公开(公告)号：US11065689B2

公开(公告)日：2021-07-20

申请号：US15953329

申请日：2018-04-13

Applicant: Applied Materials, Inc.

Inventor： David Masayuki Ishikawa ,  Paul J. Steffas ,  Nag B. Patibandla

IPC: B22F10/20 ,  B33Y10/00 ,  B23K26/06 ,  B22F3/00 ,  G02B26/10 ,  G02B26/12 ,  B33Y30/00 ,  B22F12/45 ,  B23K26/082 ,  B23K26/342 ,  B23K26/067 ,  B33Y40/00 ,  B22F10/30

Abstract: An additive manufacturing system includes a platform, a dispenser to dispense a plurality of layers of feed material on a top surface of the platform, a light source to generate a first light beam and a second light beam, a polygon mirror scanner, a galvo mirror scanner positioned adjacent to the polygon mirror scanner, and a controller. The controller is coupled to the light source, the polygon mirror scanner and the galvo mirror scanner, and the controller is configured to cause the light source and polygon mirror scanner to apply the first light beam to a region of the layer of feed material, and to cause the light source and galvo mirror scanner to apply the second light beam to at least a portion of the region of the layer of feed material.

公开(公告)号：US20180369914A1

公开(公告)日：2018-12-27

申请号：US15953347

申请日：2018-04-13

Applicant: Applied Materials, Inc.

Inventor： David Masayuki Ishikawa ,  Paul J. Steffas ,  Nag B. Patibandla

IPC: B22F3/105 ,  B22F3/00 ,  B33Y10/00 ,  B33Y30/00 ,  B33Y40/00 ,  G02B26/10 ,  G02B26/12

Abstract: An additive manufacturing system includes a platform, a dispenser to dispense a plurality of layers of feed material on a top surface of the platform, a light source to generate three light beams, a first polygon mirror scanner, a galvo mirror scanner, and a second polygon mirror scanner configured to direct the first, second and third light beams, respectively, to impinge the layer of the feed material on the platform, and a controller. The controller is configured to cause the light source and first and second polygon mirror scanners to apply the first light beam to a region of the layer of feed material, and to cause the light source and galvo mirror scanner to apply the second light beam to at least a portion of the region of the layer of feed material.

公开(公告)号：US11135773B2

公开(公告)日：2021-10-05

申请号：US15992081

申请日：2018-05-29

Applicant: Applied Materials, Inc.

Inventor： David Masayuki Ishikawa ,  Paul J. Steffas ,  Ajey M. Joshi

IPC: B29C64/277 ,  B33Y30/00 ,  B29C64/393 ,  B29C64/268 ,  B29C64/153 ,  B33Y10/00 ,  B22F3/00 ,  B33Y50/02 ,  B29C64/245 ,  B29C64/295 ,  B29C64/135 ,  B29C64/165 ,  B29C64/205

Abstract: An additive manufacturing apparatus includes a platform, a dispenser to deliver a plurality of successive layers of feed material on the platform, a light source to generate one or more light beams, a first galvo mirror scanner positioned to direct a first light beam onto a topmost layer of the plurality of successive layers, a second galvo mirror scanner positioned to direct a second light beam onto the topmost layer of the plurality of successive layers, and a controller configured to cause the first galvo mirror scanner to direct the first light beam to pre-heat or heat-treat an area of the topmost layer and to cause the second galvo mirror scanner to direct the second light beam to fuse the area of the topmost layer.

公开(公告)号：US11084097B2

公开(公告)日：2021-08-10

申请号：US15992094

申请日：2018-05-29

Applicant: Applied Materials, Inc.

Inventor： David Masayuki Ishikawa ,  Paul J. Steffas ,  Ajey M. Joshi

IPC: B22F10/20 ,  B33Y10/00 ,  B33Y50/02 ,  B23K26/082 ,  B29C64/393 ,  B33Y30/00 ,  B29C64/165 ,  B29C64/205 ,  B22F3/00 ,  B22F10/30 ,  B29C64/135

Abstract: A method of additive manufacturing includes storing a plurality of predetermined cell processing recipes, dispensing a layer of a plurality of successive layers of feed material on a platform, receiving data describing an area of the layer of the feed material to fuse, determining a combination of a plurality of non-overlapping cells that substantially cover the area, and sequentially processing the plurality of cells. Each cell processing recipe includes scan path data indicating a path for an energy beam to follow, and different cell processing recipes having different paths for the energy beam. Each cell of the plurality of cells gets an associated cell processing recipe selected from the plurality of predetermined cell processing recipes. Each cell is processed by causing an energy beam to follow the first path for the cell processing recipe associated with the cell.

公开(公告)号：US20180264549A1

公开(公告)日：2018-09-20

申请号：US15904204

申请日：2018-02-23

Applicant: Applied Materials Inc.

Inventor： David Masayuki Ishikawa ,  Paul J. Steffas ,  Brian Hayes Burrows

IPC: B22F3/10 ,  B22F3/105 ,  B22F3/24 ,  B33Y10/00 ,  B33Y30/00 ,  B33Y50/02

CPC classification number: B22F3/1055 ,  B22F3/1017 ,  B22F3/24 ,  B22F2003/1056 ,  B22F2003/1057 ,  B22F2003/248 ,  B22F2999/00 ,  B28B1/001 ,  B28B17/0081 ,  B33Y10/00 ,  B33Y30/00 ,  B33Y50/02 ,  Y02P10/295 ,  B22F3/004 ,  B22F2207/15 ,  B22F2203/11

Abstract: An additive manufacturing system includes a platform to support an object to be fabricated, a dispenser to deliver a plurality of layers of a feed material over the platform, a controller configured to store digital data representing a pre-defined pattern, a laser configured to generate a laser beam to impinge an outermost layer of the feed material and coupled to the controller to fuse the feed material in the pre-defined pattern, and a plurality of independently controllable infrared lamps, each infrared lamp directed to a different section of an outermost layer of the feed material.

