U.S. patent application number 14/636607 was filed with the patent office on 2015-10-08 for method for fusing a workpiece.
The applicant listed for this patent is ARCAM AB. Invention is credited to Johan Backlund, Tomas Lock.
Application Number | 20150283613 14/636607 |
Document ID | / |
Family ID | 54208925 |
Filed Date | 2015-10-08 |
United States Patent
Application |
20150283613 |
Kind Code |
A1 |
Backlund; Johan ; et
al. |
October 8, 2015 |
METHOD FOR FUSING A WORKPIECE
Abstract
Various embodiments of the present invention relate to a method
for welding a workpiece comprising the steps of: making a first
weld at a first position on said workpiece with a high energy beam,
deflecting the high energy beam with at least one deflection lens
for making a second weld at a second position on said workpiece,
focusing the high energy beam on said workpiece with at least one
focusing lens, shaping the high energy beam on said workpiece with
at least one astigmatism lens so that the shape of the high energy
beam on said workpiece is longer in a direction parallel to a
deflection direction of said high energy beam than in a direction
perpendicular to said deflection direction of said high energy
beam. The invention is also related to the use of an astigmatism
lens and to a method for forming a three dimensional article.
Inventors: |
Backlund; Johan; (Onsala,
SE) ; Lock; Tomas; (Vaestra Froelunda, SE) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
ARCAM AB |
Moelndal |
|
SE |
|
|
Family ID: |
54208925 |
Appl. No.: |
14/636607 |
Filed: |
March 3, 2015 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
|
61974304 |
Apr 2, 2014 |
|
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|
Current U.S.
Class: |
419/53 ;
219/121.14; 219/121.63; 219/121.64; 264/497; 425/174.4; 425/78 |
Current CPC
Class: |
B33Y 10/00 20141201;
B23K 26/0648 20130101; B22F 2003/1057 20130101; B23K 26/0732
20130101; B29C 64/393 20170801; B28B 1/001 20130101; B33Y 30/00
20141201; B22F 3/1055 20130101; B23K 15/02 20130101; B23K 15/0013
20130101; B23K 26/702 20151001; B29C 64/153 20170801; Y02P 10/25
20151101; B23K 26/0736 20130101; B28B 17/0081 20130101; B33Y 50/02
20141201; B23K 26/342 20151001; G02B 27/0911 20130101; B23K 15/0086
20130101; B29K 2105/251 20130101; B23K 26/0738 20130101; B22F
2003/1056 20130101; B23K 26/0643 20130101 |
International
Class: |
B22F 3/105 20060101
B22F003/105; B28B 17/00 20060101 B28B017/00; B29C 67/00 20060101
B29C067/00; B28B 1/00 20060101 B28B001/00; B23K 15/00 20060101
B23K015/00; B23K 26/34 20060101 B23K026/34 |
Claims
1. A method for welding a workpiece, said method comprising the
steps of: making a first weld at a first position on said workpiece
with a high energy beam; deflecting the high energy beam with at
least one deflection lens to make a second weld at a second
position on said workpiece; focusing the high energy beam on said
workpiece with at least one focusing lens; and shaping the high
energy beam on said workpiece with at least one astigmatism lens so
that the shape of the high energy beam on said workpiece is longer
in a direction parallel to a deflection direction of said high
energy beam than in a direction perpendicular to said deflection
direction of said high energy beam, wherein a ratio of a length of
said high energy beam in said parallel direction and said
perpendicular direction is varying as a function of the power of
said energy beam on said workpiece.
2. The method according to claim 1, wherein said high energy beam
is at least one of an electron beam or a laser beam.
3. The method according to claim 1, wherein said deflection source
is at least one of a tiltable mirror or a tiltable lens.
4. The method according to claim 1, wherein said deflection source
is a deflection coil.
5. The method according to claim 1, wherein said workpiece is a
powder material layer in an additive manufacturing process.
6. The method according to claim 1, wherein a ratio of a length of
said high energy beam in said parallel direction and said
perpendicular direction is also varying as a function of the
position of said high energy beam on said workpiece.
7. The method according to claim 1, wherein said energy beam is at
least five (5) times longer in a direction parallel to the
deflection direction compared to a direction perpendicular to said
deflection direction.
8. The method according to claim 1, wherein said energy beam is at
least ten (10) times longer in a direction parallel to the
deflection direction compared to a direction perpendicular to said
deflection direction.
9. The method according to claim 1, wherein a mean spot size on
said workpiece in a direction perpendicular to the scanning
direction is smaller than a mean spot size on said workpiece in a
direction parallel to the scanning direction for a full scan
length, a full cross section and/or for a full 3-dimensional
article.
10. The method according to claim 1, wherein one or more of the
steps of deflecting, focusing, and shaping the high energy beam are
performed via execution of one or more computer processors.
11. A method of using of an astigmatism lens in additive
manufacturing for forming a three-dimensional article through
successive fusion, with a high energy beam, of parts of at least
one layer of a powder bed provided on a work table, which parts
correspond to successive cross sections of the three dimensional
article, said method comprising the step of: using said astigmatism
lens to prolong the size the high energy beam on said layer of
powder bed in a direction parallel to a deflection direction more
than in a direction perpendicular to said deflection direction,
wherein a ratio of a length of said high energy beam in said
parallel direction and said perpendicular direction is varying as a
function of the power of said energy beam on said workpiece.
12. A method for forming a three-dimensional article through
successively depositing individual layers of powder material that
are fused together so as to form the article, said method
comprising the steps of: providing at least one high energy beam
source for emitting a high energy beam for at least one of heating
or fusing said powder material; providing a deflection source for
deflecting the high energy beam on said powder material; providing
a focus lens for focusing said high energy beam on said powder
material; and shaping the high energy beam on said powder layer
with at least one astigmatism lens so that the shape of the high
energy beam on said layer of powder is longer in a direction
parallel to a deflection direction of said high energy beam than in
a direction perpendicular to said deflection direction of said high
energy beam, wherein a ratio of a length of said high energy beam
in said parallel direction and said perpendicular direction is
varying as a function of the power of said energy beam on said
workpiece.
13. The method according to claim 12, wherein said high energy beam
is at least one of an electron beam or a laser beam.
14. The method according to claim 12, wherein said deflection
source is at least one of a tiltable mirror or a tiltable lens.
15. The method according to claim 12, wherein said deflection
source is a deflection coil.
16. The method according to claim 12, wherein a ratio of a length
of said high energy beam in said parallel direction and said
perpendicular direction is also varying as a function of the
position of said high energy beam on said workpiece.
17. The method according to claim 12, wherein said energy beam is
at least five (5) times longer in a direction parallel to the
deflection direction compared to a direction perpendicular to said
deflection direction.
18. The method according to claim 12, wherein said energy beam is
at least ten (10) times longer in a direction parallel to the
deflection direction compared to a direction perpendicular to said
deflection direction.
19. The method according to claim 12, wherein a mean spot size on
said workpiece in a direction perpendicular to the scanning
direction is smaller than a mean spot size on said workpiece in a
direction parallel to the scanning direction for a full scan
length, a full cross section and/or for a full 3-dimensional
article.
20. The method according to claim 12, wherein: the method further
comprises the step of receiving and storing, within one or more
memory storage areas, a model of said at least one
three-dimensional article; and at least the step of shaping the
high energy beam is performed via execution of one or more computer
processors.
21. An apparatus for forming a three-dimensional article through
successively depositing individual layers of powder material that
are fused together so as to form the article, said apparatus
comprising: at least one high energy beam source for emitting a
high energy beam for at least one of heating or fusing said powder
material; a deflection source for deflecting the high energy beam
on said powder material; a focus lens for focusing said high energy
beam on said powder material; at least one astigmatism lens; and at
least one controller configured to control said at least one
astigmatism lens so as to shape the high energy beam on said powder
layer such that the shape of the high energy beam on said layer of
powder is longer in a direction parallel to a deflection direction
of said high energy beam than in a direction perpendicular to said
deflection direction of said high energy beam, wherein a ratio of a
length of said high energy beam in said parallel direction and said
perpendicular direction is varying as a function of the power of
said energy beam on said workpiece.
