as filament breakage during printing will cause major interruptions of the printing process. Using chemical means is not preferred due to risks involved when using strong acid (sulfuric acid) or dichloromethane (carcinogenic).

[0067] Another approach is to directly feed the coated filament. With protective coating 169, the printable filament length is then extended to kilometers range. However, as filament is commonly coated by flammable polymers e.g., acrylics, this approach can cause an open flame on the filament due to the high printing temperature, leading to the printing failure and likely destruction of filament and damage to the 3D printer. Besides, standard coating has a thickness at about 62.5 m, considerably too thick for glass 3D printing. Direct burning of the thick coating is not an ideal solution as it may produce more combustion bi-products, be more likely to leave residues affecting the purity of the print, and it is not energy efficient.

[0068] Our approach is to produce the glass filament 160 with thin flame retardant and self-extinguishing coating 169. As the hot-zone 140 is heated to very high temperatures, using e.g., CO.sub.2-laser beams, the coating will start to burn near the hot-zone 140, i.e., the hot-zone 140 itself can be used to remove the protective coating 169. While the protective coating 169 is flame retardant and self-extinguishing, the risk of open flame is eliminated. Once the lasers and filament feeding are turned off, the combustion process of the coating will stop. A thin coating will be easily burnt off. Besides increasing efficiency and reducing environmental impact, it will also reduce the production of combustion bi-products. The ideal coating may have a non-toxic chemical composition to further reduce toxic fumes produces during combustion e.g., should not contain halogens.

[0069] The inventive filament 160 for additive manufacturing provides for the possibility to apply a thin flame retardant and self-extinguishing protective coating layer 169 to glass filament, while still providing mechanical and chemical protection of the filament during (temporary) storage and handling. The protective coating 169 may be easily removed by thermal means (heating/plasma/laser irradiation). The protective coating 169 may not contain toxic elements or produce toxic combustion products when burned. The protective coating 169 may not have properties of self-sustained combustion.

[0070] The additive manufacturing method according to the present invention may be used for producing a three-dimensional component made of glass. Said method comprising the steps of feeding a glass filament having a flame retardant and/or self-extinguishing protective film applied to the surface thereof, from the filament feeding nozzle to a heating source for removing said flame retardant and self-extinguishing protective coating and softening said glass fiber and applying said softened glass fiber to a surface of a substrate or print/object, wherein said flame retardant and self-extinguishing protective coating is made of polyimide-based material and has a thickness in the range of 1 m to 50 m, wherein the fed glass filament length L is less than 5 millimeters. The feeding of glass filament may be continuous or discontinuous.

[0071] FIG. 2 depicts a side view of a filament feeding nozzle 120. Extending from said filament feeding nozzle 120 is a filament 160. The length of said filament from an exit of said filament feeding nozzle 120 to a surface of a substrate 130 where at least one laser beam impinges on said filament is denoted by L. It shall be understood that the fed glass filament length L is the distance between the filament feeding nozzle 120 and the surface onto which the glass filament 160 is applied, either the surface of the substrate 130 or the surface of print/object. In various example embodiments the fed glass filament length L may be larger than 10 mm but according to the present invention less than 5 mm. A larger L than 5 millimeters will increase the filament deviation, denoted by dashed filament in FIG. 2. Any filament deviation which may be a distance between a non-deviated center-portion of a tip 180 of said filament 160 to a deviated center portion of the same tip 180 will result in a misalignment of said filament with respect of its intended position on said surface of said substrate or print/object, which in turn may result in a defective three-dimensional article and/or decreases the precision of the additive manufacturing. A small portion of the protective coating 169 will stay on the filament outside said filament feeding nozzle exit during additive manufacturing due to the fact that the protective coating is flame retardant and/or self-extinguishing. A length of said small portion of said remaining protective coating during manufacturing may be at least few tenth of mm.

[0072] FIG. 3a-c depicts three different types of glass filaments 160 with protective coating 169, which may be used in the additive manufacturing process. FIG. 3a depicts a single composition (rod/fiber filament), where the composition (type of glass) can be high purity silica glass, e.g., fused silica and fused quartz glass (used for printing high purity transparent glass). These materials have low thermal expansion coefficient. i.e., does not need heated print plate and post thermal annealing is not always necessary. Silica glass filament with GeO.sub.2, Al.sub.2O.sub.3, B.sub.2O.sub.3, or F co-doping, or combinations of these. Multifilament printing (together with silica glass filament) can be used to create 3D prints with designed shape and refractive index structure. Example can be fabrication of optical fiber preforms or different optical components. Silica glass doped with rare earth oxides, of e.g., Er, Yb, Er/Yb in combination with additional dopants (e.g., GeO.sub.2, Al.sub.2O.sub.3, B.sub.3O.sub.3, F). These filaments can be used to create 3D prints of active laser material. Silicates, boro-silicates, alumino-boro silicates and soda-lime glass present low (er) cost materials of standard type. Due to higher thermal expansion coefficients these may require heated printing plate and post thermal annealing to alleviate stress.

[0073] FIG. 3b depicts a glass filament 160 with a central air hole 162, i.e., a capillary or hollow structure. These capillary/hollow filaments can be used to print different types of glass/air structures. If pressure control is applied to the inner section of the capillary filament, active contraction/expansion of the filament during printing is possible. The volume of said air hole 162 may be between 10-70% of a volume of said glass content in said glass filament 160. The air hole 162 may be centered or non-centered in said glass filament 160. In various example embodiments said glass filament 160 may be provided with a plurality of air holes.

[0074] FIG. 3c depicts a glass filament 160 consisting of silica-based composition contain a central core structure 160 of a refractive index modifying dopant, e.g., GeO.sub.2, Al.sub.2O.sub.3, B.sub.3O.sub.3, F. These core/cladding filaments, which function as optical waveguides, can be used to print optical circuits on different types of glass substrates for use in telecommunication, sensing or biomedical applications. Other core materials, besides glass based, include semiconductor and alloys, e.g., silicon, germanium etc.

[0075] The filament may be continuously fed towards a substrate, while simultaneously, a hot-zone created by a single or multiple laser beams bond them together. The relative motion between the substrate and the filament is under computer control to define the printed shape.

[0076] Simple structures such as micro-spheres, pillars, lines, circles and nano-tapers etc. were printed by single deposition. Printing free-standing models/arrays was also demonstrated. Multi-layer printing in complex geometry was realized. Both hollow models (vase mode) and dense models (100% infill) were printed using the glass filament. Conclusively, the glass filament is applicable to all glass 3d printing tests above and the performance is similar to the plastic filament in FDM systems.

FEASIBLE MODIFICATIONS OF THE INVENTION

[0077] The invention is not limited only to the embodiments described above and shown in the drawings, which primarily have an illustrative and exemplifying purpose. This patent application is intended to cover all adjustments and variants of the preferred embodiments described herein, thus the present invention is defined by the wording of the appended claims and the equivalents thereof. Thus, the equipment may be modified in all kinds of ways within the scope of the appended claims.

[0078] Throughout this specification and the claims which follows, unless the context requires otherwise, the word comprise, and variations such as comprises or comprising, will be understood to imply the inclusion of a stated integer or steps or group of integers or steps but not the exclusion of any other integer or step or group of integers or steps.