Composite object

Abstract

The invention relates to a composite object (100) and to a method for producing such a composite object (100). The composite object (100) comprises a base part (102) and a 3D printed metal part (104). The base part (102) comprises a first major surface (110) and a second major surface (120) arranged opposite the first major surface (110). The first major surface (110) and the second major surface (120) are framed by a first major edge (112) and a second major edge (122), respectively. An edge surface (130) is connecting the first major edge (112) with the second major edge (122). The 3D printed metal part (104) is adhered to the base part (102) and formed by depositing a 3D printable metal material on at least a portion of the edge surface (130) of the base part (102). A thickness of the base part (102) varies between the first major edge (112) and the second major edge (122). The thickness of the base part (102) varies from a first thickness at the first major edge (112) to a second, larger, thickness at the second major edge (122).

Description

[0001] 2024PF80239 1

[0002] Composite object

[0003] FIELD OF THE INVENTION

[0004] The present invention relates to 3D metal printing. More specifically, the present invention is related to a composite object produced by Extreme High-speed Laser Material Deposition.

[0005] BACKGROUND OF THE INVENTION

[0006] 3D Printing is known for its free form designs, as it is not constraint by releasing geometries as conventional mold-based manufacturing technologies. Extreme Highspeed Laser Material Deposition (EHLA) is a metal printing process that is fast and reliable. It produces thin wall metal products. The printing starts on a prepared build plate. This build plate will remain part of the product. Removing is possible, but not preferred because of additional handling.

[0007] However, although fast and reliable, there still remain various aspects of EHLA that are in need of improvement. For example, there is still a need for improving the functionality and appearance of composite objects produced by EHLA.

[0008] SUMMARY OF THE INVENTION

[0009] It is of interest to provide a composite object that is capable of overcoming drawbacks of prior art devices.

[0010] This and other objects are achieved in a first aspect by providing a composite object having the features of the appended independent claim. Preferred embodiments are defined in the appended dependent claims.

[0011] Hence, according to a first aspect, there is provided a composite object comprising a base part. The base part comprises a first major surface and a second major surface arranged opposite the first major surface. The first major surface is framed by a first major edge. The second major surface is framed by a second major edge. The base part comprises an edge surface connecting the first major edge with the second major edge.

[0012] By a surface being framed by an edge, it is to be understood that the edge encircles the area of the surface. The base part may be made of metal. The base part may be 2024PF80239 2 made of any composite material, for example, metal based. The base part may have any shape. For example, the base part may have a circular, oval, elliptical, or any odd shape.

[0013] The composite object further comprises a 3D printed metal part adhered to the base part. The 3D printed metal part is formed by depositing a 3D printable metal material on at least a portion of the edge surface of the base part.

[0014] 3D printing may also be referred to as additive manufacturing. The 3D printed metal part is printed directly on the base part. It is to be understood that the 3D printable metal material is deposited to have a direction of extension with a major component being perpendicular to a plane of extension of the second major surface. In other words, if the plane of extension of the second major surface is seen as a horizontal plane, the 3D printable metal material is deposited with a main component in the vertical direction, pointing away from both the first major surface and the second major surface. That is, the 3D printable metal material may be deposited with a deviation from the vertical direction of up to at least 20 degrees.

[0015] A thickness of the base part is defined as seen in a direction perpendicular to a plane of extension of the first major surface. The thickness of the base part varies between the first major edge and the second major edge from a first thickness at the first major edge to a second thickness at the second major edge. The second thickness being larger than the first thickness. In other words, the thickness variation occurs in a direction that is seen as being perpendicular to the direction that the thickness extends. The thickness increases in a direction away from the first major edge, towards the second major edge.

[0016] In the composite object, the first major edge of the base part is an exposed outer edge of the composite object, and the second major edge of the base part is obscured by the 3D printed metal part.