22. The apparatus according to claim 21, wherein said high energy
beam is at least one of an electron beam or a laser beam.
23. The apparatus according to claim 21, wherein said deflection
source is at least one of a tiltable mirror or a tiltable lens or a
deflection coil.
24. The apparatus according to claim 21, wherein a ratio of a
length of said high energy beam in said parallel direction and said
perpendicular direction is also varying as a function of the
position of said high energy beam on said workpiece.
25. The apparatus according to claim 21, wherein said energy beam
is at least five (5) times longer in a direction parallel to the
deflection direction compared to a direction perpendicular to said
deflection direction.
26. The apparatus according to claim 21, wherein said energy beam
is at least ten (10) times longer in a direction parallel to the
deflection direction compared to a direction perpendicular to said
deflection direction.
27. The apparatus according to claim 21, wherein a mean spot size
on said workpiece in a direction perpendicular to the scanning
direction is smaller than a mean spot size on said workpiece in a
direction parallel to the scanning direction for a full scan
length, a full cross section and/or for a full 3-dimensional
article.
28. An apparatus for welding a workpiece, said apparatus
comprising: a high energy beam configured to make a first weld at a
first position on said workpiece; at least one deflection lens
configured to deflect the high energy beam so as to cause the high
energy beam to make a second weld at a second position on said
workpiece; at least one focusing lens configured to focus the high
energy beam on said workpiece; and at least one astigmatism lens;
and at least one controller configured to: shape the high energy
beam on said workpiece with said at least one astigmatism lens so
that the shape of the high energy beam on said workpiece is longer
in a direction parallel to a deflection direction of said high
energy beam than in a direction perpendicular to said deflection
direction of said high energy beam, wherein a ratio of a length of
said high energy beam in said parallel direction and said
perpendicular direction is varying as a function of the power of
said energy beam on said workpiece.
29. A computer program product for forming a three-dimensional
article through successively depositing individual layers of powder
material that are fused together so as to form the article, the
computer program product comprising at least one non-transitory
computer-readable storage medium having computer-readable program
code portions stored therein, the computer-readable program code
portions comprising: an executable portion configured to provide at
least one high energy beam source for emitting a high energy beam
for at least one of heating or fusing said powder material; an
executable portion configured to provide a deflection source for
deflecting the high energy beam on said powder material; an
executable portion configured to provide a focus lens for focusing
said high energy beam on said powder material; an executable
portion configured to shape the high energy beam on said powder
layer with at least one astigmatism lens so that the shape of the
high energy beam on said layer of powder is longer in a direction
parallel to a deflection direction of said high energy beam than in
a direction perpendicular to said deflection direction of said high
energy beam, wherein a ratio of a length of said high energy beam
in said parallel direction and said perpendicular direction is
varying as a function of the power of said energy beam on said
workpiece.
30. A computer program product for welding a workpiece, the
computer program product comprising at least one non-transitory
computer-readable storage medium having computer-readable program
code portions stored therein, the computer-readable program code
portions comprising: an executable portion configured to make a
first weld at a first position on said workpiece with a high energy
beam; an executable portion configured to deflect the high energy
beam with at least one deflection lens for making a second weld at
a second position on said workpiece; an executable portion
configured to focus the high energy beam on said workpiece with at
least one focusing lens; and an executable portion configured to
shape the high energy beam on said workpiece with at least one
astigmatism lens so that the shape of the high energy beam on said
workpiece is longer in a direction parallel to a deflection
direction of said high energy beam than in a direction
perpendicular to said deflection direction of said high energy
beam, wherein a ratio of a length of said high energy beam in said
parallel direction and said perpendicular direction is varying as a
function of the power of said energy beam on said workpiece.
Description
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application claims priority to and the benefit of U.S.
Provisional Patent Application Ser. No. 61/974,304, filed Apr. 2,
2014, the contents of which as are hereby incorporated by reference
in their entirety.
BACKGROUND
[0002] 1. Related Field
[0003] Various embodiments of the present invention relates to a
method for welding a workpiece and a method for forming a
three-dimensional article.
[0004] 2. Description of Related Art
[0005] Freeform fabrication or additive manufacturing is a method
for forming three-dimensional articles through successive fusion of
chosen parts of powder layers applied to a worktable. A method and
apparatus according to this technique is disclosed in US
2009/0152771.
[0006] Such an apparatus may comprise a work table on which the
three-dimensional article is to be formed, a powder dispenser,
arranged to lay down a thin layer of powder on the work table for
the formation of a powder bed, a ray gun for delivering energy to
the powder whereby fusion of the powder takes place, elements for
control of the ray given off by the ray gun over the powder bed for
the formation of a cross section of the three-dimensional article
through fusion of parts of the powder bed, and a controlling
computer, in which information is stored concerning consecutive
cross sections of the three-dimensional article. A
three-dimensional article is formed through consecutive fusions of
consecutively formed cross sections of powder layers, successively
laid down by the powder dispenser.
[0007] There is always a demand for decreasing or minimizing the
time for fusing powder material in additive manufacturing or when
welding pieces together. One way to increase the efficiency and the
speed in AM or when welding in general is to increase the power of
the energy beam and at the same time increase the speed of
deflection of said energy beam. The deposited power per surface
unit can thereby be kept constant but being distributed faster over
the surface which is to be fused or welded. However, this only
works until a predetermined power and speed of deflection of said
energy beam. If increasing the power over a predetermined value,
the speed of deflection will be too fast so that the heat from the
energy beam will not have sufficient time to penetrate into the
material to be fused or welded. With a too high power and thereby a
too fast speed of deflection of said energy beam, the surface
temperature will become too high so that the material which is to
be fused or welded is instead evaporated.
[0008] There is a need in the art to beyond that predetermined
power and speed of deflection in welding and without evaporating
the material which is to be fused or welded.
BRIEF SUMMARY
[0009] Having this background, an object of the invention is to
provide a method for welding or additive manufacturing with
improved efficiency. The above-mentioned object is achieved by the
features according to the claims contained herein.
[0010] According to various embodiments, a method for welding a
workpiece is provided. The method comprising the steps of: making a
first weld at a first position on said workpiece with a high energy
beam, deflecting the high energy beam with at least one deflection
lens for making a second weld at a second position on said
workpiece, focusing the high energy beam on said workpiece with at
least one focusing lens, shaping the high energy beam on said
workpiece with at least one astigmatism lens so that the shape of
the high energy beam on said workpiece is longer in a direction
parallel to a deflection direction of said high energy beam than in
a direction perpendicular to said deflection direction of said high
energy beam, wherein a ratio of a length of said high energy beam
in said parallel direction and said perpendicular direction is
varying as a function of the power of said energy beam on said
workpiece.
[0011] An advantage of the present invention is that the beam power
may be increased substantially or very substantially, as one
increases the astigmatism and the scan speed while still fusing the
powder or welding the pieces together to a sufficient depth while
avoiding evaporation due to excessive temperatures. This may also
result in decreased building time. Another advantage of the present
invention is that the fusing accuracy or melt width perpendicular
to the scanning direction may be kept constant irrespective of the
used beam power and scan speed.
[0012] In an example embodiment of the present invention said
energy beam is a laser beam or an electron beam. A non-limiting
advantage of at least this embodiment is that the invention is
independent of the energy beam source used.
[0013] In still another example embodiment of the present invention
a ratio of a length of said high energy beam in said parallel
direction and said perpendicular direction may also be varied as a
function of the position of said high energy beam on said
workpiece. A non-limiting advantage of at least this embodiment is
that the protraction of the beam spot may not only be beam power
dependent but may also be depending on the pattern which is to be
fused.
