# US 2019/0314930 A1 · Method for additively manufacturing at least one three-dimensional object > Agents: this data is available as JSON from the patentgrep API and MCP server — see https://patentgrep.com/llms.txt - Number: US 2019/0314930 A1 - Document ID: US20190314930A1 - Status: Published application - Kind: A1 - Application number: 16/275,271 - Filed: 2019-02-13 - Published: 2019-10-17 - Earliest claimed: 2018-04-13 - Assignees: Concept Laser GmbH - Applicants: Concept Laser GmbH - Inventors: Daniel WINIARSKI; Alexander HOFMANN - Web page: https://patentgrep.com/patent/US20190314930A1 ## 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] - B23K 26/034: {Observing the temperature of the workpiece} - B23K 26/0884: {in at least three axial directions, e.g. manipulators, robots} - B23K 26/1464: {Supply to, or discharge from, nozzles of media, e.g. gas, powder, wire} - B23K 26/1476: {Features inside the nozzle for feeding the fluid stream through the nozzle} - B23K 26/342: Build-up welding - B33Y 10/00: Processes of additive manufacturing - B33Y 30/00: Apparatus for additive manufacturing; Details thereof or accessories therefor - B33Y 50/02: for controlling or regulating additive manufacturing processes - B22F 10/14: by jetting of binder onto a bed of metal powder - B22F 10/368: Temperature or temperature gradient, e.g. temperature of the melt pool - B22F 12/37: Rotatable - B22F 12/67: Blades - B29C 64/205: Means for applying layers - 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 - B23K: SOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM - 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 Method for additively manufacturing at least one three-dimensional object (2) by means of successive layerwise selective irradiation and consolidation of build material layers (3) applied in a build plane (BP) of an apparatus (1) for additively manufacturing three-dimensional objects (2) by means of at least one energy beam (5), wherein at least one build material layer (3) which is to be selectively irradiated and consolidated by means of the energy beam (5) comprises at least one build material layer section (11) having a curved shape with respect to at least one extension direction of the build material layer (3). ## Claims ### Claim 1 Method for additively manufacturing at least one three-dimensional object (2) by means of successive layerwise selective irradiation and consolidation of build material layers (3) applied in a build plane (BP) of an apparatus (1) for additively manufacturing three-dimensional objects (2) by means of at least one energy beam (5), wherein at least one build material layer (3) which is to be selectively irradiated and consolidated by means of the energy beam (5) comprises at least one build material layer section (11) having a curved shape with respect to at least one extension direction of the build material layer (3). ### Claim 2 (depends on 1) Method according to claim 1, wherein the or an at least one curved shape build material layer section (11) comprises at least one elevating or elevated portion (11a), particularly at least one portion which elevates and/or is elevated relative to a reference level or plane (RP), and/or at least one lowering or lowered portion (11b), particularly at least one lowering or lowered portion which lowers and/or is lowered relative to the reference level or plane (RP). ### Claim 3 (depends on 2) Method according to claim 2, wherein the elevated portions (11a) are elevated by an elevating value which is determined on basis of an elevation factor and the layer thickness (t) of the respective build material layer (3), particularly by multiplication of an elevation factor with the layer thickness (t) of the respective build material layer (3); and/or the lowered portions (11b) are lowered by a lowering value which is determined on basis of a lowering factor and the layer thickness (t) of the respective build material layer (3), particularly by multiplication of a lowering factor with the layer thickness (t) of the respective build material layer (3). ### Claim 4 (depends on 1) Method according to claim 1, wherein a plurality of build material layers (11) are applied in such a manner that the respective build material layers (3) comprise at least one curved shape build material layer section (11), whereby the elevating or elevated portions (11a) and/or the lowering or lowered portions (11b) of respective curved shaped build material layer sections (11) of adjacently disposed build material layers (3) have the same slopes. ### Claim 5 (depends on 4) Method according to claim 4, wherein a plurality of build material layers (3) are applied in such a manner that the respective build material layers (3) comprise at least one curved shape build material layer section (11), whereby the elevating or elevated portions (11a) and/or the lowering or lowered portions (11b) of respective curved shaped build material layer sections (11) of adjacently disposed build material layers (3) have the same slopes such that a lower build material layer (3) engages with a vertically directly adjacently disposed upper build material layer (3). ### Claim 6 (depends on 4) Method according to claim 4, wherein a plurality of build material layers (3) are applied in such a manner that the respective build material layers (3) comprise at least one curved shape build material layer section (11), whereby the elevating or elevated portions (11a) and/or the lowering or lowered portions (11b) of respective curved shaped build material layer sections (11) of adjacently disposed