Additive layer manufacturing method for producing three-dimensional object and three-dimensional object

Simple SummaryContent extracted from patent full text and abstract with AI.

This patent describes an additive layer manufacturing (3D printing) method for making a three-dimensional object using powder material that is selectively melted or sintered with a laser or particle beam. The method allows for the creation of objects consisting of multiple portions connected by a support structure, typically formed by several support legs extending between portions. The process enables construction either by building portions sequentially or by constructing a support structure between pre-existing portions.

Use CasesContent extracted from patent full text and abstract with AI.

• Manufacturing complex mechanical parts with internal support structures
• Producing custom medical implants or prosthetics with specific geometries
• Creating lightweight aerospace or automotive components with optimized strength-to-weight ratios
• Building intricate prototypes and functional models in product development
• Generating objects with overhangs or multiple interconnected sections for industrial or engineering use

BenefitsContent extracted from patent full text and abstract with AI.

• Allows for the production of intricate or complex geometries that are difficult or impossible to make with traditional manufacturing
• Enables precise placement of support structures, which can improve part strength and reduce material waste
• Supports the construction of multi-part assemblies in a single build process, enhancing design flexibility
• Improves efficiency for rapid prototyping and small-batch production
• Potentially reduces the need for post-processing and manual assembly due to integrated connections and supports

Technical Classifications (CPCs)

Inventors & Applicants

Patent Abstract

An additive layer manufacturing method is disclosed for producing a three-dimensional object (1) and to a corresponding object. Layers of a powder material are sequently applied to a carrier and irradiated, before the following layer is applied, with a laser beam or particle beam selectively only in the areas of the layer which correspond to the three-dimensional object to be produced. Irradiation occurs such that the powder material in the corresponding areas is locally melted or sintered. The object (1) is provided with a first portion (2), a second portion (3) and a support structure (4) which is arranged between the two portions and used for the connection between the two portions. When the layers are constructed layer by layer, the first portion is constructed before the second portion or the first portion is provided as a separate component, on which the support structure and second portion are constructed. The support structure is constructed in the form of a plurality of support legs (9), which extend from the first portion to the second portion and are connected thereto at their opposite ends and are spaced apart from one another at least along part of their length.