[0014] According to another aspect of the present invention it is
provided a method of using an astigmatism lens in additive
manufacturing for forming a three-dimensional article through
successive fusion, with a high energy beam, of parts of at least
one layer of a powder bed provided on a work table, which parts
correspond to successive cross sections of the three dimensional
article, said astigmatism lens may be used for prolonging the size
the high energy beam on said layer of powder bed in a direction
parallel to a deflection direction more than in a direction
perpendicular to said deflection direction, wherein a ratio of a
length of said high energy beam in said parallel direction and said
perpendicular direction is varying as a function of the power of
said energy beam on said workpiece.
[0015] A non-limiting advantage of at least this embodiment is that
the method of using the astigmatism lens may be widened from the
normal use where the beam spot shape is corrected back to its
original shape due to distortions introduced in the lens system
between the energy beam source and the target surface. According to
the present invention the astigmatism lens system, which may be a
true lens system in case of a laser beam and an electrical coil
system in case of an electron beam, may be used for shaping the
beam so as to protract the beam size in a direction parallel to the
deflection direction giving a beam shape which is longer in a
direction parallel to the scanning direction compared to a
direction perpendicular to said scanning direction. The degree of
said protraction is at least varying as a function of the power of
said energy beam.
[0016] In still another aspect of the present invention it is
provided a method for forming a three-dimensional article through
successively depositing individual layers of powder material that
are fused together so as to form the article, said method
comprising the steps of: providing at least one high energy beam
source for emitting a high energy beam for at least one of heating
or fusing said powder material, providing a deflection source for
deflecting the high energy beam on said powder material, providing
a focus lens for focusing said high energy beam on said powder
material, shaping the high energy beam on said powder layer with at
least one astigmatism lens so that the shape of the high energy
beam on said layer of powder is longer in a direction parallel to a
deflection direction of said high energy beam than in a direction
perpendicular to said deflection direction of said high energy
beam, wherein a ratio of a length of said high energy beam in said
parallel direction and said perpendicular direction is varying as a
function of the power of said energy beam on said workpiece.
[0017] A non-limiting advantage of various embodiments of the
present invention is that the power may be increased substantially
or very substantially, the more power the more astigmatism and
faster scan speed. This also results in decreased building time for
additively manufactured parts. Another advantage of the present
invention is that the fusing accuracy or melt width perpendicular
to the scanning direction may be kept constant irrespective of the
used beam power and scan speed, meaning that the accuracy is not
affected when decreasing the building time for additively
manufactured parts according to the present invention.
[0018] In an example embodiment of the present invention said
energy beam is a laser beam or an electron beam. A non-limiting
advantage of at least this embodiment is that the invention is
independent of the energy beam source used.
[0019] In still another example embodiment of the present invention
a ratio of a length of said high energy beam in said parallel
direction and said perpendicular direction is also varying as a
function of the position of said high energy beam on said
workpiece. A non-limiting advantage of at least this embodiment is
that the protraction of the beam spot is not only beam power
dependent but also depending on the pattern which is to be
fused.
[0020] In yet another example embodiment of the present invention a
mean spot size on said workpiece in a direction perpendicular to
the scanning direction is smaller than a mean spot size on said
workpiece in a direction parallel to the scanning direction for a
full scan length, a full cross section and/or for a full
3-dimensional article. A non-limiting advantage of at least this
embodiment is that one may choose for which part of the build the
mean spot size in a direction parallel to the scanning direction is
longer than the mean spot size in a direction perpendicular to the
scanning direction.
[0021] In yet another example embodiment of the present invention,
any of the described methods may be performed, at least in part via
execution of one or more computer processors.
[0022] In yet another example embodiment of the present invention,
an apparatus is provided for forming a three-dimensional article
through successively depositing individual layers of powder
material that are fused together so as to form the article. The
apparatus comprises: at least one high energy beam source for
emitting a high energy beam for at least one of heating or fusing
said powder material; a deflection source for deflecting the high
energy beam on said powder material; a focus lens for focusing said
high energy beam on said powder material; at least one astigmatism
lens; and at least one controller configured to control said at
least one astigmatism lens so as to shape the high energy beam on
said powder layer such that the shape of the high energy beam on
said layer of powder is longer in a direction parallel to a
deflection direction of said high energy beam than in a direction
perpendicular to said deflection direction of said high energy
beam, wherein a ratio of a length of said high energy beam in said
parallel direction and said perpendicular direction is varying as a
function of the power of said energy beam on said workpiece.
[0023] In yet another example embodiment of the present invention
an apparatus for welding a workpiece is provided. The apparatus
comprises in certain embodiments: a high energy beam configured to
make a first weld at a first position on said workpiece; at least
one deflection lens configured to deflect the high energy beam so
as to cause the high energy beam to make a second weld at a second
position on said workpiece; at least one focusing lens configured
to focus the high energy beam on said workpiece; and at least one
astigmatism lens; and at least one controller configured to: shape
the high energy beam on said workpiece with said at least one
astigmatism lens so that the shape of the high energy beam on said
workpiece is longer in a direction parallel to a deflection
direction of said high energy beam than in a direction
perpendicular to said deflection direction of said high energy
beam, wherein a ratio of a length of said high energy beam in said
parallel direction and said perpendicular direction is varying as a
function of the power of said energy beam on said workpiece.
[0024] In yet another example embodiment of the present invention a
computer program product for forming a three-dimensional article
through successively depositing individual layers of powder
material that are fused together so as to form the article is
provided. The computer program product comprises at least one
non-transitory computer-readable storage medium having
computer-readable program code portions stored therein. The
computer-readable program code portions comprise: an executable
portion configured to provide at least one high energy beam source
for emitting a high energy beam for at least one of heating or
fusing said powder material; an executable portion configured to
provide a deflection source for deflecting the high energy beam on
said powder material; an executable portion configured to provide a
focus lens for focusing said high energy beam on said powder
material; and an executable portion configured to shape the high
energy beam on said powder layer with at least one astigmatism lens
so that the shape of the high energy beam on said layer of powder
is longer in a direction parallel to a deflection direction of said
high energy beam than in a direction perpendicular to said
deflection direction of said high energy beam, wherein a ratio of a
length of said high energy beam in said parallel direction and said
perpendicular direction is varying as a function of the power of
said energy beam on said workpiece.
[0025] In yet another example embodiment of the present invention a
computer program product for welding a workpiece is provided. The
computer program product comprises at least one non-transitory
computer-readable storage medium having computer-readable program
code portions stored therein. The computer-readable program code
portions comprise: an executable portion configured to make a first
weld at a first position on said workpiece with a high energy beam;
an executable portion configured to deflect the high energy beam
with at least one deflection lens for making a second weld at a
second position on said workpiece; an executable portion configured
to focus the high energy beam on said workpiece with at least one
focusing lens; and an executable portion configured to shape the
high energy beam on said workpiece with at least one astigmatism
lens so that the shape of the high energy beam on said workpiece is
longer in a direction parallel to a deflection direction of said
high energy beam than in a direction perpendicular to said
deflection direction of said high energy beam, wherein a ratio of a
length of said high energy beam in said parallel direction and said
perpendicular direction is varying as a function of the power of
said energy beam on said workpiece.
BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS
[0026] Having thus described the invention in general terms,
reference will now be made to the accompanying drawings, which are
not necessarily drawn to scale, and wherein:
[0027] FIG. 1 depicts a schematic graph of a beam power as a
function of scan speed;
[0028] FIG. 2 depicts a view from above of an additive
manufacturing process with an enlarged view of the beam spot
configuration;
[0029] FIG. 3 depicts an example embodiment of a freeform
fabrication or additive manufacturing apparatus in which the method
may be implemented;
[0030] FIG. 4A depicts a beam spot configuration according to prior
art;
[0031] FIG. 4B depicts an example embodiment of a beam spot
configuration according to the present invention;
[0032] FIG. 5A-5C depicts three different beam spot configurations
for different beam power;
[0033] FIG. 6 depicts an example embodiment for accomplishing an
appropriate beam spot shape in a laser beam based system,
[0034] FIG. 7 depicts an example embodiment for accomplishing an
appropriate beam spot shape in an electron beam based system,
and
[0035] FIG. 8 depicts a schematic flow chart of a method according
to the present invention.
