# US 11,077,500 B2 · Three-dimensional shaping method

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- Number: US 11,077,500 B2
- Document ID: US11077500B2
- Status: Granted
- Kind: B2
- Application number: 16/139,492
- Filed: 2018-09-24
- Published: 2019-01-24
- Granted: 2021-08-03
- Earliest claimed: 2015-02-16
- Assignees: Matsuura Machinery Corporation
- Applicants: Matsuura Machinery Corporation
- Inventors: Kousuke Ishimoto; Makoto Ichimura; Kouichi Amaya
- Web page: https://patentgrep.com/patent/US11077500B2

## CPC

- B29C 64/153: using layers of powder being selectively joined, e.g. by selective laser sintering or melting
- B22F 10/28: Powder bed fusion, e.g. selective laser melting [SLM] or electron beam melting [EBM]
- B22F 10/366: Scanning parameters, e.g. hatch distance or scanning strategy
- B22F 10/50: Treatment of workpieces or articles during build-up, e.g. treatments applied to fused layers during build-up
- B22F 10/85: for controlling or regulating additive manufacturing processes
- B29C 64/188: involving additional operations performed on the added layers, e.g. smoothing, grinding or thickness control (surface shaping B29C59/00; after-treatment of articles without altering their shape B29C71/00)
- B29C 64/393: for controlling or regulating additive manufacturing processes
- B22F 2003/247: {Removing material: carving, cleaning, grinding, hobbing, honing, lapping, polishing, milling, shaving, skiving, turning the surface}
- B22F 2998/10: Processes characterised by the sequence of their steps
- B33Y 10/00: Processes of additive manufacturing
- B33Y 50/02: for controlling or regulating additive manufacturing processes
- Y02P 10/25: Process efficiency
- B29C: SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING (making preforms B29B11/00; making laminated products by combining previously unconnected layers which become one product whose layers will remain together B32B37/00 - B32B41/00)
- B22F: WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER (making alloys by powder metallurgy C22C); APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
- B33Y: ADDITIVE MANUFACTURING, i.e. MANUFACTURING OF THREE-DIMENSIONAL [3D] OBJECTS BY ADDITIVE DEPOSITION, ADDITIVE AGGLOMERATION OR ADDITIVE LAYERING, e.g. BY 3D PRINTING, STEREOLITHOGRAPHY OR SELECTIVE LASER SINTERING
- Y02P: CLIMATE CHANGE MITIGATION TECHNOLOGIES IN THE PRODUCTION OR PROCESSING OF GOODS

## Abstract

A three-dimensional shaping method in which the powder supplying blade 2 is able to travel without any problems, in which a control system stores in advance a fine sintered region 11 so that any one of a cross-sectional area or a mean diameter in the horizontal direction, a shaping width and an undercut angle at the end is equal to or less than a predetermined extent, or the control system makes a determination in a sintering step, for said each element, so in the case of the raised sintered portions 12 forming on the upper side of the sintered region 11, a rotating cutting tool 3 cuts the raised sintered portions 12 entirely or partially, thereby achieving the object.

## Claims

### Claim 1

A three-dimensional shaping method for forming a three-dimensional product, comprising the steps of:
(1)-1 forming forming a powder layer with a predetermined thickness,
(1)-2 on each said layer to be sintered, in which instructions that raised sintered portions are formed after sintering from a sintered region, with positions in a horizontal direction and a height direction having one of a cross-sectional circular area and a diameter of the circular area before sintering the region, is based according to the following comparison standard:
whether the one of the cross-sectional circular area and the diameter is greater than a predetermined value,
(2)-1 in the case that the one of the cross-sectional circular area and the diameter of the circular area is greater than the predetermined value such that the raised sintered portions are not formed, causing the region to be sintered,
(2)-2 (i) in the case that the one of the cross-sectional circular area and the diameter of the circular area is not greater than the predetermined value such that the raised sintered portions are formed, temporarily stocking positions in the horizontal direction and the height direction at a region of the one of the cross-sectional circular area and the diameter of the circular area,
(ii) causing the respective powder layer to be sintered after said temporarily stocking,
(iii) causing a rotating cutting tool to cut the stocked positions, so that the rotating cutting tool cuts any raised sintered portions,
(3) causing a cutting tool to cut a periphery thereof while traveling along an outside edge of the periphery to form the layer of an article, the step of cutting a periphery occurring according to one of the following:
if the step (2)-2 (iii) occurs, after the step (2)-2 (iii), or
if the step (2)-2 (iii) does not occur, after the sintering in step (2)-1 and
(4) repeating steps (1)-(3) for each layer in an additive manufacturing process.

### Claim 2 (depends on 1)

The three-dimensional shaping method according to claim 1, wherein one of:
the cross-sectional circular area is π mm2 and
the diameter of the circular area is 2 mm.