Patent Application
20240269919
The present invention relates in general to the field of additive manufacturing. In particular, the present invention relates to a method and apparatus for forming three-dimensional component/objects from a feedstock made of glass.
In glass 3D printing or additive manufacturing, the existing technologies include (1) hot extruding from a furnace, (2) glass rods deposition, (3) stereolithography/ink-jetting with glass-polymer mixed solution, and (4) glass filament deposition.
However, in [J. M. Hostetler et al., FIBER-FED PRINTING OF FREE-FORM FREE-STANDING GLASS STRUCTURES, Solid Freeform Fabrication 2018: Proceedings of the 29th Annual International, 994-1002] only one laser beam is used to soften the glass filament. This asymmetric heating significantly limits the directional printing capability. The inhomogeneous temperature gradient in the molten glass filament can result in high residual stress in the print risking from material failures and disruption of the printing process. This technique uses bare glass filament which means in prior to the printing the coating needs to be removed from the glass filament. This approach, however, causes the fiber to be left unprotected during the last stage; the mechanical feeding of the fiber into the hot-zone. The stripping process also limits the total length of the printable glass filament (i.e., maximum mechanical stripping of less than a few meters, maximum chemical stripping less than several 10's of meters), which severely damages the continuity and capability (volume) of the 3D printing process.
In [T. Grabe, et al., Additive Manufacturing of fused silica using coaxial laser glass deposition, experiment, simulation and discussion, Proc. SPIE 11677, Laser 3D Manufacturing VIII, 116770Z (8 Mar. 2021)], one laser beam is split into 4 partial beams. However, the quality of the split beams is poor as they are not uniform Gaussian laser beams. The inhomogeneous heating problem still exists. In this method, coated glass filament is used. The coating is burnt off near the hot-zone, i.e., the hot-zone itself can be used to remove the coating. A problem with said method with commonly used fiber coatings is that it may cause unwanted combustion bi-products, be more likely to leave residues affecting the purity of the print. Another issue is that the coating can ignite and start to burn off long lengths of filament even after the heat source is turned off. Therefore, process gas is needed to suppress coating combustion. To burn off the coating, excessive energy is needed which cause massive glass vaporization during printing.
Glass vaporization is very common and hard to eliminate during laser-based glass processing. The vaporization creates unwanted fume silica particles which are adhesive to surfaces. Existence of fume silica particles raises the risk of optics contamination and destruction in the system. The control of vaporization rate and fume direction is critical.
Additive manufacturing using bare glass filaments possess poor mechanical properties, and thus are susceptible to breakage. In order for mechanical and chemical protection of the glass filament during storage and handling, a protective coating is required. The protective coating can be applied during filament fabrication.
In prior glass additive manufacturing the coating needs to be removed from the glass filament. Stripping off the coating can be performed using mechanical or chemical means (e.g., using sulfuric acid, dichloromethane) prior feeding the filament into the hot additive fabrication zone. This approach, however, causes the fiber to be left unprotected during the last stage; the mechanical feeding of the fiber into the hot-zone. As stripping the coating may further weaken the mechanical strength of the filament, this is not an ideal solution as filament breakage during printing will cause major interruptions of the printing process. Using chemical means is not preferred due to risks involved when using strong acid (sulfuric acid) or dichloromethane (carcinogenic).
In glass 3D printing, the glass filament is continuously fed to a hot-zone at 1800 to 2200° C. One common method is to feed pure glass filament. However, since most of the glass filament is produced with coating, removal of the coating is required to produce pure glass filament prior to printing. Stripping off the coating can be performed using mechanical or chemical means (e.g., using sulfuric acid, dichloromethane). The striping process limits the total length of the printable glass filament (i.e., maximum mechanical stripping is usually shorter than 2 m, maximum chemical stripping is usually shorter than 50 m), which severally damages the continuity and capability (volume) of the 3D printing process. As the filament can become brittle without coating and stripping the coating may further weaken the mechanical strength of the filament, this brings extra risks as filament breakage during printing will cause major interruptions of the printing process.
An alternative approach is to burn off the coating. As the hot-zone is heated to very high temperatures the coating will start to burn near the hot-zone, i.e., the hot-zone itself can be used to remove the coating. A problem with said method is that it may cause printing failures, combustion bi-products, be more likely to leave residues affecting the purity of the print and is not energy efficient. Yet another issue is that there is a problem of controlling the amount of burned off coating: it may happen that coating may start to burn off for the full filament length.
