DE102016218491A1 - Device for producing a component, powder reservoir, system and method for producing a component - Google Patents

Abstract

The present invention relates to a device (101) for producing a component (1) in a powder-based layer construction method comprising a construction space (10) and a construction section (20) with a laser device (21), wherein in the construction space (10) material powder (60, 61) as a powder bed (11) can be arranged in layers and the component (1) by an action of the laser device (21) on the material powder (60, 61) is produced in layers. Furthermore, the invention relates to a powder reservoir (50, 51) for such a device (101), the powder reservoir (50, 51) comprising a reservoir (53) for receiving a material powder (60, 61), and a system of such a device and at least two such powder reservoir. Furthermore, the invention relates to a method for producing a component (1) in a powder-based layer construction method, wherein the component is produced by the action of a laser device on layers of a powder bed.

Description

The present invention relates to a device for producing a component in a powder-based layer construction method, comprising a construction space and a construction section with a laser device, wherein in the space material powder as a powder bed can be arranged in layers and the component is produced in layers by an action of the laser device on the material powder. Furthermore, the invention relates to a powder reservoir for such a device, the powder reservoir having a reservoir for receiving a material powder, and a system of such a device and at least two such powder reservoir. Furthermore, the invention relates to a method for producing a component in a powder-based layer construction method, wherein the component is produced by the action of a laser device on layers of a powder bed.

In modern production technology, it is generally known to produce components in powder-based layer construction processes in devices designed for this purpose. For this purpose, material powder is usually taken from a powder reservoir and arranged in a powder layer in a space of such a device. This is usually done in a protective gas atmosphere, for example, to prevent oxidation processes of the material powder. By acting on a laser device, the material powder can be locally melted or at least fused, whereby at these points a layer of the component to be produced is generated. The remaining material powder forms a powder bed, which surrounds the component during the manufacturing process. The powder bed with the component arranged therein is subsequently lowered in the installation space by the thickness of one layer, a new layer of powder material is applied by a coater, and the next layer of the component is produced by the action of the laser device. Successively components, in particular with complicated, for example, undercuts, having geometries can be produced in this way.

A problem with known production methods or devices for producing such components is in particular a change of the powder reservoir used. In this case, for example, an exchange of an empty powder reservoir against a full powder reservoir is often complex, even if it is filled with the same material powder. The decisive factor here is that for such a change of the powder reservoir of the manufacturing process usually has to be completely interrupted. Cleaning the powder feeder is often required. Also, a rebuilding of a protective gas atmosphere is often required. In a conversion of the material powder used beyond a transfer or reading parameters of the new material powder is necessary. Overall, such a change is time consuming and causes high costs, especially by a production shutdown during the long makeready.

It is therefore an object of the present invention, the disadvantages described above in a device for producing a component in a powder-based layer construction method, a powder reservoir for such a device, a system of such a device and at least two such powder reservoir and a method for producing a component in a powder-based layer construction process at least partially correct. In particular, it is an object of the present invention to provide a device for producing a component in a powder-based layer construction method, a powder reservoir for such a device, a system of such a device and at least two such powder reservoir and a method for producing a component in a powder-based layer construction method, which enable a change of a powder reservoir used in a simple and cost-effective manner, and in particular reduce a set-up time required thereby.

The above object is achieved by a device for Production of a component in a powder-based layer construction method with the features of independent claims 1 and 2, by a powder storage container for such a device having the features of independent claim 11, by a system of a device for producing a component in a powder-based layer construction method and at least two powder storage containers with the features of the independent claim 15 and by a method for producing a component in a powder-based layer construction method with the features of the independent claim 16. Further features and details of the invention will become apparent from the dependent claims, the description and the drawings. In this case, features and details that are described in connection with the device according to the invention apply, of course, also in connection with the powder reservoir according to the invention, the system according to the invention and the method according to the invention and in each case vice versa, so that with respect to the disclosure of the individual aspects of the invention is always reciprocally referred to or . can be.