[0036] FIG. 9 is a block diagram of an exemplary system 1020
according to various embodiments;
[0037] FIG. 10A is a schematic block diagram of a server 1200
according to various embodiments; and
[0038] FIG. 10B is a schematic block diagram of an exemplary mobile
device 1300 according to various embodiments.
DETAILED DESCRIPTION OF VARIOUS EMBODIMENTS
[0039] Various embodiments of the present invention will now be
described more fully hereinafter with reference to the accompanying
drawings, in which some, but not all embodiments of the invention
are shown. Indeed, embodiments of the invention may be embodied in
many different forms and should not be construed as limited to the
embodiments set forth herein. Rather, these embodiments are
provided so that this disclosure will satisfy applicable legal
requirements. Unless otherwise defined, all technical and
scientific terms used herein have the same meaning as commonly
known and understood by one of ordinary skill in the art to which
the invention relates. The term "or" is used herein in both the
alternative and conjunctive sense, unless otherwise indicated. Like
numbers refer to like elements throughout.
[0040] Still further, to facilitate the understanding of this
invention, a number of terms are defined below. Terms defined
herein have meanings as commonly understood by a person of ordinary
skill in the areas relevant to the present invention. Terms such as
"a", "an" and "the" are not intended to refer to only a singular
entity, but include the general class of which a specific example
may be used for illustration. The terminology herein is used to
describe specific embodiments of the invention, but their usage
does not delimit the invention, except as outlined in the
claims.
[0041] The term "three-dimensional structures" and the like as used
herein refer generally to intended or actually fabricated
three-dimensional configurations (e.g., of structural material or
materials) that are intended to be used for a particular purpose.
Such structures, etc. may, for example, be designed with the aid of
a three-dimensional CAD system.
[0042] The term "electron beam" as used herein in various
embodiments refers to any charged particle beam. The sources of
charged particle beam can include an electron gun, a linear
accelerator and so on.
[0043] FIG. 3 depicts an embodiment of a freeform fabrication or
additive manufacturing apparatus 300 in which the present method
may be implemented. The apparatus 300 comprising an electron gun
302; two powder hoppers 306, 307; a start plate 316; a build tank
312; a powder distributor 310; a build platform 314; beam managing
optics 305; and a vacuum chamber 320.
[0044] The vacuum chamber 320 is capable of maintaining a vacuum
environment by means of a vacuum system, which system may comprise
a turbo-molecular pump, a scroll pump, an ion pump and one or more
valves which are well known to a skilled person in the art and
therefore need no further explanation in this context. The vacuum
system is controlled by a control unit 340.
[0045] The electron gun 302 is generating an electron beam which is
used for melting or fusing together powder material 318 provided on
the start plate 316. The electron gun 302 may be provided in or in
connection to the vacuum chamber 320. The control unit 340 may be
used for controlling and managing the electron beam emitted from
the electron beam gun 302. The beam managing optics may comprise at
least one focusing coil, at least one deflection coil and at least
one astigmatism coil which may be electrically connected to the
control unit 340. In an example embodiment of the invention the
electron gun may generate a focusable electron beam with an
accelerating voltage of about 60 kV and with a beam power in the
range of 0-10 kW. The pressure in the vacuum chamber may be in the
range of 1.times.10.sup.-3-1.times.10.sup.-6 mBar when building the
three-dimensional article by fusing the powder layer by layer with
the energy beam.
[0046] Instead of using one or a plurality of electron beam sources
one or a plurality of laser beam sources may be used for generating
one or a plurality of laser beams for melting the powder material
or for welding pieces together according to the present
invention.
[0047] The powder hoppers 306, 307 comprise the powder material to
be provided on the start plate 316 in the build tank 312. The
powder material may for instance be pure metals or metal alloys
such as titanium, titanium alloys, aluminum, aluminum alloys,
stainless steel, Co--Cr--W alloy, etc. Instead of using two powder
hoppers one powder hopper may be used. In another example
embodiment another known type of powder feed and/or powder storage
may be used.
[0048] The powder distributor 310 is arranged to lay down a thin
layer of the powder material on the start plate 316. During a work
cycle the build platform 314 will be lowered successively in
relation to the ray gun, electron beam based or laser beam based,
after each added layer of powder material. In order to make this
movement possible, the build platform 314 is in one embodiment of
the invention arranged movably in vertical direction, i.e., in the
direction indicated by arrow P. This means that the build platform
314 starts in an initial position, in which a first powder material
layer of necessary thickness has been laid down on the start plate
316. The build platform is thereafter lowered in connection with
laying down a new powder material layer for the formation of a new
cross section of a three-dimensional article. Means for lowering
the build platform 314 may for instance be through a servo engine
equipped with a gear, adjusting screws etc.
[0049] A three-dimensional article which is formed through
successive fusion of parts of a powder bed, which parts corresponds
to successive cross sections of the three-dimensional article,
comprising a step of providing a model of the three dimensional
article. The model may be generated via a CAD (Computer Aided
Design) tool.
[0050] A first powder layer may be provided on the work table 316
by distributing powder evenly over the worktable according to
several methods. One way to distribute the powder is to collect
material fallen down from the hopper 306, 307 by a rake system. The
rake is moved over the build tank thereby distributing the powder
over the start plate. The distance between a lower part of the rake
and the upper part of the start plate or previous powder layer
determines the thickness of powder distributed over the start
plate. The powder layer thickness can easily be adjusted by
adjusting the height of the build platform 314.
[0051] An energy beam is directed over the work table 316 causing
the first powder layer to fuse in selected locations to form a
first cross section of the three-dimensional article. The energy
beam may be an electron beam or a laser beam. The beam is directed
over the work table 316 from instructions given by a control unit
340. In the control unit instructions for how to control the beam
gun for each layer of the three-dimensional article is stored.
[0052] After a first layer is finished, i.e., the fusion of powder
material for making a first layer of the three-dimensional article,
a second powder layer is provided on the work table 316. The second
powder layer is preferably distributed according to the same manner
as the previous layer. A powder distributor in the form of a single
rake system, i.e., where one rake is catching powder fallen down
from both a left powder hopper 306 and a right powder hopper 307,
the rake as such can change design.
[0053] After having distributed the second powder layer on the work
table 316, the energy beam is directed over the work table causing
the second powder layer to fuse in selected locations to form a
second cross section of the three-dimensional article. Fused
portions in the second layer may be bonded to fused portions of the
first layer. The fused portions in the first and second layer may
be melted together by melting not only the powder in the uppermost
layer but also remelting at least a fraction of a thickness of a
layer directly below the uppermost layer.
[0054] FIG. 1 depicts a schematic graph 175 of a beam power as a
function of scan speed. For beam power lower than a predetermined
value an essentially circular beam spot may be used for fusing
powder material or for welding pieces together. If increasing the
beam power over a predetermined value, and thereby increasing the
scan speed over a predetermined value, the material will start to
boil instead of melt. The reason for this boiling of material is
that the deflection or scan speed of the energy beam will be too
fast so that the heat from the energy beam will not have sufficient
time to penetrate into the material to be fused or welded. With a
too high power and thereby a too fast speed of deflection of said
energy beam, the surface temperature will become too high so that
the material which is to be fused or welded is instead
evaporated.