build material layers (3) have the same slopes such that top side portions of elevated portions (11a) of a lower build material layer (3) engage with bottom side portions of elevated portions (11a) of a directly adjacently applied upper build material layer (3) in vertical direction and/or such that bottom side portions of lowered portions (11b) of an upper build material layer (3) engage with top side portions of lowered portions (11b) of a directly adjacently applied lower build material layer (3) in a vertical direction. ### Claim 7 (depends on 1) Method according to claim 1, wherein build material layer sections (11) having a curved shape are generated by concertedly changing the distance between a build material application element (13), which is configured to apply an amount of build material (4) in the build plane (BP) so as to generate a build material layer (3) which is to be selectively irradiated and consolidated, particularly the free end of the build material application element (13) being oriented towards the build plane (BP), and the build plane (BP), particularly the freely exposed top surface of the build plane (BP), during a build material application process. ### Claim 8 (depends on 1) Method according to claim 1, wherein the at least one build material layer (3) which is to be selectively irradiated and consolidated comprising at least one build material layer section (11) having a curved shape with respect to at least one extension direction of the build material layer (3) is generated by moving a build material application element (13), which is configured to apply an amount of build material (4) in the build plane (BP) so as to generate a build material layer (3) which is to be selectively irradiated and consolidated, in a combined motion in at least two different motion components across the build plane (BP), whereby a first motion component is or comprises a motion of the build material application element (13) in a direction parallel to the build plane (BP) and at least one further motion component is or comprises a motion of the build material application element (13) in a direction not parallel to the build plane (BP). ### Claim 9 (depends on 1) Method according to claim 1, wherein the at least one build material layer (3) which is to be selectively irradiated and consolidated comprising at least one build material layer section (11) having a curved shape with respect to at least one extension direction of the build material layer (3) is generated by moving a build material application element (13), which is configured to apply an amount of build material (4) in the build plane (BP) so as to generate a build material layer (3) which is to be selectively irradiated and consolidated, in a combined motion defined by at least two different motion components across the build plane (BP), whereby a first motion component is or comprises a motion of the build material application element (13) in a direction parallel to the build plane (BP) and at least one further motion component is or comprises a rotary motion, particularly a pivot motion, of the build material application (13) element around a rotary axis. ### Claim 10 (depends on 1) Method according to claim 1, wherein the at least one build material layer (3) which is to be selectively irradiated and consolidated comprising at least one build material layer section (119 having a curved shape with respect to at least one extension direction of the build material layer (3) is generated by a controlled, particularly oscillating, upward and downward motion of a moveably supported carrying element (10) carrying the build material layers (3) while a build material application element (13) moves across the build plane (BP). ### Claim 11 (depends on 1) Method according to claim 1, wherein at least one irradiation parameter, particularly the vertical focus position of the energy beam (5), for selectively irradiating respective build material layers (3) is determined on basis of the curved shaped build material layer section (11), particularly with regard to at least one irradiation and/or consolidation criterion. ### Claim 12 (depends on 1) Method according to claim 1, wherein the build data (BD) on basis of which the three-dimensional object (2) is additively manufactured contains the at least one build material layer (3) comprising the at least one build material layer section (11) having a curved shape. ### Claim 13 (depends on 1) Control unit (6) for an apparatus (1) for additively manufacturing at least one three-dimensional object (2) by means of successive layerwise selective irradiation and consolidation of build material layers (3) applied in a build plane (BP) of a respective apparatus (1), the control unit (6) being configured to control the application of build material (4), particularly in accordance with the method according to claim 1, in such a manner that at least one build material layer (3) which is to be selectively irradiated and consolidated is applied in such a manner that the build material layer (3) comprises at least one build material layer section (11) having a curved shape with respect to at least one extension direction of the build material layer (3). ### Claim 14 (depends on 13) Apparatus (1) for additively manufacturing at least one three-dimensional object (2) by means of successive layerwise selective irradiation and consolidation of layers of build material (3) applied in the build plane (BP) of the apparatus (1) by means of at least one energy beam (5), comprising a control unit (6) according to claim 13.