Powder bed fusion apparatus and methods

EP4766514A1Pending Publication Date: 2026-07-01RENISHAW PLC
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Patent Information

Authority / Receiving Office
EP · EP
Patent Type
Applications
Current Assignee / Owner
RENISHAW PLC
Filing Date
2024-08-23
Publication Date
2026-07-01

AI Technical Summary

Technical Problem

The use of a bidirectional wiper in powder bed fusion apparatuses leads to uneven irradiation times across different portions of a powder layer, resulting in inefficiencies and increased build times due to the need to delay the movement of the wiper to allow sufficient time for irradiation.

Method used

A method is developed to determine an optimal irradiation sequence for powder bed fusion processes, where the movement of the recoater forming powder layers differs for each layer. This method allocates energy beams to specific irradiation regions based on the recoater's movement, ensuring that each region is fully irradiated before being covered by the next powder layer.

Benefits of technology

The proposed method enhances the efficiency of the powder bed fusion process by ensuring continuous movement of the wiper and energy beams, thereby reducing build times and minimizing interruptions in the process.

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Abstract

A powder bed fusion process comprising forming powder layers (L1 to L11) of a powder bed (104) with the recoater (109) and, when a recoater (109) is moving across the powder bed (104) to form each powder layer (L1 to L11) of a plurality of the powder layers, operating at least one scanner (106a, 106b, 106c, 106d) to steer a corresponding energy beam (118a, 118b, 118c, 118d) across the powder bed (104) such that the energy beam (118a, 118b, 118c, 118d) irradiates the powder bed (104) to melt powder. A plurality of regions (130 to 141) of the powder layer (L3) are consolidated to form together a consolidated section within the powder layer (L3) 10 by melting powder of each region (130 to 141) together with powder of at least one other powder layer (L2, L4) through the irradiation of the powder bed (104) by the energy beam (118a, 118b, 118c, 118d), powder of different ones of the regions (130 to 141) melted en masse with powder of different other powder layers (L2 or L4).
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