WO2018/163006 continuous filament feeding for glass 3D printing. The printing uses glass rods as raw material. Feeding rods are loaded in a rotating cassette and fed through a printing head and deposited on a substrate. The continuous feeding is realized by thermally bonding the rods during the process. Unable to print glass at higher temperatures limits material selection. The problem with this system is the risk of nozzle damaging by molten glass, the printing volume is limited by the cassette volume, the bonding area still generate inconsistency in the feeding, leads to inhomogeneous print quality and the setup is considered to be of high mechanical complexity.
The present invention aims at obviating the aforementioned problems. A primary object of the present invention is to provide an improved apparatus for forming three-dimensional components of glass.
Another object of the invention is to provide an additive manufacturing method for forming a three-dimensional component of glass.
According to the invention at least the primary object is attained by means of the system having the features defined in the independent claims.
Preferred embodiments of the present invention are further defined in the dependent claims.
According to a first aspect of the present invention it is provided an additive manufacturing method for forming a three-dimensional component/object of glass comprising the steps of:
An advantage of this embodiment is that any fumes created at the additive fabrication hot-zone of the glass filament may escape from said additive fabrication hot-zone without contaminating laser optics or without interfering with the laser beam during melting/softening of said glass filament.
In various example embodiments of the present invention said glass filament is fed essentially perpendicular to said surface of the stage or object.
The advantage of these embodiments is that the precision of the manufactured details may be increased compared to providing said glass filament essentially non perpendicular to said substrate.
In various example embodiment of the present invention at least one laser beam emanating from at least one source is used for heating said glass filament.
The advantage of these embodiment sis that one or a plurality of laser beams emanating from one or a plurality of laser beam sources may be used for heating/melting said glass filament.
In various example embodiments of the present invention glass filament material is hollow.
The advantage of these embodiments is that said hollow structure of said filament may be built in said final three-dimensional component, such as for instance microfluidic structures.
In various example embodiments of the present invention said glass filament material is having a protective film made of polyimide having a thickness in the range of 1 μm 50 μm.
The advantage of these embodiments is that said filament is protected prior to use at the same time as this protective film is automatically removed during use in additive manufacturing and exhibits very little for not saying no contamination of the manufactured material and its guiding optics for the laser beam.
In various example embodiments of the present invention said glass filament is heated by at least three laser beams having a wavelength above 2 μm.
The advantage of these embodiments is that multiple laser beams provided symmetrically around the glass filament may speed up the melting/softening time. Another advantage is that the wavelength and/or the number of laser beams may be selected to have a customized heating efficiency.
In various example embodiments of the present invention said glass filament is a coated glass fiber having a diameter in the range of 100-500 μm.
The advantage of these embodiments is that various diameters of the glass filament may be used to maximize precision or manufacturing speed. A further advantage of the present invention is that an optical fiber may be used as feedstock material.
In various example embodiments of the present invention said stage is a glass plate is having a thickness in the range of 80%-300% of the diameter of said glass filament. The thickness may be in the range of a few tenth of a mm to several cm's.
The advantage of these embodiments is that the manufacturing method is compatible with very thin substrates.
In various example embodiments of the present invention further comprising the step of preheating said glass filament prior to heating it with said at least one laser beam.
The advantage of these embodiments is that less laser power may be necessary in order to reach a desired melting/softening temperature of the glass filament. Preheating may be performed by resistive heating in a filament feeding nozzle.
In various example embodiments of the present invention the distance between a filament feeding nozzle and a point of intersection of said glass filament with said laser beam is less than 5 mm. The angle of a laser beam with respect to the surface of the stage or object to which said glass filament is to be applied may be in the range of 30-60°. A plurality of laser beams may be configured for intersecting at said glass filament essentially symmetrically around said glass filament.
The advantage of these embodiments is that the short distance increases the precision of the manufacturing of the three-dimensional component. The short distance may be used because of a self-extinguishing nature of the protective film on said glass filament. The impinging angle of said laser beam is chosen so that said hot-zone is applied in said glass filament and said stage for efficient fusing of said stage and said glass filament. The stage may further be heated from behind by means of an independent heating source such as at least one another laser beam impinging from opposite side to where said glass filament is applied on said stage.
In various example embodiments of the present invention said glass filament is made of at least two different materials plus a protective film.
The advantage of these embodiments is that functional optical waveguides may be manufactured such as optical circuits for use in telecommunication, sensing or biomedical applications.
In another aspect of the present invention, it is provided an apparatus for additive manufacturing of glass component/object comprising:
Further advantages with and features of the invention will be apparent from the following detailed description of preferred embodiments.
