US 20190291209A1

( 19) United States

(12 )Khairallah
Patent Application Publication ( 10) Pub . No.: US 2019 /0291209 A1
et al. (43) Pub . Date: Sep . 26 , 2019
(54 ) ADDITIVE MANUFACTURING POWER MAP B33Y 30/00 ( 2006 .01 )
TO MITIGATE OVERHANG STRUCTURE B33Y 50 /02 (2006 . 01)
B23K 26 / 354 ( 2006 .01)
( 71 ) Applicant: LAWRENCE LIVERMORE (52 ) CPC
U .S . CI...............
NATIONAL SECURITY , LLC , B23K 26 /34 (2013 .01) ; B33Y 10 / 00
Livermore , CA (US) ( 2014 . 12); B23K 26 /354 (2015 .10 ) ; B33Y
( 72 ) Inventors: Saad A . Khairallah , Livermore, CA 50 /02 (2014 . 12 ); B33Y 30 /00 (2014 .12 )
(US ); Gabe Guss , Manteca , CA (US );
Wayne E . King, Danville, CA (US );
Manyalibo Joseph Matthews, (57 ) ABSTRACT
Livermore , CA (US)
(21) Appl. No.: 16 /152,763 A laser powder bed fusion additive manufacturing system
for producing a part by creating a power map that is an
(22 ) Filed : Oct. 5 , 2018 intelligent feed forward model to control the laser powder
Related U .S . Application Data bed fusion additive manufacturing for producing the part
and using the power map to control the laser powder bed
(60 ) Provisional application No. 62/647,358 , filed on Mar. fusion additive manufacturing for producing the part. This
23 , 2018 . includes an apparatus for producing a part including a
powder bed , a laser that produces a laser beam , a propor
Publication Classification tional integral derivative controller that creates a power map
(51 ) Int . Ci. that describes laser power requirements as the laser moves
B23K 26 /34 ( 2006 .01) along a path , wherein the laser power requirements prevent
B33Y 10 /00 ( 2006 .01 ) defects in the part.

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US 2019 /0291209 A1 Sep . 26 , 2019

ADDITIVE MANUFACTURING POWER MAP scope of the apparatus, systems, and methods is not intended
TO MITIGATE OVERHANG STRUCTURE to be limited to the particular forms disclosed and the
application covers all modifications, equivalents , and alter
CROSS -REFERENCE TO RELATED natives falling within the spirit and scope of the apparatus,
APPLICATIONS systems, and methods as defined by the claims.
[0001] This application claims priority to and benefit [0010 ] The inventors ' apparatus , systems and methods
under 35 U .S .C . $ 119 ( e ) of U .S . Provisional Patent Appli provide an intelligent feed forward model to control additive
cation No. 62 /647 ,358 filed Mar. 23 , 2018 entitled " additive manufacturing (AM ) laser powder bed fusion process ,
manufacturing power map to mitigate overhang structure,” whereby, the laser crosses an overhang section and creates a
the content of which is hereby incorporated by reference in smooth overhand inner walls , with little to no dross forma
its entirety for all purposes. tion . This is accomplished by controlling the laser power
through a computer model. The description below describes
STATEMENT AS TO RIGHTS TO using a proportional integral derivative (PID ) controller to
APPLICATIONS MADE UNDER FEDERALLY create a power map . The benefit of the process map is to
SPONSORED RESEARCH AND eliminate dross formation in overhangs built using AM .
DEVELOPMENT These rough surface defects are random in nature . Their
presence prevent machine to machine reproducibility of
[0002 ] The United States Government has rights in this same AM parts . Also , they have a deleterious effect on part
application pursuant to Contract No . DE - AC52-07NA27344 properties . Removing them is a major need and requirement
between the United States Department of Energy and Law for future AM machines.
rence Livermore National Security, LLC for the operation of [0011 ] The inventors ' apparatus , systems and methods
Lawrence Livermore National Laboratory . have use in additive manufacturingmachines that use energy
beams to create AM parts for any application .