According to a first aspect of the invention, the object is achieved by a device for producing a component in a powder-based layer construction method, comprising a construction space and a construction section with a laser device, wherein material powder can be arranged as a powder bed in layers in the construction space and the component by the action of the laser device on the Material powder is produced in layers. A device according to the invention is characterized in that a first docking area for docking at least a first powder reservoir with a first material powder and a coating device is arranged in the construction section, wherein the coating device has a driven and movably mounted coating element for removing material powder from the first powder reservoir and for arranging of the removed material powder in the installation space as a layer of the powder bed, and wherein the device has at least one supply device with a feed element, in which at least two powder storage containers are arranged, for selectively feeding one of the powder storage containers to the first docking area.

By a device according to the invention according to the first aspect of the invention components can be produced in a powder-based layer construction process. For example, a device according to the invention can have, for example, a control unit in order to be able to carry out such a powder-based layer construction method. All the advantages of such a layer construction method, for example a production of components with complicated, complex geometries or a cost-efficient production of component small series or component prototypes, can thus also be provided with a device according to the invention. In the construction space of the device according to the invention, a powder bed is formed from successively arranged layers of a material powder, wherein after each arrangement of a new layer of material powder a layer of the component to be produced is produced from the material powder by the action of a laser device. The laser device is arranged in a construction section of the device, which is preferably located above the installation space. Particularly preferably, the construction section can be designed as a separate building module from the installation space.

According to the invention, a first docking area is provided in the construction section of a device according to the first aspect of the invention in addition to, for example, the laser device. In this docking area, a powder reservoir can be arranged, in particular docked. Docking in the sense of the invention may particularly preferably comprise a gas-tight arrangement, both with regard to a stationary arranged state of the powder reservoir and with respect to a docking or undocking process of the powder reservoir in the first docking area. It can thereby be provided that a, in particular continuous protective gas atmosphere can be built up and also maintained continuously throughout the construction phase. The powder reservoirs which can be arranged in the docking area provide material powder for the production process of the component. In this case, these material powders in different powder reservoirs may be identical, but alternatively also different, for example with regard to a type of material, a material quality and / or material quality, be formed.

A device according to the invention also has in its construction section a coating device with a coater element. The number of coater elements is not limited, so that if technically necessary and useful, two or more coater elements may be present. By means of the coater element of the coater, it is possible to arrange material powder from the first powder reservoir arranged in the first docking area in the construction space as a layer in the powder bed. If necessary and possible, an entire component can also be made of material powder from only a single powder reservoir arranged in the first docking area.

Essential to the invention, the device has at least one feeding device with a feed element. In this case, at least two powder reservoirs can be arranged in the feed element, which can optionally be supplied by the feed element to the first docking area. In other words, the powder supply container arranged in the first docking area of a device according to the invention according to the first aspect of the invention can be exchanged or exchanged by the supply device. The feed element may also accommodate more than two powder reservoirs. By means of such a feeding device, an acceleration of a setting-up process of a device according to the invention can be made possible. Thus, for example, a powder storage container, which contains a material powder which is required in the production process of the component, can be arranged in the feed element of the delivery device. As soon as the powder storage container or the material powder contained in the docking area is no longer needed, the new powder storage container can be supplied automatically and in particular quickly to the docking area by the feed element of the supply device. This can preferably be made gas-tight in such a way that a protective gas atmosphere of the device, which can prevail in particular in the construction section, is maintained. Overall, therefore, by such Feeding device to be accelerated replacement of the powder reservoir at a docking area of a device according to the invention.