A more complete understanding of the abovementioned and other features and advantages of the present invention will be apparent from the following detailed description of preferred embodiments in conjunction with the appended drawings, wherein:
The process invention here refers to a new Additive Manufacturing (AM) process where using a digital model, a component geometry is built by fusing filaments/fibers that are melted layer-by-layer or in batches of layers using an energy source such as a laser beam through either selective melting or simple scanning of the printed profile, following the fusion process.
This invention is about a direct manufacturing process by integrating the protective film removal of the filament with the printing process. This means, that the new process will be able to manufacture fully or near-fully dense glass components using glass filaments and will overcome all the shortcomings of the prior art glass manufacturing methods.
The new process will enable direct manufacturing of glass components without any of the safety precautions and/or health risks associated with the use of prior art glass filaments.
The filament feeding nozzle 120 and/or the stage 130 may be arranged on at least one motorized support. A control unit may control the relative movement of said filament feeding nozzle 120 with respect to said stage 130. Said control unit may also control print head optics and laser.
In
A first step is the fusion and deposition of feedstock material onto the stage 130. The filament feeding nozzle 120 locally deposits the feedstock material along a predefined path. The filament feeding nozzle 120 may heat the feedstock material before it leaves the nozzle 120 on its way towards the stage 130. The filament feeding nozzle 120 may be adapted to the size and shape of the feedstock material. A three-axes kinematic may position the filament feeding nozzle 120 in the machine's work envelope to generate the three-dimensional component made of glass layer-by-layer. The feedstock material 160 is a glass filament. In
A CO2-laser operating at a wavelength of 10.6 μm may be used. At this wavelength silica glass is opaque, resulting in efficient heating. The absorption depth is approximately 2 μm to 40 μm and is efficient for heating glass filaments on the order of 100's of μm in diameter. For larger glass filaments the shallow penetration depth at 10.6 μm makes it difficult to heat rapidly. Using a CO-laser operating at 5.5 μm is more suitable for glass filaments larger than approximately 0.5 mm. The penetration depth at 5.5 μm is much larger (100's of μm) resulting in more efficient energy deposition into the glass filament 160.
A DOE 145 may be used to split the original laser beam 150 to at least three uniform laser beams 150′. Several secondary beam steering mirrors 165 may be used to direct the split laser beams 150′ into the hot-zone 140. A first optional beam steering mirror 115 may be used for making the laser beam path more compact and facilitate beam alignment. The at least three second beam steering mirrors 165 deflects the at least three laser beams to a hot-zone 140 where the at least three laser beams impinge on said glass filament 160. A quarter-wave plate 125 may be used to control the polarization of the laser beam. Using a circularly polarized beam ensures that the split laser beams 150′ are identical as the DOE 145 may have some polarization dependence. A circularly polarized beam can also be achieved using a reflective phase retarder as (first or second) beam steering mirror 115. A focusing lens 135 may be used to change the focal spot size at the hot-zone 140, enabling to modify the heating dynamics. The focus lens 135 may be mounted on a computer controlled motorized translation stage. The depicted DOE is a 2×2 DOE, i.e., splitting a single laser beam 150 into 4 laser beams 150′. The pyramid mirror 155 may be used to deflect the beams 150′ from the DOE 145. Using a pyramid mirror 155 as depicted in
Laser and beam steering may comprise a beam tap, which couples out a few percent of the laser beam power that is monitored using a reference power meter. Input from the reference power meter is used as a feedback signal in order to stabilize laser power, using e.g., a closed-loop feedback system. A shutter may be used to turn on/off the laser beam of the print head. When off (closed) the beam is directed to a beam dump which can also be an extra power meter. When on (opened) the beam then enters the print head. In
One or several filament feeders may be used to add feedstock during printing. The print stage may be a 3- (x-y-z), 4-, or 5-axis translation system holding the substrate or print profile. When using silicate glass filaments (e.g., borosilicate or soda-lime glass) the build volume may also include a heating chamber. For fused silica or fused quartz glass filaments this may be less of a problem (due to extremely low thermal expansion coefficient) and printing can be performed without extra heating. To improve bonding to the substrate, irradiation using a separate laser beam below the point where the softened glass filament is to be deposited can be used. A laser operating at visible wavelengths is used for beam alignment as both CO2- and CO-laser operate in the infrared wavelength spectrum. The alignment precision may be critical to achieve homogeneous heating of the filament. The alignment technique is based on using the filament as a small interferometer.