BACKGROUND [0012 ] The apparatus , systems, and methods are suscep
tible to modifications and alternative forms. Specific
Field of Endeavor embodiments are shown by way of example . It is to be
[0003] The present application relates to additive manu understood that the apparatus, systems, and methods are not
facturing and more particularly to Additive Manufacturing : limited to the particular forms disclosed . The apparatus,
Power map to mitigate overhang structure . systems, and methods cover all modifications, equivalents ,
and alternatives falling within the spirit and scope of the
State of Technology application as defined by the claims.
[ 0004 ] This section provides background information BRIEF DESCRIPTION OF THE DRAWINGS
related to the present disclosure which is not necessarily
prior art. [0013] The accompanying drawings , which are incorpo
[0005 ] The challenge is to build an overhang structure rated into and constitute a part of the specification , illustrate
using AM , without formation of dross . That is how to specific embodiments of the apparatus, systems, and meth
maintain a smooth surface at the overhang . ods and, together with the general description given above ,
10006 ] These overhang structures can differ in build qual and the detailed description of the specific embodiments,
ity from machine to machine due to the randomness of the serve to explain the principles of the apparatus, systems, and
dross process . methods.
[ 0007] There is no prior art other than trial and error, and [0014 ] FIG . 1 illustrates an object constructed using an
still, this does not produce optimal overhang structure . AM and using a first material and a second material.
[ 0008 ]. The inventors ' method uses Intelligent Feed For [ 0015 ) FIG . 2 is a simplified schematic depiction further
ward principle by employing an additive manufacturing illustrating the object constructed using an AM .
power map an PID loop within a computational simulation . [0016 ] FIG . 3 is a simplified illustration showing the
This helps maintain a constant melt pool depth , by auto construct of an object using an AM system and a first
matically monitoring the laser energy deposition . Hence , material and a second material.
since dross is equivalent to randomly produced melt depth 0017 ] FIG . 4 illustrates an object constructed using AM .
that exceeds the accepted roughness threshold , the PID [0018 ] FIG . 5 illustrates the object being constructed using
controls the amount of melt depth and keeps it in control, AM .
constant, hence avoiding wild fluctuations (dross ) and help [0019 ] FIG . 6 illustrates the object being constructed using
keep the surface smooth . AM with illustration of dross formation in an overhang.
[0020] FIG . 7 illustrates the final finished workpiece !
SUMMARY object constructed using AM and the inventors ' power map
apparatus , systems and methods.
[0009 ] Features and advantages of the disclosed apparatus,
systems, and methods will become apparent from the fol DETAILED DESCRIPTION OF SPECIFIC
lowing description . Applicant is providing this description , EMBODIMENTS
which includes drawings and examples of specific embodi
ments, to give a broad representation of the apparatus , [0021] Referring to the drawings, to the following detailed
systems, and methods. Various changes and modifications description , and to incorporated materials , detailed informa
within the spirit and scope of the application will become tion about the apparatus, systems, and methods is provided
apparent to those skilled in the art from this description and including the description of specific embodiments . The
by practice of the apparatus, systems, and methods. The detailed description serves to explain the principles of the
US 2019 /0291209 A1 Sep . 26 , 2019

apparatus, systems, and methods. The apparatus, systems, A common problem encountered is that dross or overhang
and methods are susceptible to modifications and alternative 209 can occur. Dross or overhang 209 is shown in the
forms. The application is not limited to the particular forms features 104 and 106 .
disclosed . The application covers all modifications , equiva 10035 ] Referring now to FIG . 3 , a simplified illustration
lents, and alternatives falling within the spirit and scope of shows the construct of an object using an using an AM
the apparatus , systems, and methods as defined by the system with a first material and a second material. The
claims. components illustrated in FIG . 3 are identified and described
10022] The inventors have developed an intelligent feed below .
forward model to control additive manufacturing (AM ) laser [0036 ] Reference Numeral 300 — System for constructing
powder bed fusion process , whereby, the laser crosses an an object.
overhang section and creates a smooth overhand inner walls , [0037 ] Reference Numeral 302 – Object.
with little to no dross formation . This is accomplished by [0038 ] Reference Numeral 304 — Build platform .
controlling the laser power through a computer model. The [0039 ] Reference Numeral 306 — First material .