[0017] It is a realization that the variation in thickness of the base part between the first and second major edge causes at least a portion of the thickness of the base part to be obscured by the 3D printed metal part deposited on at least a portion of the edge surface. In other words, when viewing the composite object from a distance, a thickness of the base part that can be seen is less than a thickness of the second thickness, because the second thickness is partially obscured. An inner space may be defined by the base part and the 3D printed metal part, the edge surface being obscured by the 3D printed metal part when viewing the composite object from a location outside the inner space may be understood as it is hidden from sight when viewing the composite object from a distance, ideally when viewed from a 2024PF80239 3 location from where the second major surface and portions of the edge surface that are within the inner space cannot be seen as they are obscured by the 3D printed metal part.

[0018] An advantage of the composite object is thus that at least a portion of the edge surface of the base part is hidden from sight. It is realized that the portion of the edge surface that is not hidden from sight can be controlled by controlling the shape of the edge surface, as well as controlling the first thickness and the second thickness. It is further realized that the portion of the edge surface that is not hidden from sight can be controlled depending on the location of the 3D printable metal part on the edge surface. The 3D printable metal part may be deposited to cover the portion of the edge surface adjoining the first major edge, in which case the edge surface is obscured by the 3D printed metal part as much as possible for a given shape of the edge surface.

[0019] The aforementioned effects ensure that any undesired contrast in the visual appearance of the edge of the base part (as can be seen when viewing the composite object from a distance) and the wall of the metal part that has been 3D printed onto it is minimized. This is especially the case when the base part is a smooth and shiny metal piece (such as an aluminum piece), as a 3D printed metal part typically has a relatively coarse and matte appearance. By minimizing the undesired contrast, the overall visual appearance of the composite object is improved.

[0020] Further advantages include the fact that the build plate can be provided with high resolution patterns (small holes, slots); it can also be prepared with threaded holes as well as having a very smooth (mirror finish). For some applications, such as filters, the build plate may be made from porous metal plates as well.

[0021] According to a second aspect, there is provided a method for producing a composite object comprising a 3D printed metal part adhering to a base part. The method comprises providing the base part. The base part comprises a first major surface and a second major surface arranged opposite the first major surface. The first major surface is framed by a first major edge. The second major surface is framed by a second major edge. The base part comprises an edge surface connecting the first major edge with the second major edge.

[0022] The method comprises depositing a 3D printable material, such as a metal powder or a metal wire, on at least a portion of the edge surface to form and adhere the 3D printed metal part to the base part. The composite object is thereby formed.

[0023] A thickness of the base part is defined as seen in a direction perpendicular to a plane of extension of the first major surface. The thickness of the base part varies between the 2024PF80239 4 first major edge and the second major edge from a first thickness at the first major edge to a second thickness at the second major edge. The second thickness being larger than the first thickness.

[0024] A method for producing a composite object according to the second aspect may have the same advantages, or similar advantages, as the advantages described in conjunction with the first aspect.

[0025] In some embodiments, the thickness of the base part may vary from the first thickness to the second thickness in a steplike formation. The thickness may vary from the first thickness to the second thickness in one step. In a further embodiment, the thickness may vary from the first thickness to the second thickness in a plurality of steps.

[0026] By varying the thickness in a steplike formation, the portion of the edge surface can easily be controlled by controlling the first thickness, the number of steps, the thickness change between steps, and the location of the 3D printable metal part on the edge surface. A steplike formation is easily and advantageously obtained by milling.

[0027] In some embodiments, the edge surface may be chamfered. The first thickness may approach zero. By the thickness approaching zero, it is meant that a sharp edge is formed at the first major edge.

[0028] The shape of the chamfering may be linear but may have any shape whereby the thickness of the base part varies from the first thickness at the first major edge to the second thickness at the second major edge. For example, the chamfering may have a convex or concave shape, be a combination of several linear segments with different angles relative to the plane of extension of the first major surface, include steps, and any combination thereof.

[0029] An advantage of a chamfered edge is that it enables obscuring a larger portion of the edge surface compared to an edge surface of a different shape. In particular, as the first thickness approaches zero in a chamfered edge surface, it becomes possible to fully obscure the edge surface.

[0030] A very thin edge is advantageous because of its inherent limited thermal mass, i.e. it is easy and fast to heat a thin edge up to melting temperature for making a proper bond.