A He—Ne laser (632.8 nm wavelength), e.g., is focused onto the filament at the specified position for the intersection of the 4 laser beams (corresponding to the hot-zone). Light from the red laser may be reflected at the two interfaces of the glass fiber. The round glass fiber may form a concentric cavity interferometer (CCI). The two reflections of the CCI may interfere with each other forming interference fringes. When the temperature increases at the location of the focused He—Ne laser, the fringes move outwards, while they move inwards when decreasing in temperature. The procedure for aligning the CO2- or CO-laser beams then becomes straight forward. Each beam is precisely aligned simply by maximizing the fringe shift (increasing temperature).
One feedstock feeding nozzle 120 may provide feedstock material 160 at a first predetermined layer area of the three-dimensional component and two or more nozzles may be used for a second predetermined layer area of the three-dimensional component, i.e., the layer formation may alter between one, two, three or more nozzles depending on the shape of the layer to be formed and/or type of material to be added. In various example embodiments a plurality of nozzles for providing feed stock onto the substrate may have the same diameter or different diameters. A plurality of filament feeding nozzles may provide feedstock material of different glass materials.
In synchronization to filament extrusion, the functional point (hot-zone) is positioned according to a predefined path. This path is derived by slicing the geometry of the workpiece into layers and calculating a time-efficient trajectory for the extrusion of the filament 160. The positioning may be done by a three-axes positioning unit. It is intended to extend the manufacturing flexibility with a five-axes kinematic in order to further realign the workpiece with reference to the gravity field of Earth.
In a first option simultaneous processing with a travelling laser beam, sintering/melting the deposited glass filament 160, following in close proximity to the filament deposition.
Alternatively, sintering/melting a thin layer/s of the glass filament with high power laser beam through selective laser scanning of the latest printed layer/s. The process may require a controlled heat input and timing. To ensure geometric accuracy, in situ measurements may be made which enable the direct compensation of the process variance. Imperfections in the material may require a quality inspection of the sintered/melted glass layers. In situ quality control ensuring geometric accuracy, appropriate temperature, and gas content and pressure in the printing environment.
One or a plurality of laser beams may be used simultaneously for melting/softening the glass filament.
Bare glass filaments possess poor mechanical properties, and thus are susceptible to breakage. In order for mechanical and chemical protection of the glass filament during storage and handling, a protective coating is required. The protective coating can be applied during filament fabrication, using, e.g., a fiber draw tower used to produce optical fibers. A furnace heats the preform (large version of filament in both shape and composition). The softened glass is then pulled using a capstan in combination with a diameter gauge for the correct filament dimensions. As the filament is being pulled, the preform is fed further into the furnace. Typically, a coating resin may be introduced into a coating cup, which the filament is passing through. The coating may then be subsequently cured, either thermally or using e.g., UV lamps, prior to winding the filament onto storage and transport spools. Curing temperatures for polyimide coatings on optical fibers may typically be performed in the temperature range of about 100 to 400° C.
Polyimide coated optical fibers can survive operating temperatures of around 300° C., and are commonly used for higher-temperature (sensing) applications. Here coating thickness of 10 to 15 μm is typically used. Thicker coatings can be applied by repeating the coating procedure, adding multiple coating layers.
For glass filaments the coating thickness should be as thin as possible, while ensuring sufficient mechanical and chemical protection of the fiber. The filaments we have evaluated that gave good results have a single layer polyimide coating thickness of approximately 5 μm.
Suitable outer diameters of glass filaments are in the range 100 μm to 500 μm. The diameter has a large impact on the mechanical properties of the filament with increased diameter resulting in more stiff filaments. The translation of the nozzle and filament relative to the printed structure, during printing, results in a lateral force on the filament. A deviation of the filament position depends on viscosity and surface tension of the liquid glass in the hot-zone, as well as printing speed. A schematic of a printing nozzle and extruding filament is shown in the figure below. With a stiffer filament, the distance between the filament feeding nozzle and hot-zone can be increased. The filament diameter, nozzle design, and distance to the hot-zone therefore has a large effect on the print accuracy/quality. A large filament diameter and short extruding filament length will reduce the filament deviation during printing. Increasing the filament diameter reduces the resolution of the printer. If the extruding filament length is too short the filament feeding nozzle can be damaged by the hot-zone.
The total deflection/deviation δ is given by:
where F is the retention force applied by the relative movement during printing process, L is the extruding filament length, E is the Young's modulus of the filament material, r is the radius of the filament. Theoretically, under the same processing conditions the filament with a diameter of 200 μm deflects one quarter to that of the filament having a diameter of 125 μm. Using a filament diameter of 200 μm and an extruding filament length smaller than 5 mm, the deflection results in sub-μm and can be considered negligible.