Applicants will describe using a proportional integral [00401 Reference Numeral 308 — First printhead.
derivative ( PID ) controller to create a power map . The [0041] Reference Numeral 310 — First material stream .
benefit of the process map is to eliminate dross formation in 0042 ] Reference Numeral 312 - Second material.
overhangs built using AM . These rough surface defects are [0043 ] Reference Numeral 314 Second printhead .
random in nature. Their presence prevent machine to 0044 ] Reference Numeral 316Second material stream .
machine reproducibility of same AM parts . Also , they have [0045 ] Reference Numeral 318 - Arrows indicating pos
a deleterious effect on part properties . Removing them is a sible movement directions for print heads 308 and 314 .
major need and requirement for future AM machines. The [0046 ] Reference Numeral 320 Computer/Controller.
inventor's apparatus, systems and methods will be used in [0047 ] The system 300 for constructing an object is an AM
additive manufacturing machines that use energy beams to system for producing an object 302. The part 306 of the
create AM parts for any application . object 302 is constructed of the first material 306 . One or
[0023] Referring now to the drawings and in particular to more features made of the second material 312 are included
FIG . 1 and FIG . 2 , simplified schematic depictions illus in the object 302 .
trates an object constructed using an AM . FIGS. 1 and 2 will [0048 ] The system 300 incudes a build platform 304 , a
be used to demonstrate dross formation in overhangs. FIG . first printhead 308 , and a second printhead 314 . A first
1 illustrates an object constructed using an AM and using a material 306 is directed into the first printhead 308 and is
first material and a second material. As illustrated , the extruded from the first printhead 308 in a first material
depiction in FIG . 1 includes a number of components . The stream 310 to produce the part 306 of the object 302. A
components illustrated in FIG . 1 are identified and described second material 312 is directed into the second printhead
below . 314 and is extruded from the second printhead 314 in a
[0024 ] Reference Numeral 100 — Object. second material stream 316 to produce the feature made of
the second material 312 . Relative movement between the
[0025 ] Reference Numeral 102 — The part of object 100 build platform 304 and the first and second printhead 308
consisting of a first material. and 314 is illustrated by the arrows 318 . A computer /
[0026 ] Reference Numeral 104 Simple square openings controller 320 directs operation of the system 300 to produce
features to be built into object 100 . the object 302 .
[0027 ] Reference Numeral 106 — Simple round holes fea (0049] Referring now to FIGS. 4 , 5 , and 6 ; illustrations
tures to be built into object 100 . will be used to further demonstrate dross formation in
Reference Numeral 108 — Bridging material of made of a overhangs. FIG . 4 illustrates an object constructed using an
second material used in the AM of object 100 . AM . The components illustrated in FIG . 4 are identified and
[0028 ] Referring now to FIG . 2 , a simplified schematic described below .
depiction further illustrates the object 100 constructed using [0050 ] Reference Numeral 400 — Object .
an AM and helps demonstrate dross formation in overhangs . [0051] Reference Numeral 402 — Layers of melted pow
The components illustrated in FIG . 2 are identified and der.
described below . [0052] Reference Numeral 404 — Layers of bridging mate
[0029 ] Reference Numeral 100 _ Object. rial made of a second material.
[ 0030 ] Reference Numeral 102 — The part of object 100 [0053 Reference Numeral 406 – Laser beam .
consisting of a first material. [0054 ] Reference Numeral 408 — Laser beam path .
[0031] Reference Numeral 104 _ Simple square openings [0055 ] Reference Numeral 410 - A single layer of the
layers of melted powder 402.
features to be built into object 100 . [0056 ] FIG . 4 illustrates a moment in time in the AM
[0032 ] Reference Numeral 106 — Simple round holes fea construction of the object 400 . In FIG . 4 an object 400 being
tures to be built into object 100 . made of a first material and a second material is shown . The
[ 0033) Reference Numeral 209Dross or overhang that firstmaterial is the layers ofmelted powder 402 . The second
can occur during AM constructing of a desired object. material is the layers of the bridging material 404 . The
[0034 ] The description of the components illustrated in second material 404 will eventually be removed to complete
FIG . 2 having been completed , the operational aspects of the final workpiece /object 400 . Note that for simplicity only
constructing the object 100 using an AM system that incor the overall second material 404 is shown and the individual
porates the inventor 's apparatus, systems and methods will layers of the second material do not appear .
