# US 2015/0360288 A1 · Optimized additive manufacturing process

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- Number: US 2015/0360288 A1
- Document ID: US20150360288A1
- Status: Published application
- Kind: A1
- Application number: 14/739,739
- Filed: 2015-06-15
- Published: 2015-12-17
- Earliest claimed: 2014-06-13
- Assignees: ZIN Technologies
- Applicants: Zin Technologies, Inc.
- Inventors: BART F. ZALEWSKI
- Web page: https://patentgrep.com/patent/US20150360288A1

## CPC

- B29C 64/153: using layers of powder being selectively joined, e.g. by selective laser sintering or melting
- B22F 3/16: in successive or repeated steps
- B22F 10/34: of powder characteristics, e.g. density, oxidation or flowability
- B22F 10/80: Data acquisition or data processing
- B33Y 10/00: Processes of additive manufacturing
- B33Y 30/00: Apparatus for additive manufacturing; Details thereof or accessories therefor
- B22F 1/065: Spherical particles
- B22F 10/28: Powder bed fusion, e.g. selective laser melting [SLM] or electron beam melting [EBM]
- B22F 10/36: of energy beam parameters
- Y02P 10/25: Process efficiency
- Y02P 80/40: Minimising material used in manufacturing processes
- 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 method for additive manufacturing a multilayered part includes optimizing a powder material based on at least one parameter characterizing the powder material. Each layer of the multilayered part formed from the optimized powder material is optimized based on at least one parameter characterizing the layer. The multilayered part is formed using additive manufacturing based on the optimized powder material and optimized layers constituting the multilayered part. The multilayered part is optimized based on at least one parameter characterizing the multilayered part.

## Claims

### Claim 1

A method for additive manufacturing a multilayered part comprising:
optimizing a powder material based on at least one parameter characterizing the powder material;
optimizing each layer of the multilayered part formed from the optimized powder material based on at least one parameter characterizing the layer; and
forming the multilayered part using additive manufacturing based on the optimized powder material and optimized layers constituting the multilayered part, the multilayered part being optimized based on at least one parameter characterizing the multilayered part.

### Claim 2 (depends on 1)

The method of claim 1, wherein the parameters characterizing the powder material comprise at least one of material distribution, compaction, viscosity, and shape.

### Claim 3 (depends on 2)

The method claim 2, wherein prior to the forming, the method includes compacting the powder material according to a compaction parameter to provide the optimized powder material that is used to form the multilayered part.

### Claim 4 (depends on 3)

The method claim 3, wherein the compaction includes polarizing the powder material.

### Claim 5 (depends on 1)

The method of claim 1, wherein the parameters characterizing each layer of the multilayered part comprise at least one of topology, material orientation, layer thickness, surface finish, and material cost.

### Claim 6 (depends on 1)

The method of claim 1, wherein the parameters characterizing the multilayered part comprise at least one of part orientation, laser path, product cost, and production schedule.

### Claim 7 (depends on 1)

The method claim 1, wherein the method is stored in memory and implemented as instructions executed by one or more processing units.

### Claim 8

A non-transitory computer readable medium having instructions programmed to perform a method comprising:
optimizing a powder material based on at least one parameter characterizing the powder material;
optimizing each layer of the multilayered part formed from the optimized powder material based on at least one parameter characterizing each respective layer; and
controlling an additive manufacturing device to form the multilayered part using additive manufacturing based on the optimized powder material and each of the optimized layers constituting the multilayered part, the multilayered part being optimized based on at least one parameter characterizing the multilayered part.

### Claim 9 (depends on 8)

The computer readable medium of claim 8, wherein the parameters characterizing the powder material comprise at least one of material distribution, compaction, viscosity, and shape.

### Claim 10 (depends on 9)

The computer readable medium of claim 9, wherein the controlling further comprising controlling compacting the powder material according to a compaction parameter to provide the optimized powder material that is used to form the multilayered part.

### Claim 11 (depends on 10)

The computer readable medium of claim 10, wherein the controlling includes controlling polarizing the powder material according to the compaction parameter prior to forming at least some of the layers of the multilayered part.

### Claim 12 (depends on 8)

The computer readable medium of claim 8, wherein the parameters characterizing each layer of the multilayered part comprise at least one of topology, material orientation, layer thickness, surface finish, and material cost.

### Claim 13 (depends on 8)

The computer readable medium of claim 8, wherein the parameters characterizing the multilayered part comprise at least one of part orientation, laser path, product cost, and production schedule.

### Claim 14 (depends on 8)

The computer readable medium of claim 8, wherein the method is stored in memory and implemented as instructions executed by one or more processing units.

### Claim 15

A system comprising:
a material optimizing component, executed by a computing device, for optimizing a powder material based on at least one parameter characterizing the powder material;
a structural optimization component, executed by a computing device, for optimizing each layer of the multilayered part formed from the optimized powder material based on at least one parameter characterizing the layer; and
an additive manufacturing device to form the multilayered part using an additive manufacturing process that is controlled for each layer of the multilayered part based on the optimized powder material and optimized layers constituting the multilayered part, the multilayered part being optimized based on at least one parameter characterizing the multilayered part.

### Claim 16 (depends on 15)

The system of claim 15, wherein the parameters characterizing the powder material comprise at least one of material distribution, compaction, viscosity, and shape.

### Claim 17 (depends on 16)

The system of claim 16, wherein the additive manufacturing device is configured, in response to control instructions provided by the computing device, to compact the powder material according to the compaction parameter prior to forming at least some of the layers of the multilayered part..

### Claim 18 (depends on 17)

The system of claim 17, wherein the additive manufacturing device is configured to control polarization of the powder material according to the compaction parameter prior to forming at least some of the layers of the multilayered part.

### Claim 19 (depends on 15)

The system of claim 15, wherein the parameters characterizing each layer of the multilayered part comprise at least one of topology, material orientation, layer thickness, surface finish, and material cost.

### Claim 20 (depends on 15)

The system of claim 15, wherein the parameters characterizing the multilayered part comprise at least one of part orientation, laser path, product cost, and production schedule.