[0055] The invention solves this problem by protracting the spot,
i.e., extending the spot dimension parallel to the scan direction
and essentially keeping its dimension perpendicular to the scan
direction. In FIG. 1 an essentially circular spot may be used for
beam power and scan speed below P1 and S1 respectively. For beam
power and scan speed above P1 and S1 respectively the beam spot is
protracted in the direction parallel to the scan direction. By
letting the beam spot being protracted parallel to the scan
direction the surface temperature may be decreased since the power
in said beam is distributed over a larger area. The heat from the
beam spot may, because of this beam power distribution over a
larger area, have sufficient time to penetrate into the material
and thereby minimizing the radiated energy from the melt pool and
thereby minimizing the boiling or evaporation of material. By
protracting the beam spot in parallel to the scan direction, larger
beam powers may be used compared to if a circular spot would have
been used with a maintained resolution of the fusing or welding.
The protracted beam spot may follow an intended scanning path so
that the longer dimension of said beam spot follows the beam path,
i.e., the dimension perpendicular to the scanning direction is
smaller than the dimension parallel to the scanning direction
irrespective of the direction of the intended beam path.
[0056] FIG. 2 depicts a view from above of an additive
manufacturing process with an enlarged view 200 of the beam spot
configuration. In FIG. 2 a cross section 270 of a three dimensional
article is being built by melting powder material inside a build
chamber 290 with an energy beam 210. The energy beam 210 is melting
the material according to predetermined instructions stored in a
control unit. The scan direction in FIG. 2 is denoted by an arrow
240. A number of scan lines 250 have already been provided onto the
powder material in order to build the cross section of the three
dimensional article. One scan line 220 is being provided onto the
powder material and an enlarged view 200 of the beam spot 230
illustrates that the actual length L of the beam spot 230 in
parallel to the scan direction 240 is larger than the dimension of
the beam spot 230 perpendicular to the scan direction denoted by
H.
[0057] FIG. 4A illustrates a beam spot shape when using beam power
lower than a predetermined value. In FIG. 4A the horizontal size L1
of the beam spot in parallel to the scan direction is essentially
equal to the vertical size H1 of the beam spot perpendicular to the
scan direction.
[0058] FIG. 4B illustrates a beam spot shape when using a beam
power higher than said predetermined value. In FIG. 4B the
horizontal size L2 of the beam spot in parallel to the scan
direction is substantially larger than the vertical size H1 of the
beam spot perpendicular to the scan direction. As can be seen the
vertical size H1 of the beam spot perpendicular to the scan
direction is equal in FIGS. 4A and 4B. Any scan direction may be
used, i.e. not only the horizontal scan direction as have been
illustrated in the figures. The beam spot size for beam powers
larger than a predetermined value may be larger in a direction in
parallel to the scan direction than in a direction perpendicular to
the scan direction for any scan direction.
[0059] FIG. 5A-5C depicts three different beam spot configurations
for three different beam power. The first beam spot 510 in FIG. 5A
has a first beam power. The second beam spot 520 in FIG. 5B has a
second beam power which is higher than said first beam power. The
third beam spot 530 in FIG. 5C has a third beam power which is
higher than said second beam power. The first length L3 of said
first beam spot 510 is shorter than said second length L4 of said
second beam spot 520 which is shorter than the third length L5 of
said third beam spot 530. The first, second and third beam spot
have all the same size H1 perpendicular to the scan direction. In
FIG. 5A-5C the shape of the beam spot is illustrated to be
elliptical. However, any protracted shape of the beam spot may be
used such as rectangular or polygonal or any other suitable
mathematical function where the size of the beam spot is protracted
in the scanning direction compared to the size perpendicular to the
scanning direction.
[0060] FIG. 6 depicts an example embodiment of beam management
optics in a laser beam based system. A laser beam 605 is emanating
from a laser beam source 610. Before reaching a target surface 660
which may be a powder layer in a layer based additive manufacturing
process or solid pieces which are about to be welded together, said
laser beam 605 is passing through an astigmatism lens system 620, a
focusing lens system 630, a deflection lens system 640, and an
optional reflective surface 650. A control unit 680 may be
controlling the laser beam source 610 and said lens systems 620,
630, 640. The focusing lens 630 system may comprise one or a
plurality of lenses which may be rotatable and/or tiltable and/or
translatable (movable along the optical axis) with respect to an
optical axis. The focusing lens system 630 may be creating a
predetermined beam spot size on the target surface 660. The lenses
in the focusing lens system 630 may be fully or partially
transparent. The deflection lens system 640 may comprise one or a
plurality of lenses which may be rotatable and/or tiltable and/or
translatable (movable along the optical axis) with respect to an
optical axis. The deflection lens system 640 may position the beam
spot at any predetermined position within given limitations, which
are defined by the maximum deflection of the beam spot, at said
target surface 660.
[0061] The astigmatism lens system 620 may comprise one or a
plurality of lenses which may be rotatable and/or tiltable and/or
translatable (movable along the optical axis) with respect to an
optical axis. When a beam is deflected certain aberrations is
introduced into the beam spot which is depending on the degree of
deflection. The beam is more or less distorted depending on the
degree of deflection which may be compensated by the astigmatism
lens system 620. According to the present invention said beam spot
may not only be compensated for distortions which may be introduced
by the other lens systems, but said astigmatism lens system 620 may
also intentionally distorting the beam spot shape so as to protract
the beam spot in a direction parallel to the direction of beam
deflection. The degree of protraction in said direction parallel to
said deflection direction may at least be depending on the beam
power of said energy beam. In an example embodiment said beam spot
shape is protracted parallel to said deflection direction as a
linearly function of said beam power above a predetermined beam
power. In another example embodiment said beam spot shape is
protracted parallel to said deflection direction as a polynomial
function of said beam power above a predetermined beam power.
[0062] FIG. 7 depicts an example embodiment of beam management
optics in a electron beam based system. An electron beam 750 is
emanating from an electron beam source 710. Before reaching a
target surface 760, which may be a powder layer in a layer based
additive manufacturing process or solid pieces which are about to
be welded together, said electron beam 750 may be passing through a
astigmatism lens system 720, a focusing lens system 730, an
deflection lens system 740. A control unit 680 may control the
electron beam source and said beam shaping optics. The focusing
lens system 730 may comprise one or a plurality of focusing coils.
The focusing lens system 730 may create a predetermined beam spot
size on the target surface 760.
[0063] The deflection lens system 740 may comprise one or a
plurality of deflection coils. The deflection lens system 740 may
position the beam spot at any predetermined position within given
limitations, which are defined by the maximum deflection of the
beam spot, at said target surface 760.
[0064] The astigmatism lens system 720 may comprise one or a
plurality of astigmatism coils. When a beam is deflected certain
aberrations is introduced into the beam spot which is depending on
the degree of deflection. The beam may be more or less distorted
depending on the degree of deflection which may be compensated by
the astigmatism lens system 720. According to the present invention
said beam spot is not only compensated for distortions, which may
be introduced by the other lens systems, but said astigmatism lens
system 720 may also intentionally distort the beam spot shape so as
to protract the beam spot in a direction parallel to the direction
of beam deflection. The degree of protraction in said direction
parallel to said deflection direction may at least be depending on
the beam power of said energy beam. In an example embodiment said
beam spot shape may be protracted parallel to said deflection
direction as a linearly function of said beam power above a
predetermined beam power. In another example embodiment said beam
spot shape may be protracted parallel to said deflection direction
as a polynomial function of said beam power above a predetermined
beam power. In an example embodiment a plurality of astigmatism
lenses may be used for generating an arbitrary orientation of said
protracted beam in any position of the workpiece.