now be considered . The bridging material 108 has been f0057 ] The laser beam 406 moves along the laser beam
etched /removed leaving the features 104 and 106 exposed . path 408 to melt the metal powder and form the solidified
US 2019 /0291209 A1 Sep . 26 , 2019

layers of the object 400 . FIG . 4 illustrates a moment in time layers of the second material do not appear. In FIG . 6 an
in the AM construction of the object 400 when the single additional layer 412 of melted powder has been applied on
layer 410 has been applied . The layers of the first material top of the layer 410 .
402 and the layers of the second bridging material 404 have 10079 ]. In each pass 408 of the laser beam 406 in the areas
been laid down . outside of area 414 the beam 406 not only melts/fuses the
[0058 ] Referring now to FIG . 5 the object 400 being additional layer 412 , the laser beam 406 also fuses the layer
constructed using an AM is illustrated . The components 412 to the layer 410 below layer 412 . If the laser beam
illustrated in FIG . 5 are identified and described below . power remains constant in the area labeled 414 , too much
[0059 ] Reference Numeral 400 — Object. energy will be applied . This leads to melting into the bridge
[0060 ] Reference Numeral 402 — Layers of melted pow material 40 and the formation of dross /overhang 416 that
der. will remain after removal of the bridging material in a later
[ 0061] Reference Numeral 404 _ Layers ofbridging mate step of the AM process . FIG . 6 shows dross /overhang 416
rial made of a second material. extending into the second bridging material 404 . This dross/
[ 0062 ] Reference Numeral 406 — Laser beam . overhang 416 will remain after removal of the bridging
[0063] Reference Numeral 408 — Laser beam path . material 404 in a later step of the AM process .
[0064] Reference Numeral 410 — A single layer of the [0080 ] The inventor's additive manufacturing power map
layers ofmelted powder 402 . mitigates overhang defects by reducing the laser power as
10065 ) Reference Numeral 412 — An additional layer of the laser beam moves along the area labeled 414 . A tracer
the layers of melted powder 402 . point can be used by a PID controller. By requesting the
[ 0066 FIG . 5 illustrates another moment in time in the temperature variable at that point to be equal to melting
AM construction of the object 400 . In FIG . 5 the object 400 temperature , the PID controller will control the power to
being made of a first material and a second material is achieve this end .
shown. The first material is the layers ofmelted powder 402 .
The second material is the layers of the bridging material [0081 ] The inventors' apparatus, systems and methods
404 . The second material 404 will eventually be removed to provide a solution to the problem illustrated in FIGS . 4 , 5 ,
complete the final workpiece /object 400. Note that for and 6 . The inventors additive manufacturing power map
simplicity only the overall second material 404 is shown and mitigates overhang structures . The inventors additive manu
the individual layers of the second material do not appear. In facturing power map uses an intelligent feed forward model
FIG . 5 an additional layer 412 of melted powder is shown to control additive manufacturing (AM ) laser powder bed
being applied on top of the layer 410 . fusion process , whereby, the laser crosses an overhang
[0067] The laser beam 406 moves along the laser beam section and creates a smooth overhand inner walls , with little
path 408 to melt the metal powder and form the solidified to no dross formation . This is accomplished by controlling
the laser power through a computer model. A proportional
layers of the object 400 . FIG . 5 illustrates another moment integral derivative (PID ) controller creates a power map .
in time in the AM construction of the object 400 when the The benefit of the process map is to eliminate dross forma
layers of the first material 402 including the single layer 410
and the layers of the second bridging material 404 have been tion in overhangs built using AM . These rough surface
laid down. FIG . 5 shows the additional layer 412 ofmelted defects are random in nature . Their presence prevent
powder being applied on top of the layer 410. machine to machine reproducibility of same AM parts. Also ,
[0068] Referring now to FIG . 6 the object 400 being they have a deleterious effect on part properties. Removing
constructed using an AM is shown with illustration of dross them is a major need and requirement for future AM
formation in an overhang. The components illustrated in machines .