[0031] In some embodiments, the base part may comprise a first metal plate and a second metal plate. The first metal plate may comprise a primary first plate surface forming the first major surface of the base part and being framed by the first major edge. The second metal plate may comprise a primary second plate surface forming the second major surface of the base part and being framed by the second major edge. The first metal plate may comprise 2024PF80239 5 a secondary first plate surface arranged opposite the primary first place surface. The second metal plate comprises a secondary second plate surface arranged opposite the primary second plate surface. The second metal plate may be arranged on the second metal plate such that the secondary first plate surface and the secondary second plate surface are arranged opposite each other.

[0032] An advantage of the base part comprising the first metal plate and the second metal plate is simplified fabrication. That is, two metal plates requires simple actions of cutting two plates having a relative thin material, which is easier and cheaper than cutting a relatively thicker plate and adding a post processing step for making the step profile by milling the relatively thicker plate.

[0033] Further, the first and the second metal plate may comprise different materials. The materials of the first and the second metal plate may be chosen to optimize the thermomechanical (TM) stability of the composite object. The materials of the first and the second metal plate may be chosen to facilitate easier post processing of the composite object, post processing may for example comprise drilling holes or carving out shapes in the base part.

[0034] According to some embodiments, the first metal plate may be thinner than the second metal plate. The surface area of the first major surface may be larger than a surface area of the second major surface. A thickness of the first metal plate may correspond to the first thickness of the base part. Thus, a thinner first metal plate means a thinner first thickness, and thus the possibility to obscure a larger portion of the edge surface. The first plate may be a standardized part, while the second plate may be in the form of a customized laser cut part, thereby facilitating customization of the build plate.

[0035] In some embodiments, the base part is made of metal. Metal is advantageous, for example when a choice has been made to fabricate a metal object such as a metal luminaire. An object made fully of metal, the metal being of one type / grade, then a very homogenous object is provided having a minimum of thermo-mechanical and thermal mismatches.

[0036] In a further aspect, there is provided a lighting device comprising a composite object as summarized above. The composite object may be configured as one or more of (i) at least part of a lighting device housing, (ii) at least part of a wall of a lighting chamber, and (iii) an optical element. The lighting device may further comprise a connector mechanically and electrically connected to a socket of the lighting device. 2024PF80239 6

[0037] Such a lamp or luminaire provides the effects and advantages as summarized above.

[0038] The composite object is not intended solely for lighting devices, and may for example, but not limited to, be used in applications such as engine parts and axels. Various materials may be used, such as Aluminum, Steel, Ti, Ti - alloys and various metal mixes.

[0039] BRIEF DESCRIPTION OF THE DRAWINGS

[0040] This and other aspects of the present invention will now be described in more detail, with reference to the appended drawings showing embodiment(s) of the invention.

[0041] Figure la schematically illustrates a side view of a composite object.

[0042] Figure lb schematically illustrates atop view of a composite object.

[0043] Figure 2a schematically illustrates a side view of a base part.

[0044] Figure 2b schematically illustrates a cross-sectional side view of a composite object along the axis A- A.

[0045] Figure 2c schematically illustrates a side view of a composite object.

[0046] Figure 3a schematically illustrates a side view of base part.

[0047] Figure 3b schematically illustrates a cross-sectional side view of a composite object along the axis A- A.

[0048] Figure 3c schematically illustrates a side view of a composite object.

[0049] Figure 4a schematically illustrates a side view of a base part.

[0050] Figure 4b schematically illustrates a cross-sectional side view of the composite object along the axis A- A.

[0051] Figure 4c schematically illustrates a side view of the composite object.

[0052] Figure 5 schematically illustrates a 3D printing process.

[0053] Figure 6 schematically illustrates a method for producing a composite object.

[0054] Figure 7 schematically illustrates a lighting device.

[0055] DETAILED DESCRIPTION OF THE EMBODIMENTS

[0056] As illustrated in figure la and lb, an embodiment of a composite object 100 comprises a base part 102. The base part comprises a first major surface 110 and a second major surface 120 arranged opposite the first major surface 110. The first major surface 110 is framed by a first major edge 112. The second major surface 120 is framed by a second major 2024PF80239 7 edge 122. The base part comprises an edge surface 130 connecting the first major edge 112 with the second major edge 122.