In particular, characterized in that at least two powder reservoir are arranged in the feeder and that either one of the two powder reservoir in the first docking area of a device according to the invention can be arranged by the feeder, several advantages of the invention result. Thus, for example, if in both powder reservoirs an identical material powder is located and the powder reservoir, which is currently located in the first docking area of the device according to the invention, runs empty, this can be easily changed by the feeder, without a manufacturing process of the component are substantially interrupted or canceled got to. The manufacturing process can be easily continued by using the material powder of the second powder reservoir. Also, an exchange of a powder reservoir with a first material powder against a powder reservoir with a second, different material powder can be carried out analogously to faster and without significant interruption of the manufacturing process. In other words, a set-up time for retrofitting the device, in particular for exchanging a powder reservoir, can thus be reduced, in particular minimized. The manufacturing process, in particular the provision of material powder, can be continued in this case by a replacement of the arranged in the first docking powder reservoir, which is simple and in particular quickly performed by the feeder, without significant interruption. For the alternative case, that the powder reservoirs arranged in the supply device contain different material powders, a corresponding change of the powder reservoir arranged in the first docking area of a device according to the invention can make it possible to produce one-piece components from these different materials in a monolithic manufacturing process. Elaborate, multi-stage manufacturing processes, which are often at least time-consuming and expensive or even completely impossible, can be avoided in this way or even made possible for the first time. Overall, a production process of a component in a powder-based layer construction method can thus be improved by an apparatus according to the invention, in particular with regard to a time expenditure in the production as well as with regard to the possibilities in the production of the components.

According to a second aspect of the invention, the object is achieved by a device for producing a component in a powder-based layer construction method, comprising a construction space and a construction section with a laser device, wherein material powder can be arranged in layers as a powder bed in the construction space and the component by acting on the laser device Material powder is produced in layers. A device according to the invention according to the second aspect of the invention is characterized in that in the construction section a first docking area for docking at least a first powder reservoir with a first material powder, a second docking area for docking at least one second powder reservoir with a second material powder and a coating device is arranged the coater device has a driven and movably mounted coater element for removing material powder optionally from the first powder reservoir or from the second powder reservoir and for arranging the removed material powder in the construction space as a layer of the powder bed.

By a device according to the invention according to the second aspect of the invention, components can also be produced in a powder-based layer construction process. A device according to the invention according to the second aspect of the invention may also have, for example, a control unit in order to be able to carry out such a powder-based layer construction method. It is in the space and the device according to the invention according to the second aspect of the invention, a powder bed each formed successively arranged layers of a material powder, wherein after each arrangement of a new layer of material powder by the action of a laser device, a layer of the component to be produced is produced from the material powder. The laser device is arranged in a construction section of the device, which is preferably located above the installation space. Particularly preferably, the construction section can be designed as a separate building module from the installation space. All the advantages of such a layer construction method, for example a production of components with complicated, complex geometries or a cost-efficient production of small series or component prototypes, can thus also be provided with a device according to the invention according to the second aspect of the invention.

Essential to the invention, a first docking area and a second docking area are provided in the construction section of a device according to the invention according to the second aspect of the invention in addition to, for example, the laser device. The number of docking areas is not limited to two, so that if technically necessary and useful, three or more docking areas may be present. In each of these docking areas a powder reservoir can be arranged, in particular docked. Docking in the sense of the invention may in this case particularly preferably comprise a gas-tight arrangement, both with regard to a stationary arranged state of the powder reservoir and with respect to a docking or undocking operation of the powder reservoir in the respective docking area, so that constructed throughout the construction period, in particular continuous inert gas atmosphere and also can be maintained continuously. The powder reservoirs which can be arranged in the docking areas provide a first and a second material powder for the production process of the component. In this case, these material powders can be identical, but alternatively also different, for example with regard to a type of material, a material quality and / or material quality, be formed.

A device according to the invention according to the second aspect of the invention further comprises in its construction section a coater device with a coater element. The number of coater elements is not limited, so that if technically necessary and useful, two or more coater elements may be present. By means of the coater element of the coater, it is possible, optionally, to arrange material powder from the first powder reservoir or from the second powder reservoir in the construction space as a layer in the powder bed. If necessary and possible, an entire component can also be made of material powder from only one of the arranged in the docking powder reservoir.