[0065] In a laser beam based and electron beam based system said
protraction parallel to the deflection direction may not only
depend on the power of said energy beam but also on the position on
said target surface. More particularly said protraction of said
energy beam may depend, in addition to said energy beam power, on
the actual fusing or welding position of said energy beam spot on
said target surface. In an additive manufacturing process, said
protraction may depend on the actual position of said energy beam
spot with respect to said pattern which is to be fused, i.e., a
more protracted beam spot may be used in the middle section of a
scan length compared to at the start or stop position of the scan
line. If melting a contour the protraction may be altered during
the melting of said contour depending on the derivate of the
contour and the distance to said contour derivate. In an example
embodiment the protraction, power and scan speed of the beam spot
on said workpiece may be chosen so as to optimize the build
time.
[0066] FIG. 8 depicts a schematic flow chart of a method according
to the present invention for welding a workpiece or for fusing
together powder material according to a predetermined scheme for
building a three dimensional article layer by layer. In a first
step denoted 810 a first weld is made at a first position on said
workpiece or powder surface with a high energy beam. In a second
step denoted 820 the high energy beam is deflected with at least
one deflection lens for making a second weld at a second position
on said workpiece or said powder surface. In a third step denoted
830 the high energy beam is focused on said workpiece with at least
one focusing lens. In a fourth step denoted 840 the high energy
beam is shaped on said workpiece or powder surface with at least
one astigmatism lens so that the shape of the high energy beam on
said workpiece is longer in a direction parallel to a deflection
direction of said high energy beam than in a direction
perpendicular to said deflection direction of said high energy
beam, wherein a ratio of a length of said high energy beam in said
parallel direction and said perpendicular direction is varying as a
function of the power of said energy beam on said workpiece. An
increased power of the beam spot on said workpiece will demand for
higher scan speed of said beam spot on said workpiece.
[0067] The ratio of said length in said parallel direction and said
length in said perpendicular direction with respect to said
deflection direction of said energy beam may be one of a group of
5, 10, 15 or 20. In an example embodiment said length in said
parallel direction and said perpendicular direction is essentially
equal for beam power below a predetermined value which will not
cause evaporation of the material to fuse with a predetermined weld
or fusing width, since the speed and powder of said beam spot on
said workpiece will not cause evaporation of the workpiece
material.
[0068] In an example embodiment of the present invention a mean
spot size on said workpiece in a direction perpendicular to the
scanning direction is smaller than the mean spot size on said
workpiece in a direction parallel to the scanning direction for a
full scan length, a full cross section and/or for a full
3-dimensional article.
[0069] Fusing or welding with a protracted beam spot may have the
effect of using higher beam spot power and higher beam scanning
speed. A protracted beam spot may decrease the surface temperature
for a given scanning speed compared with a circular spot having the
same power and a diameter equal to the smaller dimension of the
protracted beam spot. A protracted beam spot may allow for a higher
scanning speed with preserved resolution in a direction
perpendicular to the scanning direction compared with a circular
spot having a diameter equal to the smaller dimension of the
protracted beam spot. A protracted beam spot may allow for heat to
penetrate into the material instead of evaporating the material as
may be the case with a circular spot. A protracted beam spot may
decrease the manufacturing time for an additively manufactured
3-dimensional article compared with a circular spot having the same
power and a diameter equal to the smaller dimension of the
protracted beam spot.
[0070] In another aspect of the invention it is provided a program
element configured and arranged when executed on a computer to
implement a method for forming at least one three-dimensional
article through successive fusion of parts of a powder bed, which
parts correspond to successive cross sections of the
three-dimensional article, the method comprising the steps of:
providing a model of the at least one three-dimensional article;
applying a first powder layer on a work table; directing a first
energy beam from a first energy beam source over the work table so
as to cause the first powder layer to fuse in first selected
locations according to corresponding models so as to form a first
cross section of the three-dimensional article, where the first
energy beam is configured to fuse at least a first region of a
first cross section with two or more parallel scan lines in a first
direction; and determining a distance between two adjacent of the
two or more parallel scan lines, which are used for fusing the
powder layer, as a function of a length of at least one of the two
adjacent scan lines. The program element may be installed in a
computer readable storage medium. The computer readable storage
medium may be any control unit as described elsewhere herein or
another separate and distinct control unit. The computer readable
storage medium and the program element, which may comprise
computer-readable program code portions embodied therein, may
further be contained within a non-transitory computer program
product. Further details regarding these features and
configurations are provided, in turn, below.
[0071] As mentioned, various embodiments of the present invention
may be implemented in various ways, including as non-transitory
computer program products. A computer program product may include a
non-transitory computer-readable storage medium storing
applications, programs, program modules, scripts, source code,
program code, object code, byte code, compiled code, interpreted
code, machine code, executable instructions, and/or the like (also
referred to herein as executable instructions, instructions for
execution, program code, and/or similar terms used herein
interchangeably). Such non-transitory computer-readable storage
media include all computer-readable media (including volatile and
non-volatile media).
[0072] In one embodiment, a non-volatile computer-readable storage
medium may include a floppy disk, flexible disk, hard disk,
solid-state storage (SSS) (e.g., a solid state drive (SSD), solid
state card (SSC), solid state module (SSM)), enterprise flash
drive, magnetic tape, or any other non-transitory magnetic medium,
and/or the like. A non-volatile computer-readable storage medium
may also include a punch card, paper tape, optical mark sheet (or
any other physical medium with patterns of holes or other optically
recognizable indicia), compact disc read only memory (CD-ROM),
compact disc compact disc-rewritable (CD-RW), digital versatile
disc (DVD), Blu-ray disc (BD), any other non-transitory optical
medium, and/or the like. Such a non-volatile computer-readable
storage medium may also include read-only memory (ROM),
programmable read-only memory (PROM), erasable programmable
read-only memory (EPROM), electrically erasable programmable
read-only memory (EEPROM), flash memory (e.g., Serial, NAND, NOR,
and/or the like), multimedia memory cards (MMC), secure digital
(SD) memory cards, SmartMedia cards, CompactFlash (CF) cards,
Memory Sticks, and/or the like. Further, a non-volatile
computer-readable storage medium may also include
conductive-bridging random access memory (CBRAM), phase-change
random access memory (PRAM), ferroelectric random-access memory
(FeRAM), non-volatile random-access memory (NVRAM),
magnetoresistive random-access memory (MRAM), resistive
random-access memory (RRAM), Silicon-Oxide-Nitride-Oxide-Silicon
memory (SONOS), floating junction gate random access memory (FJG
RAM), Millipede memory, racetrack memory, and/or the like.
[0073] In one embodiment, a volatile computer-readable storage
medium may include random access memory (RAM), dynamic random
access memory (DRAM), static random access memory (SRAM), fast page
mode dynamic random access memory (FPM DRAM), extended data-out
dynamic random access memory (EDO DRAM), synchronous dynamic random
access memory (SDRAM), double data rate synchronous dynamic random
access memory (DDR SDRAM), double data rate type two synchronous
dynamic random access memory (DDR2 SDRAM), double data rate type
three synchronous dynamic random access memory (DDR3 SDRAM), Rambus
dynamic random access memory (RDRAM), Twin Transistor RAM (TTRAM),
Thyristor RAM (T-RAM), Zero-capacitor (Z-RAM), Rambus in-line
memory module (RIMM), dual in-line memory module (DIMM), single
in-line memory module (SIMM), video random access memory VRAM,
cache memory (including various levels), flash memory, register
memory, and/or the like. It will be appreciated that where
embodiments are described to use a computer-readable storage
medium, other types of computer-readable storage media may be
substituted for or used in addition to the computer-readable
storage media described above.
[0074] As should be appreciated, various embodiments of the present
invention may also be implemented as methods, apparatus, systems,
computing devices, computing entities, and/or the like, as have
been described elsewhere herein. As such, embodiments of the
present invention may take the form of an apparatus, system,
computing device, computing entity, and/or the like executing
instructions stored on a computer-readable storage medium to
perform certain steps or operations. However, embodiments of the
present invention may also take the form of an entirely hardware
embodiment performing certain steps or operations.