公开(公告)号：US11117194B2

公开(公告)日：2021-09-14

申请号：US15904161

申请日：2018-02-23

Applicant: Applied Materials, Inc.

Inventor： David Masayuki Ishikawa ,  Paul J. Steffas ,  Brian Hayes Burrows

IPC: B22F10/20 ,  B33Y30/00 ,  B28B1/00 ,  B28B17/00 ,  B33Y10/00 ,  B22F3/24 ,  B33Y50/02 ,  B22F10/30 ,  B22F3/10

Abstract: An additive manufacturing system includes a platform to support an object to be fabricated, a dispenser to deliver a plurality of layers of a feed material over the platform, a controller configured to store digital data representing a pre-defined pattern, a laser configured to generate a laser beam to impinge an outermost layer of the feed material and coupled to the controller to fuse the feed material in the pre-defined pattern, and a plurality of independently controllable infrared lamps, each infrared lamp directed to a different section of an outermost layer of the feed material.

公开(公告)号：US20180369961A1

公开(公告)日：2018-12-27

申请号：US15990408

申请日：2018-05-25

Applicant: Applied Materials, Inc.

Inventor： David Masayuki Ishikawa ,  Paul J. Steffas ,  Ajey M. Joshi

IPC: B23K26/342 ,  B33Y10/00 ,  B33Y40/00 ,  B33Y30/00 ,  B23K26/03 ,  B23K26/06 ,  B23K26/082 ,  B23K26/14 ,  B23K26/70

Abstract: An additive manufacturing apparatus and methods relating to forming multiple layers on an object on a support including dispensing a layer of feed material over the support, fusing a portion of the layer of feed material to form a fused portion in the layer, determining to rework a particular region in the fused portion, and reworking the particular region. Reworking the particular region includes establishing a gas flow directed towards the particular region and producing a melt pool having a keyhole within the particular region.

公开(公告)号：US11331855B2

公开(公告)日：2022-05-17

申请号：US16189740

申请日：2018-11-13

Applicant: Applied Materials, Inc.

Inventor： Zhengping Yao ,  Paul J. Steffas

IPC: B29C64/268 ,  B29C64/277 ,  B22F3/00 ,  B33Y10/00 ,  B33Y30/00 ,  B22F3/18 ,  B22F12/00 ,  G02B26/10 ,  G02B26/12 ,  G02B7/182 ,  B33Y70/00 ,  B33Y40/00 ,  B29C64/153 ,  B22F10/10

Abstract: An additive manufacturing apparatus includes a platform, a dispenser configured to deliver a plurality of successive layers of feed material on a platform, a light source configured to generate a light beam, an auxiliary polygon mirror scanner configured to receive the light beam from the light source and reflect the light beam, and a primary mirror scanner to receive the light beam reflected by the auxiliary polygon mirror scanner and direct the light beam to impinge on an exposed layer of feed material.

公开(公告)号：US10960605B2

公开(公告)日：2021-03-30

申请号：US16155460

申请日：2018-10-09

Applicant: Applied Materials, Inc.

Inventor： Raanan Zehavi ,  Hou T. Ng ,  Nag B. Patibandla ,  Eric Ng ,  Ajey M. Joshi ,  Kashif Maqsood ,  Paul J. Steffas

IPC: B29C64/329 ,  B29C64/153 ,  B29C64/209 ,  B22F3/105 ,  B33Y10/00 ,  B33Y30/00 ,  B29C64/343 ,  B29C64/336 ,  B29C64/371 ,  B33Y40/00 ,  B29C64/245 ,  B29C64/393 ,  B33Y50/02 ,  B33Y70/00 ,  B29K71/00

Abstract: A dispensing system for an additive manufacturing includes a powder source that contains powder to form an object, and an array of nozzles positioned at a base of the powder source over a top surface of a platen where the object is to be formed. The powder flows from the powder source through the nozzles to the top surface. A respective powder wheel in each nozzle controls a flow rate of the powder. Each wheel has multiple troughs on surface of the wheel. When a motor rotates the wheel, the troughs transport the powder through the nozzle. The rotation speed of the wheel controls the flow rate. For solid parts of the object, the wheel rotates and allows the powder to be deposited on the top surface. For empty parts of the object, the wheel remains stationary to prevent the powder from flowing to the surface.

公开(公告)号：US20190151944A1

公开(公告)日：2019-05-23

申请号：US16169988

申请日：2018-10-24

Applicant: Applied Materials, Inc.

Inventor： Paul J. Steffas ,  Ajey M. Joshi ,  Jeffrey L. Franklin ,  Zhihong Lin

IPC: B22F3/105 ,  B23K26/06 ,  B23K26/073 ,  B23K26/082 ,  B23K26/08 ,  B29C64/153 ,  B29C64/20

Abstract: An additive manufacturing apparatus includes a platform, a dispenser to deliver a plurality of successive layers of feed material onto the platform, a light source to generate a light beam, a first polygon mirror scanner to reflect the light beam towards the platform, and a second polygon mirror scanner to reflect the light beam towards the platform. The light beam is alternately directed to the first polygon mirror scanner and the second polygon mirror scanner such that the light beam is directed to the first polygon mirror scanner during a dead time of the second polygon mirror scanner and the light beam is directed to the second polygon mirror scanner during a dead time of the first polygon mirror scanner.