In particular, the fact that in a device according to the invention according to the second aspect of the invention, two powder reservoirs are present and that can be removed from powder storage containers material powder and arranged in the powder bed in the space by the coater element optionally, there are several advantages of the invention. Thus, for example, if there is an identical material powder in both powder reservoirs and one of the powder reservoir runs empty, this can be easily changed without a production process of the component must be interrupted or canceled. The manufacturing process can be easily continued using the material powder of the second, at least partially filled, powder reservoir. Also, an exchange of a powder reservoir with a first material powder against a powder reservoir with a second, different material powder, can be carried out analogously to faster and without significant interruption of the manufacturing process. In other words, a set-up time for retrofitting the device, in particular for exchanging a powder reservoir, can thus be reduced, in particular minimized. The manufacturing process, in particular the provision of material powder, can be continued in this case by switching to the material powder in the second powder reservoir without substantial interruption. For the alternative case, that the powder reservoirs contain different material powders can be made possible by a device according to the invention to produce one-piece components from these different materials in a monolithic manufacturing process. Elaborate, multi-stage manufacturing processes, which are often time-consuming and expensive, can be avoided in this way. Combinations of material powders, which can be provided in known devices for powder-based layer construction process only with great effort or even not at all, can be realized by a device according to the invention. For example, components may be made from a powder material, with powder material having different grain sizes being used for different regions of the component. As a result, for example, a different density and / or hardness of the material in different areas of the finished component can be produced. Also, for example, when using different metals as material powder alloys of these metals can be produced in any desired and especially precisely adjustable composition. For this purpose, it can be provided, in particular, to form a layer of the powder bed by means of material powder from both powder storage containers. Overall, a production process of a component in a powder-based layer construction method can thus be improved by an apparatus according to the invention, in particular with regard to a time expenditure in the production as well as with regard to the possibilities in the production of the components.

Furthermore, in a device according to the invention in accordance with the second aspect of the invention, it can be provided that the device has at least one feed device with a feed element in which the at least two powder storage containers are arranged, for selectively feeding one of the powder storage containers to the first docking area or to the second docking area. In this case, each of the docking areas is preferably assigned in each case one feed device. The feed element may also accommodate more than two powder reservoirs. By means of such a feeding device, a further acceleration of a setting-up process of a device according to the invention can be made possible. Thus, for example, a powder storage container, which contains a material powder which is required in the production process of the component, can be arranged in the feed element of the delivery device. As soon as in the Docking area arranged powder reservoir or the material contained in this material powder is no longer needed, it can be fed automatically and in particular quickly the docking area by the feed element he feeding the new powder reservoir. This can preferably be made gas-tight in such a way that a protective gas atmosphere of the device, which can prevail in particular in the construction section, is maintained. Overall, a replacement of the powder reservoir at a docking area of a device according to the invention can thus be further accelerated by such a feeder.

The advantageous embodiments and further developments described below can be provided in each case in a device according to the invention according to the first second aspect of the invention or in a device according to the invention according to the second aspect of the invention.

In this case, a device according to the invention can be further developed such that the feed element has a pivoting element and / or a turret element and / or a magazine element. This enumeration is not completed, so that other feeding elements can be provided in a feeding device of a device according to the invention, as far as technically reasonable and possible. In this case, a pivoting element and a turret element each have holding elements for the powder reservoir, which are rotatably mounted about a central axis. A pivoting element has two such holding elements and can accommodate two powder reservoirs accordingly. A turret element has three or more retaining elements and thus can accommodate a correspondingly more powder reservoir. In a magazine element, the powder reservoirs are arranged on a conveyor belt or the like, so that here too a larger number, in particular 4 or more, powder reservoir can be supplied to a docking area by a single feeder. Particularly diverse possibilities in the production of a component, in particular with regard to a selection of the materials used, can be provided thereby.

It can also be provided in a device according to the invention that the first docking area and / or the second docking area has a sealing element for gas-tight docking of the respective powder reservoir. By means of such a sealing element, which may in particular also be designed in several parts, it can be provided in a particularly simple manner when changing the powder reservoir arranged in the docking area that a protective gas atmosphere present in the construction section is maintained. Such a sealing element can also be used to gas-tightly seal the respective docking area in relation to a construction area of the construction section in which, for example, the laser device is arranged and which faces the powder bed in the construction space. An additional protection of the protective gas atmosphere in the construction sector can be provided thereby. In this case, the sealing element is particularly preferably designed in such a way or adapted to the powder storage container that a docking operation in which a powder storage container is removed from a docking area and / or a new powder storage container is arranged in a docking area can be made gas-tight. In this way it can be made possible, for example, that even with an exchange of the powder storage container, a protective gas atmosphere inside a device according to the invention is not or at least not substantially impaired. In this case, it can preferably also be provided that a protective gas atmosphere is likewise formed in the interior of the powder storage container.