[0075] Various embodiments are described below with reference to
block diagrams and flowchart illustrations of apparatuses, methods,
systems, and computer program products. It should be understood
that each block of any of the block diagrams and flowchart
illustrations, respectively, may be implemented in part by computer
program instructions, e.g., as logical steps or operations
executing on a processor in a computing system. These computer
program instructions may be loaded onto a computer, such as a
special purpose computer or other programmable data processing
apparatus to produce a specifically-configured machine, such that
the instructions which execute on the computer or other
programmable data processing apparatus implement the functions
specified in the flowchart block or blocks.
[0076] These computer program instructions may also be stored in a
computer-readable memory that can direct a computer or other
programmable data processing apparatus to function in a particular
manner, such that the instructions stored in the computer-readable
memory produce an article of manufacture including
computer-readable instructions for implementing the functionality
specified in the flowchart block or blocks. The computer program
instructions may also be loaded onto a computer or other
programmable data processing apparatus to cause a series of
operational steps to be performed on the computer or other
programmable apparatus to produce a computer-implemented process
such that the instructions that execute on the computer or other
programmable apparatus provide operations for implementing the
functions specified in the flowchart block or blocks.
[0077] Accordingly, blocks of the block diagrams and flowchart
illustrations support various combinations for performing the
specified functions, combinations of operations for performing the
specified functions and program instructions for performing the
specified functions. It should also be understood that each block
of the block diagrams and flowchart illustrations, and combinations
of blocks in the block diagrams and flowchart illustrations, could
be implemented by special purpose hardware-based computer systems
that perform the specified functions or operations, or combinations
of special purpose hardware and computer instructions.
[0078] FIG. 9 is a block diagram of an exemplary system 1020 that
can be used in conjunction with various embodiments of the present
invention. In at least the illustrated embodiment, the system 1020
may include one or more central computing devices 1110, one or more
distributed computing devices 1120, and one or more distributed
handheld or mobile devices 1300, all configured in communication
with a central server 1200 (or control unit) via one or more
networks 1130. While FIG. 9 illustrates the various system entities
as separate, standalone entities, the various embodiments are not
limited to this particular architecture.
[0079] According to various embodiments of the present invention,
the one or more networks 1130 may be capable of supporting
communication in accordance with any one or more of a number of
second-generation (2G), 2.5G, third-generation (3G), and/or
fourth-generation (4G) mobile communication protocols, or the like.
More particularly, the one or more networks 1130 may be capable of
supporting communication in accordance with 2G wireless
communication protocols IS-136 (TDMA), GSM, and IS-95 (CDMA). Also,
for example, the one or more networks 1130 may be capable of
supporting communication in accordance with 2.5G wireless
communication protocols GPRS, Enhanced Data GSM Environment (EDGE),
or the like. In addition, for example, the one or more networks
1130 may be capable of supporting communication in accordance with
3G wireless communication protocols such as Universal Mobile
Telephone System (UMTS) network employing Wideband Code Division
Multiple Access (WCDMA) radio access technology. Some narrow-band
AMPS (NAMPS), as well as TACS, network(s) may also benefit from
embodiments of the present invention, as should dual or higher mode
mobile stations (e.g., digital/analog or TDMA/CDMA/analog phones).
As yet another example, each of the components of the system 1020
may be configured to communicate with one another in accordance
with techniques such as, for example, radio frequency (RF),
Bluetooth.TM., infrared (IrDA), or any of a number of different
wired or wireless networking techniques, including a wired or
wireless Personal Area Network ("PAN"), Local Area Network ("LAN"),
Metropolitan Area Network ("MAN"), Wide Area Network ("WAN"), or
the like.
[0080] Although the device(s) 1110-1300 are illustrated in FIG. 9
as communicating with one another over the same network 1130, these
devices may likewise communicate over multiple, separate
networks.
[0081] According to one embodiment, in addition to receiving data
from the server 1200, the distributed devices 1110, 1120, and/or
1300 may be further configured to collect and transmit data on
their own. In various embodiments, the devices 1110, 1120, and/or
1300 may be capable of receiving data via one or more input units
or devices, such as a keypad, touchpad, barcode scanner, radio
frequency identification (RFID) reader, interface card (e.g.,
modem, etc.) or receiver. The devices 1110, 1120, and/or 1300 may
further be capable of storing data to one or more volatile or
non-volatile memory modules, and outputting the data via one or
more output units or devices, for example, by displaying data to
the user operating the device, or by transmitting data, for example
over the one or more networks 1130.
[0082] In various embodiments, the server 1200 includes various
systems for performing one or more functions in accordance with
various embodiments of the present invention, including those more
particularly shown and described herein. It should be understood,
however, that the server 1200 might include a variety of
alternative devices for performing one or more like functions,
without departing from the spirit and scope of the present
invention. For example, at least a portion of the server 1200, in
certain embodiments, may be located on the distributed device(s)
1110, 1120, and/or the handheld or mobile device(s) 1300, as may be
desirable for particular applications. As will be described in
further detail below, in at least one embodiment, the handheld or
mobile device(s) 1300 may contain one or more mobile applications
1330 which may be configured so as to provide a user interface for
communication with the server 1200, all as will be likewise
described in further detail below.
[0083] FIG. 10A is a schematic diagram of the server 1200 according
to various embodiments. The server 1200 includes a processor 1230
that communicates with other elements within the server via a
system interface or bus 1235. Also included in the server 1200 is a
display/input device 1250 for receiving and displaying data. This
display/input device 1250 may be, for example, a keyboard or
pointing device that is used in combination with a monitor. The
server 1200 further includes memory 1220, which preferably includes
both read only memory (ROM) 1226 and random access memory (RAM)
1222. The server's ROM 1226 is used to store a basic input/output
system 1224 (BIOS), containing the basic routines that help to
transfer information between elements within the server 1200.
Various ROM and RAM configurations have been previously described
herein.
[0084] In addition, the server 1200 includes at least one storage
device or program storage 210, such as a hard disk drive, a floppy
disk drive, a CD Rom drive, or optical disk drive, for storing
information on various computer-readable media, such as a hard
disk, a removable magnetic disk, or a CD-ROM disk. As will be
appreciated by one of ordinary skill in the art, each of these
storage devices 1210 are connected to the system bus 1235 by an
appropriate interface. The storage devices 1210 and their
associated computer-readable media provide nonvolatile storage for
a personal computer. As will be appreciated by one of ordinary
skill in the art, the computer-readable media described above could
be replaced by any other type of computer-readable media known in
the art. Such media include, for example, magnetic cassettes, flash
memory cards, digital video disks, and Bernoulli cartridges.
[0085] Although not shown, according to an embodiment, the storage
device 1210 and/or memory of the server 1200 may further provide
the functions of a data storage device, which may store historical
and/or current delivery data and delivery conditions that may be
accessed by the server 1200. In this regard, the storage device
1210 may comprise one or more databases. The term "database" refers
to a structured collection of records or data that is stored in a
computer system, such as via a relational database, hierarchical
database, or network database and as such, should not be construed
in a limiting fashion.
[0086] A number of program modules (e.g., exemplary modules
1400-1700) comprising, for example, one or more computer-readable
program code portions executable by the processor 1230, may be
stored by the various storage devices 1210 and within RAM 1222.
Such program modules may also include an operating system 1280. In
these and other embodiments, the various modules 1400, 1500, 1600,
1700 control certain aspects of the operation of the server 1200
with the assistance of the processor 1230 and operating system
1280. In still other embodiments, it should be understood that one
or more additional and/or alternative modules may also be provided,
without departing from the scope and nature of the present
invention.
[0087] In various embodiments, the program modules 1400, 1500,
1600, 1700 are executed by the server 1200 and are configured to
generate one or more graphical user interfaces, reports,
instructions, and/or notifications/alerts, all accessible and/or
transmittable to various users of the system 1020. In certain
embodiments, the user interfaces, reports, instructions, and/or
notifications/alerts may be accessible via one or more networks
1130, which may include the Internet or other feasible
communications network, as previously discussed.