FIG . 6 are identified and described below . [0082] Referring now to FIG . 7, an illustration shows the
[ 0069 ] Reference Numeral 400 — Object. final finished workpiece/object 700 constructed using an AM
[ 0070 ] Reference Numeral 402 — Layers of melted pow and the inventors ' power map apparatus, systems and meth
der. ods. The components illustrated in FIG . 7 are identified and
[0071 ] Reference Numeral 404 — Layers of bridging mate described below .
rial made of a second material. Reference Numeral 700 — Finished workpiece /object.
[0072] Reference Numeral 406 — Laser beam . Reference Numeral 702 — Simple square openings and
[0073 ] Reference Numeral 408 – Laser beam path . round hole features built into finished workpiece /object 700 .
[0074] Reference Numeral 410 — A single layer of the [0083] The powder bed fusion system includes an appa
layers of melted powder 402 . ratus in which selected areas of a powder bed are solidified
[0075 ] Reference Numeral 412 — An additional layer of in a layer-by -layer manner to form a workpiece . A laser
the layers of melted powder 402 . generates a laser beam across the surface of the powder bed
00761 Reference Numeral 414 — An area where the laser to solidify predetermined areas of each layer. Applicants'
beam power remains constant. AM power map mitigates defects when the laser follows a
[0077 ] Reference Numeral 416 - Dross/ overhang 416 . laser path that produces a laser beam path on the powder
10078 ] FIG . 6 illustrates and further demonstrates dross bed .
formation in an overhang . In FIG . 6 the object 400 being [0084 ] The inventors ' power map system utilizes the PID
made of a first material and a second material is shown . The (proportional integral derivative ) to decrease the laser power
first material is the layers of melted powder 402. The second and maintain a constant melt depth . Since the energy is
material is the layers of the bridging material 404 . The accumulating in overhang region , the temperature at the
second material 404 will eventually be removed to complete tracer point is maintained fixed . The PID then controls the
the final workpiece /object 400 . Note that for simplicity only power by decreasing it, so as to decrease the amount of
the overall second material 404 is shown and the individual energy deposited and maintain a constant temperature value
US 2019 /0291209 A1 Sep . 26 , 2019

at the depth of the tracer point. This in turns guarantees fixed to be construed under the provisions of 35 U . S.C . 112, sixth
melt pool depth and prevents formation of dross. paragraph , unless the element is expressly recited using the
[ 0085 ] Additional details of the inventors ' inventors addi phrase “ means for.”
tive manufacturing power map are disclosed in the patent [0091] While the apparatus, systems, and methods may be
applications identified and described below . The content of susceptible to various modifications and alternative forms,
the patent applications identified and described below are specific embodiments have been shown by way of example
hereby incorporated herein by reference in their entirety for in the drawings and have been described in detail herein .
all purposes. However , it should be understood that the application is not
[0086 ] U .S . Provisional Patent Application No. 62/647 , intended to be limited to the particular forms disclosed .
358 filed Mar. 23 , 2018 entitled " additive manufacturing Rather, the application is to cover allmodifications , equiva
power map to mitigate overhang structure .” lents, and alternatives falling within the spirit and scope of
[0087 ] U .S . Provisional Patent Application No. 62/647, the application as defined by the following appended claims.
375 filed Mar. 23 , 2018 entitled “ additive manufacturing 1 . An additive manufacturing method for producing a
power map to mitigate defects.” workpiece , comprising the steps of:
[0088] U .S . patent application Ser. No . 16 /145,483 filed providing a first material ;
Sep . 28 , 2018 entitled " additive manufacturing power providing a second material wherein the second material
map to mitigate defects ." is a bridging material ;
[ 0089 ] Although the description above contains many providing a laser that produces a laser beam ;
details and specifics, these should not be construed as using said first material, second material, said laser , and
limiting the scope of the application but as merely providing said laser beam to produce an intermediate workpiece
illustrations of some of the presently preferred embodiments unit having a body made of said first material and
of the apparatus, systems, and methods. Other implementa features in said body wherein said features aremade of
tions, enhancements and variations can be made based on said second material;
what is described and illustrated in this patent document. creating a power map to prevent formation of overhang
The features of the embodiments described herein may be structures in said workpiece wherein said power map is
combined in all possible combinations ofmethods, appara an intelligent feed forward model;
tus, modules, systems, and computer program products . using said power map to control said laser and said laser
Certain features that are described in this patent document in beam and produce said intermediate workpiece unit
the context of separate embodiments can also be imple having a body made of said first material and features
mented in combination in a single embodiment. Conversely, in said body wherein said features are made of said
various features that are described in the context of a single second material; and
embodiment can also be implemented in multiple embodi removing said features made of said second material from
ments separately or in any suitable subcombination . More said body made of said first material to produce said
over, although features may be described above as acting in workpiece.