In glass 3D printing, the glass filament is continuously fed to a hot-zone at 1800 to 2200° C. One common method is to feed pure glass filament. However, since most of the glass filament was produced with coating, removal of the coating is required to produce pure glass filament prior to printing. Stripping off the coating can be performed using mechanical or chemical means (e.g., using sulfuric acid, dichloromethane). The striping process limits the total length of the printable glass filament i.e., maximum mechanical stripping less than a few meters, maximum chemical stripping less than a few tenths of meters, which severally damages the continuity and capability (volume) of the 3D printing process. As the filament can become brittle without coating and stripping the coating may further weaken the mechanical strength of the filament, this brings extra risks as filament breakage during printing will cause major interruptions of the printing process. Using chemical means is not preferred due to risks involved when using strong acid (sulfuric acid) or dichloromethane (carcinogenic).
Another approach is to directly feed the coated filament. With protective coating, the printable filament length is extended to kilometers range. However, as filament is commonly coated by flammable polymers e.g., acrylics, this approach can cause an open flame on the filament due to the high printing temperature, leading to the printing failure and likely destruction of the 3D printer. Besides, standard coating has a thickness at about 50 μm, considered too “thick” for glass 3D printing. Direct burning of the “thick” coating is not an ideal solution as it may produce more combustion bi-products, be more likely to leave residues affecting the purity of the print, and it is not energy efficient.
Our approach is to produce the glass filament with thin flame retardant and self-extinguishing coating. As the hot-zone is heated to very high temperatures, using CO2-laser beams, the coating will start to burn near the hot-zone, i.e., the hot-zone itself can be used to remove the coating. While the coating is flame retardant, the risk of open flame is eliminated. Once the lasers and filament feeding are turned off, the combustion of the coating will stop. A thin coating will be easily burnt off. Besides increasing efficiency and reducing environmental impact, it will also reduce the production of combustion bi-products. The ideal coating may have a non-toxic chemical composition to further reduce toxic fumes produces during combustion e.g., should not contain halogens.
The inventive filament for additive manufacturing provides for the possibility to apply a thin coating layer to glass filament, while still providing mechanical and chemical protection of the filament during (temporary) storage and handling. The coating may be easily removed by thermal means (heating/plasma/laser irradiation). The coating may not contain toxic elements or produce toxic combustion products when burned. The coating may be flame retardant and self-extinguishing.
The additive manufacturing method according to the present invention may be used for producing a three-dimensional component of glass. Said method comprising the steps of feeding a glass filament having a protective film thereon to a heating source for removing said protective film and softening said glass filament and applying said softened glass filament to the surface of a substrate, wherein said protective film is made of polyimide and having a thickness in the range of 1 μm to 50 μm. The feeding of glass filament may be continuous or discontinuous.
The filament may be continuously fed towards a substrate, while simultaneously, a hot-zone created by a single or multiple laser beams bond them together. The relative motion between the substrate and the filament is under computer control to define the printed shape.
Simple structures such as micro-spheres, pillars, lines, circles and nano-tapers etc. were printed by single deposition. Printing free-standing models/arrays was also demonstrated. Multi-layer printing in complex geometry was realized. Both hollow models (vase mode) and dense models (100% infill) were printed using the glass filament. Conclusively, the glass filament is applicable to all glass 3d printing tests above and the performance is similar to the plastic filament in FDM systems.
The flame retardant and/or self-extinguishing protective film 169 is applied to the surface of the glass filament 160.
The invention is not limited only to the embodiments described above and shown in the drawings, which primarily have an illustrative and exemplifying purpose. This patent application is intended to cover all adjustments and variants of the preferred embodiments described herein, thus the present invention is defined by the wording of the appended claims and the equivalents thereof. Thus, the equipment may be modified in all kinds of ways within the scope of the appended claims.
Throughout this specification and the claims which follows, unless the context requires otherwise, the word “comprise”, and variations such as “comprises” or “comprising”, will be understood to imply the inclusion of a stated integer or steps or group of integers or steps but not the exclusion of any other integer or step or group of integers or steps.
| Number | Date | Country | Kind |
|---|---|---|---|
| 2150940-1 | Jul 2021 | SE | national |
| Filing Document | Filing Date | Country | Kind |
|---|---|---|---|
| PCT/EP2022/069235 | 7/11/2022 | WO |