[0057] The base part may be made of metal. The base part may be made of any composite material, for example, metal based. The base part may have any shape. For example, the base part may have a circular, oval, elliptical shape but not limited thereto.

[0058] The composite object further comprises a 3D printed metal part 104 adhered to the base part 102. The 3D printed metal part is formed by depositing a 3D printable metal material on at least a portion of the edge surface 130 of the base part 102. The 3D printed metal part may fully encircle the second major surface, such that the base part 102 and the 3D printed metal part 104 may define an inner space. In said inner space, the base part 102 may be seen as a bottom and the 3D printed metal part may be seen as a side wall.

[0059] As illustrated in figure 5, a 3D printing device 500 may deposit a 3D printable metal material 510 on the edge surface 130 of the base part 102. The 3D printed metal part is thus formed from the 3D printable material 510.

[0060] A more detailed example may comprise the following steps: Step 1 : open the printing machine. Step 2: mount the build plate on the machine table with dedicated clamping / screws / vacuum / tape / magnetics. Step 3: Align the object (e.g. by the machine, by vision, or by other sensor means). Step 4: Switch on the metal powder flow. Stabilize the flow for 20 seconds. Step 5: Move the machine to the printing position with a desired speed. At defined printing height. Step 6: switch on the laser at that starting position and keep it on for the full trace. Move the full trace with constant speed. Step 7 : if the track or trace is made. Switch off the laser and move the machine to the next layer height. Usually the machine needs a deacceleration distance to slow down and start moving again towards constant speed on the next layer height.

[0061] The 3D printing may be based on metal powders or metal wires. For example, known methods such as EHLA, Direct Energy Deposition (DED), Electron Beam Melting (EBM), Metaljet and Wire Arc Additive Manufacturing (WAAM) may be used. The 3D printed metal part 104 may be adhered to the base part 102 for example by, but no limited to, brazing, soldering, molten metal particle impact, high energy solid metal particle impact or fusion bonding. 3D printing may be referred to as a form of additive manufacturing.

[0062] As illustrated in the various embodiments of figures 2 to 4, a thickness of the base part 102 is defined as seen in a direction (z) perpendicular to a plane of extension of the first major surface. The thickness of the base part varies between the first major edge 112 and 2024PF80239 8 the second major edge 122 from a first thickness 106 at the first major edge 112 to a second thickness 108 at the second major edge 122. The second thickness 108 being larger than the first thickness 106. In other words, the thickness variation occurs in a direction (x, y) that is seen as being perpendicular to the direction (z) that the thickness extends. The thickness increases in a direction (x, y) away from the first major edge, towards the second major edge.

[0063] According to a second aspect, there is provided a method 600 for producing a composite object 100 comprising a 3D printed metal part 104 adhering to a base part 102. The method comprises providing 602 the base part 102. The base part comprises a first major surface 110 and a second major surface 120 arranged opposite the first major surface 110. The first major surface 110 is framed by a first major edge 112. The second major surface 120 is framed by a second major edge 122. The base part comprises an edge surface 130 connecting the first major edge 112 with the second major edge 122.

[0064] As illustrated in figure 6, the method comprises depositing 604 a 3D printable material 510 on at least a portion of the edge surface 130 to form and adhere the 3D printed metal part 104 to the base part 102. The composite object is thereby formed.

[0065] A thickness of the base part 102 is defined as seen in a direction (z) perpendicular to a plane of extension of the first major surface. The thickness of the base part varies between the first major edge 112 and the second major edge 122 from a first thickness 106 at the first major edge 112 to a second thickness 108 at the second major edge 122. The second thickness 108 being larger than the first thickness 106.