certain combinations and even initially claimed as such , one 2 . The additive manufacturing method for producing a
or more features from a claimed combination can in some workpiece of claim 1 wherein said step of creating a power
cases be excised from the combination , and the claimed map includes using a proportional integral derivative con
combination may be directed to a subcombination or varia troller to create said power map .
tion of a subcombination . Similarly, while operations are 3. The additive manufacturing method for producing a
depicted in the drawings in a particular order, this should not workpiece of claim 1 wherein said step of creating a power
be understood as requiring that such operations be per map includes using a proportional integral derivative con
formed in the particular order shown or in sequential order , troller to predict laser power requirements to achieve melt
or that all illustrated operations be performed , to achieve pool characteristics that prevent formation of overhang
desirable results. Moreover, the separation of various system structures .
components in the embodiments described above should not 4 . The additive manufacturing method for producing a
be understood as requiring such separation in all embodi workpiece of claim 1 wherein said step of creating a power
ments. map includes using a proportional integral derivative con
10090 ] Therefore , it will be appreciated that the scope of troller to predict laser power requirements to achieve melt
the present application fully encompasses other embodi pool characteristics that eliminated defects in the part by
ments which may become obvious to those skilled in the art . controlling the laser power through a computer model.
In the claims, reference to an element in the singular is not 5 . The laser powder bed fusion additive manufacturing
intended to mean " one and only one" unless explicitly so method for producing a part of claim 1 wherein said step of
stated , but rather “ one ormore ." All structural and functional creating a power map includes using a proportional integral
equivalents to the elements of the above -described preferred derivative controller to provide a closed control loop system
embodiment that are known to those of ordinary skill in the to predict laser power requirements to achieve melt pool
art are expressly incorporated herein by reference and are characteristics that prevent formation of overhang struc
intended to be encompassed by the present claims. More tures .
over , it is not necessary for a device to address each and 6 . The laser powder bed fusion additive manufacturing
every problem sought to be solved by the present apparatus, method for producing a part of claim 1 wherein said step of
systems, and methods , for it to be encompassed by the using said power map to control said laser and said laser
present claims. Furthermore, no element or component in beam and produce said intermediate workpiece unit includes
the present disclosure is intended to be dedicated to the the step of creating a tracer point in a computer model.
public regardless of whether the element or component is 7 . The laser powder bed fusion additive manufacturing
explicitly recited in the claims. No claim element herein is method for producing a part of claim 6 wherein said step of
US 2019 /0291209 A1 Sep . 26 , 2019

creating a tracer point in a computermodel includes the step

of using said tracer point in a computer model to control said
laser and said laser beam and produce said intermediate
workpiece unit .
8. An additive manufacturing apparatus for producing a
workpiece , comprising :
a first material;
a second material wherein the second material is a bridg
ing material;
a laser that produces a laser beam ;
means for using said first material, second material, said
laser , and said laser beam to produce an intermediate
workpiece unit having a body made of said first mate
rial and features in said body wherein said features are
made of said second material ;
means for creating a power map to prevent formation of
overhang structures in said workpiece wherein said
power map is an intelligent feed forward model;
means for using said power map to control said laser and
said laser beam and produce said intermediate work
piece unit having a body made of said first material and
features in said body wherein said features are made of
said second material; and
means for removing said features made of said second
material from said body made of said first material to
produce said workpiece .