[0088] In various embodiments, it should also be understood that
one or more of the modules 1400, 1500, 1600, 1700 may be
alternatively and/or additionally (e.g., in duplicate) stored
locally on one or more of the devices 1110, 1120, and/or 1300 and
may be executed by one or more processors of the same. According to
various embodiments, the modules 1400, 1500, 1600, 1700 may send
data to, receive data from, and utilize data contained in one or
more databases, which may be comprised of one or more separate,
linked and/or networked databases.
[0089] Also located within the server 1200 is a network interface
1260 for interfacing and communicating with other elements of the
one or more networks 1130. It will be appreciated by one of
ordinary skill in the art that one or more of the server 1200
components may be located geographically remotely from other server
components. Furthermore, one or more of the server 1200 components
may be combined, and/or additional components performing functions
described herein may also be included in the server.
[0090] While the foregoing describes a single processor 1230, as
one of ordinary skill in the art will recognize, the server 1200
may comprise multiple processors operating in conjunction with one
another to perform the functionality described herein. In addition
to the memory 1220, the processor 1230 can also be connected to at
least one interface or other means for displaying, transmitting
and/or receiving data, content or the like. In this regard, the
interface(s) can include at least one communication interface or
other means for transmitting and/or receiving data, content or the
like, as well as at least one user interface that can include a
display and/or a user input interface, as will be described in
further detail below. The user input interface, in turn, can
comprise any of a number of devices allowing the entity to receive
data from a user, such as a keypad, a touch display, a joystick or
other input device.
[0091] Still further, while reference is made to the "server" 1200,
as one of ordinary skill in the art will recognize, embodiments of
the present invention are not limited to traditionally defined
server architectures. Still further, the system of embodiments of
the present invention is not limited to a single server, or similar
network entity or mainframe computer system. Other similar
architectures including one or more network entities operating in
conjunction with one another to provide the functionality described
herein may likewise be used without departing from the spirit and
scope of embodiments of the present invention. For example, a mesh
network of two or more personal computers (PCs), similar electronic
devices, or handheld portable devices, collaborating with one
another to provide the functionality described herein in
association with the server 1200 may likewise be used without
departing from the spirit and scope of embodiments of the present
invention.
[0092] According to various embodiments, many individual steps of a
process may or may not be carried out utilizing the computer
systems and/or servers described herein, and the degree of computer
implementation may vary, as may be desirable and/or beneficial for
one or more particular applications.
[0093] FIG. 10B provides an illustrative schematic representative
of a mobile device 1300 that can be used in conjunction with
various embodiments of the present invention. Mobile devices 1300
can be operated by various parties. As shown in FIG. 10B, a mobile
device 1300 may include an antenna 1312, a transmitter 1304 (e.g.,
radio), a receiver 1306 (e.g., radio), and a processing element
1308 that provides signals to and receives signals from the
transmitter 1304 and receiver 1306, respectively.
[0094] The signals provided to and received from the transmitter
1304 and the receiver 1306, respectively, may include signaling
data in accordance with an air interface standard of applicable
wireless systems to communicate with various entities, such as the
server 1200, the distributed devices 1110, 1120, and/or the like.
In this regard, the mobile device 1300 may be capable of operating
with one or more air interface standards, communication protocols,
modulation types, and access types. More particularly, the mobile
device 1300 may operate in accordance with any of a number of
wireless communication standards and protocols. In a particular
embodiment, the mobile device 1300 may operate in accordance with
multiple wireless communication standards and protocols, such as
GPRS, UMTS, CDMA2000, 1xRTT, WCDMA, TD-SCDMA, LTE, E-UTRAN, EVDO,
HSPA, HSDPA, Wi-Fi, WiMAX, UWB, IR protocols, Bluetooth protocols,
USB protocols, and/or any other wireless protocol.
[0095] Via these communication standards and protocols, the mobile
device 1300 may according to various embodiments communicate with
various other entities using concepts such as Unstructured
Supplementary Service data (USSD), Short Message Service (SMS),
Multimedia Messaging Service (MMS), Dual-Tone Multi-Frequency
Signaling (DTMF), and/or Subscriber Identity Module Dialer (SIM
dialer). The mobile device 1300 can also download changes, add-ons,
and updates, for instance, to its firmware, software (e.g.,
including executable instructions, applications, program modules),
and operating system.
[0096] According to one embodiment, the mobile device 1300 may
include a location determining device and/or functionality. For
example, the mobile device 1300 may include a GPS module adapted to
acquire, for example, latitude, longitude, altitude, geocode,
course, and/or speed data. In one embodiment, the GPS module
acquires data, sometimes known as ephemeris data, by identifying
the number of satellites in view and the relative positions of
those satellites.
[0097] The mobile device 1300 may also comprise a user interface
(that can include a display 1316 coupled to a processing element
1308) and/or a user input interface (coupled to a processing
element 308). The user input interface can comprise any of a number
of devices allowing the mobile device 1300 to receive data, such as
a keypad 1318 (hard or soft), a touch display, voice or motion
interfaces, or other input device. In embodiments including a
keypad 1318, the keypad can include (or cause display of) the
conventional numeric (0-9) and related keys (#, *), and other keys
used for operating the mobile device 1300 and may include a full
set of alphabetic keys or set of keys that may be activated to
provide a full set of alphanumeric keys. In addition to providing
input, the user input interface can be used, for example, to
activate or deactivate certain functions, such as screen savers
and/or sleep modes.
[0098] The mobile device 1300 can also include volatile storage or
memory 1322 and/or non-volatile storage or memory 1324, which can
be embedded and/or may be removable. For example, the non-volatile
memory may be ROM, PROM, EPROM, EEPROM, flash memory, MMCs, SD
memory cards, Memory Sticks, CBRAM, PRAM, FeRAM, RRAM, SONOS,
racetrack memory, and/or the like. The volatile memory may be RAM,
DRAM, SRAM, FPM DRAM, EDO DRAM, SDRAM, DDR SDRAM, DDR2 SDRAM, DDR3
SDRAM, RDRAM, RIMM, DIMM, SIMM, VRAM, cache memory, register
memory, and/or the like. The volatile and non-volatile storage or
memory can store databases, database instances, database mapping
systems, data, applications, programs, program modules, scripts,
source code, object code, byte code, compiled code, interpreted
code, machine code, executable instructions, and/or the like to
implement the functions of the mobile device 1300.
[0099] The mobile device 1300 may also include one or more of a
camera 1326 and a mobile application 1330. The camera 1326 may be
configured according to various embodiments as an additional and/or
alternative data collection feature, whereby one or more items may
be read, stored, and/or transmitted by the mobile device 1300 via
the camera. The mobile application 1330 may further provide a
feature via which various tasks may be performed with the mobile
device 1300. Various configurations may be provided, as may be
desirable for one or more users of the mobile device 1300 and the
system 1020 as a whole.
[0100] The invention is not limited to the above-described
embodiments and many modifications are possible within the scope of
the following claims. Such modifications may, for example, involve
using a different source of energy beam than the exemplified
electron beam such as a laser beam. Other materials than metallic
powder may be used, such as the non-limiting examples of:
electrically conductive polymers and powder of electrically
conductive ceramics. Indeed, a person of ordinary skill in the art
would be able to use the information contained in the preceding
text to modify various embodiments of the invention in ways that
are not literally described, but are nevertheless encompassed by
the attached claims, for they accomplish substantially the same
functions to reach substantially the same results. Therefore, it is
to be understood that the invention is not limited to the specific
embodiments disclosed and that modifications and other embodiments
are intended to be included within the scope of the appended
claims. Although specific terms are employed herein, they are used
in a generic and descriptive sense only and not for purposes of
limitation.
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