[0066] In some embodiment as illustrated in figure 2a-c, the thickness of the base part 102 may vary from the first thickness 106 to the second thickness 108 in a steplike formation. The thickness may vary from the first thickness 106 to the second thickness 108 in one step. In other words, the thickness of the base part 102 close to the first major edge 112 is the first thickness 106. The thickness of the base part 102 may be constantly the first thickness 106 for a step distance 109, the step distance 109 extending from the first major edge towards a center of the base part 102 in a direction (x, y) that is seen as being perpendicular to the direction (z) that the thickness extends. In a further embodiment, not illustrated, the thickness may vary from the first thickness 106 to the second thickness 108 in a plurality of steps, each step having a corresponding step distance. Figure 2b illustrates a cross-sectional side view along the A-A axis of the composite object according to one embodiment. Figure 2c illustrates a side view of the composite object, highlighting that a portion of the thickness of the base part 102 is obscured by the 3D printed metal part 104. When viewed from the side, as illustrated in 2024PF80239 9 figure 2b and c, only the first step of the edge surface 130 is visible, as the remainder of the edge surface 130 is obscured by the 3D printed metal part 104.

[0067] In some embodiment as illustrated in figures 3a-c, the edge surface 130 may be chamfered. The first thickness may approach zero. By the thickness approaching zero, it is meant that a sharp edge is formed at the first major edge. Figure 3b illustrates a cross- sectional side view along the A- A axis of the composite object according to one embodiment. Figure 3c illustrates a side view of the composite object, highlighting that a portion of the thickness of the base part 102 is obscured by the 3D printed metal part 104. The shape of the chamfering may be linear but may have any shape, not shown in the figures, whereby the thickness of the base part varies from the first thickness 106 at the first major edge 112 to the second thickness 108 at the second major edge 122. For example, the chamfering may have a convex or concave shape, be a combination of several linear segments with different angles relative to the plane of extension of the first major surface 112, include steps, and any combination thereof.

[0068] In some embodiments as illustrated in figures 4a-c, the base part 102 may comprise a first metal plate 140 and a second metal plate 150. The first metal plate 140 may comprise a primary first plate surface 144 forming the first major surface 110 of the base part 102 and being framed by the first major edge 112. The second metal plate 150 may comprise a primary second plate surface 154 forming the second major surface 120 of the base part 102 and being framed by the second major edge 122. The first metal plate 140 may comprise a secondary first plate surface 145 arranged opposite the primary first place surface 144. The second metal plate 150 comprises a secondary second plate surface 155 arranged opposite the primary second plate surface 154. The second metal plate 150 may be arranged on the second metal plate 140 such that the secondary first plate surface 145 and the secondary second plate surface 155 are arranged opposite each other. In other words, the second metal plate and the first metal plate are abutting each other and may be adhered to each other. The 3D printed metal part 104 is deposited on and adhered to the first metal plate 140. The 3D printed metal part 104 may adhere to the second metal plate 150. The adhering of the 3D printed metal part 104 to the second metal plate 150 may be what causes the second metal plate to be arranged on the first metal plate and may be what causes the secondary first plate surface 145 and the secondary second plate surface 155 to abut or adhere to each other.

[0069] According to some embodiments, the first metal plate may be thinner than the second metal plate. The surface area of the first major surface 110 may be larger than a 2024PF80239 10 surface area of the second major surface 120. A thickness of the first metal plate may correspond to the first thickness of the base part. Thus, a thinner first metal plate means a thinner first thickness, and thus the possibility to obscure a larger portion of the edge surface. The first and the second metal plate may be made from different materials. The first and the second metal plate may be made from different metals, metal-based composite materials, ceramic materials, or any combination thereof. Figure 4b illustrates a cross-sectional side view along the A-A axis of the composite object according to one embodiment. Figure 4c illustrates a side view of the composite object, highlighting that a portion of the thickness of the base part 102 is obscured by the 3D printed metal part 104. As illustrated in figure 4c the second metal plate 150 is obscured by the 3D printed metal part 104

[0070] In some embodiments, the base part 102 is made of metal. Alternatively, the base part may be made of metal-based composite materials, ceramic materials, or any combination thereof. That is, considering the material of the base part, it should be materials that are compatible with metal deposition from ‘molten’ metal. So, the material should withstand sufficiently the temperatures and should also provide a sufficiently good basis for metal adherence.

