Apparatus and a method for forming 3d objects

Abstract

Apparatus for forming a 3D object from powder, comprising: a) delivery means adapted to emit a flow of powder at sufficiently high velocity to enable it to form the 3D object; b) positioning means adapted adjust the position of the delivery means; and c) control means adapted to control: i) movement of the positioning means; and ii) the velocity of the flow of powder.

1 . Apparatus for forming a 3D object from powder, comprising:
 a) delivery means adapted to emit a flow of powder at sufficiently high velocity to enable it to form the 3D object;   b) positioning means adapted adjust the position of the delivery means; and   c) control means adapted to control:
 i) movement of the positioning means; and 
 ii) the velocity of the flow of powder. 
   
     
     
         2 . Apparatus according to  claim 1 , wherein the delivery means is able to adjust the temperature of the powder, and the control means is adapted to control the extent to which the delivery means does this. 
     
     
         3 . Apparatus according to  claim 1 , wherein the positioning means incorporates a spray head. 
     
     
         4 . Apparatus according to  claim 1 , wherein the positioning means incorporates a platform suitable for supporting the 3D object as it forms. 
     
     
         5 . Apparatus according to  claim 1 , wherein the control means is adapted to receive and interpret data defining the geometry of the 3D object prior to it being formed. 
     
     
         6 . Apparatus according to  claim 1 , further comprising sensing means adapted to sense one or more geometric characteristics of the 3D object as it is being formed and to communicate this/these to the control means such that the control means causes one or more of the following to change:
 a) the position of the delivery means;   b) the velocity of the powder; and   c) the temperature of the powder.   
     
     
         7 . Apparatus according to  claim 6 , wherein a geometric characteristic sensed is the height of the 3D object as it is being formed. 
     
     
         8 . Apparatus according to  claim 6 , wherein the delivery means is adapted to deliver more than one type of powder dependent on instructions from the control means. 
     
     
         9 . Apparatus according to  claim 6 , wherein the positioning means incorporates a robotic arm. 
     
     
         10 . Apparatus according to  claim 6 , wherein the positioning means is adapted to adjust the distance and/or angle between the delivery means and the platform, and the control means is adapted to control this. 
     
     
         11 . Apparatus according to  claim 1 , wherein use of the apparatus to form a 3D object comprises the control means causing one or more of the following to change during formation of the object so as to give it one or more predetermined characteristics:
 a) the position of the delivery means;   b) the velocity of the powder; and   c) the temperature of the powder.   
     
     
         12 . Apparatus according to  claim 11 , wherein at least two of a), b) and c) change during formation of the 3D object. 
     
     
         13 . Apparatus according to  claim 11 , wherein all three of a), b) and c) change during formation of the 3D object. 
     
     
         14 . Apparatus according to  claim 11 , wherein the powder is a cold spray powder. 
     
     
         15 . Apparatus according to  claim 11 , wherein the powder leaves the delivery means at a speed of 500 ms −1  to 1,000 ms −1 . 
     
     
         16 . Apparatus according to  claim 11 , wherein the 3D object is formed by applying a sequence of layers of the powder by way of the delivery means. 
     
     
         17 . Apparatus according to  claim 11 , wherein the control means comprises a computerised system adapted to send control signals to the delivery means and to the positioning means dependent on the 3D object to be formed. 
     
     
         18 . Apparatus according to  claim 11 , wherein the powder is substantially metallic. 
     
     
         19 . Apparatus according to  claim 11 , wherein the powder is at a temperature of 25° C. to 300° C. 
     
     
         20 . Apparatus according to  claim 11 , wherein the powder comprises particles having an average size of 5μ to 50μ. 
     
     
         21 . Apparatus according to  claim 11 , wherein the powder is at a temperature of 0° C. to 300° C. 
     
     
         22 . Apparatus according to  claim 11 , wherein the angle and distance between the delivery means and the 3D object changes as it is being formed.