[0071] As illustrated in figure 7, in a further aspect, there is provided a lighting device 200 comprising a composite object 100 as summarized above. The composite object 100 may be configured as one or more of (i) at least part of a lighting device housing, (ii) at least part of a wall of a lighting chamber, and (iii) an optical element. The lighting device may further comprise a connector 210 mechanically and electrically connected to a socket of the lighting device.

Claims

2024PF80239 11CLAIMS:

1. A composite object (100) comprising a base part (102) and a 3D printed metal part (104) adhered to the base part (102), wherein the base part (102) comprises a first major surface (110) and a second major surface (120) arranged opposite the first major surface (110), the first major surface (110) being framed by a first major edge (112), and the second major surface (120) being framed by a second major edge (122), wherein the base part (102) further comprises an edge surface (130) connecting the first major edge (112) with the second major edge (122), wherein the 3D printed metal part (104) is formed by depositing a 3D printable metal material (510) on at least a portion of the edge surface (130) of the base part (102), wherein a thickness of the base part (102) as seen in a direction perpendicular to a plane of extension of the first major surface (110) varies between the first major edge (112) and the second major edge (122) from a first thickness (106) at the first major edge (112) to a second thickness (108) at the second major edge (122), the second thickness (108) being larger than the first thickness (106), and wherein the first major edge (112) is an exposed outer edge of the composite object (100), and the second major edge (122) is obscured by the 3D printed metal part (140).

2. The composite object (100) according to claim 1, wherein the thickness of the base part (102) varies from the first thickness (106) to the second thickness (108) in a steplike formation.

3. The composite object (100) according to claim 2, wherein the thickness of the base part (102) varies from the first thickness (106) to the second thickness (108) in one step.

4. The composite object (100) according to claim 1, wherein the edge surface (130) is chamfered.2024PF80239 125. The composite object (100) according to claim 4, wherein the first thickness approaches zero.

6. The composite object (100) according to claim 1, wherein the base part (102) comprises a first metal plate (140) and a second metal plate (150), wherein the first metal plate (140) comprises a primary first plate surface (144) forming the first major surface (110) of the base part (102) and being framed by the first major edge (112), wherein the second metal plate (150) comprises a primary second plate surface(154) forming the second major surface (120) of the base part (102) and being framed by the second major edge (122), wherein the first metal plate (140) comprises a secondary first plate surface (145) arranged opposite the primary first place surface (144), wherein the second metal plate (150) comprises a secondary second plate surface (155) arranged opposite the primary second plate surface (154), and wherein the second metal plate (150) is arranged on the second metal plate (140) such that the secondary first plate surface (145) and the secondary second plate surface(155) are arranged opposite each other.

7. The composite object (100) according to claim 6, wherein the first metal plate (140) is thinner than the second metal plate (150).

8. The composite object (100) according to any one of the previous claims, wherein a surface area of the first major surface (110) is larger than a surface area of the second major surface (120).

9. The composite object (100) according to any one of the previous claims, wherein the base part (102) is made of metal.

10. A method (600) for producing a composite object (100) comprising a 3D printed metal part (104) adhering to a base part (102), wherein the method comprises:2024PF80239 13 providing the base part (102), the base part (102) comprising a first major surface (110) and a second major surface (120) arranged opposite the first major surface (110), the first major surface (110) being framed by a first major edge (112), and the second major surface (120) being framed by a second major edge (122), the base part (102) further comprising an edge surface (130) connecting the first major edge (112) with the second major edge (122), and depositing a 3D printable material (510) on at least a portion of the edge surface (130) to form and adhere the 3D printed metal part (104) to the base part (102), thereby forming the composite object (100), wherein a thickness of the base part (102) as seen in a direction perpendicular to a plane of extension of the first major surface (110) varies between the first major edge (112) and the second major edge (122) from a first thickness (106) at the first major edge (112) to a second thickness (108) at the second major edge (122), and wherein the second thickness (108) is larger than the first thickness (106).

11. A lighting device (200) comprising the composite object (100) according to any one of claims 1 to 9, wherein the composite object (100) is configured as one or more of (i) at least part of a lighting device housing, (ii) at least part of a wall of a lighting chamber, and (iii) an optical element.

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