Particularly preferably, a device according to the invention can be designed such that at least the first docking area and / or the second docking area has a cleaning device for cleaning the coating element. Preferably, both docking areas are equipped with such a cleaning device. An arrangement of the cleaning device in another area of the device, for example in the construction sector, is also possible within the meaning of the invention. By means of such a cleaning device, the coater element can be freed of material powder which unintentionally adheres to it. By arranging a cleaning device in one of the docking areas, such cleaning in a device according to the invention can also be provided during the production of the component, without the production process having to be interrupted or at least not substantially interrupted. In particular, the cleaning of the coater element can be carried out inside the device and automatically, without the device having to be opened for access to the coater element, wherein this opening can be effected in particular only by destroying a protective gas atmosphere. A cleaning of the coating element is alternatively and / or additionally possible after completion of a manufacturing process of a component. In particular, such a cleaning of the coater element in the course of a production process makes it possible to exchange a material powder used in a particularly simple and particularly secure manner. Contamination of a second powder material by a first powder material, which still on the coater element adheres can be safely avoided or at least significantly reduced by such a cleaning device.

In this case, a device according to the invention can be further developed such that the at least one docking area has an adjustable switch element for guiding a movement of the coating element to the cleaning device or to the respective powder container. Passing the cleaning device through the coater element is not necessary every time the coater element moves into the docking area. Thus, in particular, if only further, in particular identical, material powder is to be removed from the powder reservoir for a further layer, cleaning is dispensed with. The coating element should then not move to the cleaning device but directly to the powder reservoir. In contrast, when changing the material powder used, a cleaning is particularly preferable in order to avoid, as described above, contamination of the material powder used. By means of a switch element, such a movement of the coater element inside the device can be influenced and / or controlled particularly simply and reliably. In this case, such a switch element, for example, pneumatically, hydraulically and / or spring-mechanically driven. Time losses in the manufacture of a component can thus be reduced, without producing disadvantages in terms of component quality and / or material purity.

Also, a device according to the invention may be designed such that the construction section and / or the installation space has an excess space for the at least partial absorption of excess material powder. In order to be able to provide the most uniform possible arrangement of material powder over the entire surface of the powder bed, often more material powder can be absorbed by the coating element than is needed for the actual arrangement of the next layer of the powder bed. This non-layerable material powder can thus be referred to as excess material powder. Through an excess space such excess material powder can be absorbed. In this case, for example, the coater element is moved over a receiving opening of the excess space and the excess material powder can fall, for example, into the excess space. Contamination of the material powder in the powder reservoir and / or an avoidable loading of a cleaning device can be avoided in this way.

It can be provided according to a further development of a device according to the invention that the excess space has a movable cover for closing a receiving opening of the excess space. Such a covering element can in particular provide that the excess space is only opened as soon as a take-up of excess material powder takes place or is to take place. An unwanted introduction of material powder in the excess space, synonymous with unnecessary material consumption, can be avoided. In this case, such a cover, for example, pneumatically, hydraulically and / or spring-mechanically driven. A corresponding coupling of the cover to an existing switch element is conceivable.

In a particularly preferred embodiment of the invention, the laser device is designed to perform a laser sintering process and / or to perform a laser melting process. In this case, the respective powder material is at least rudely melted in both methods by the action of laser light of the laser device. Sintering, in which only partial melting is carried out, often requires lower laser powers than melting, in which a complete melting of the material powder takes place. According to the invention, the laser device of a device according to the invention is designed to carry out both methods. This has the particular advantage that there is no restriction with regard to the method used in the production of a single component. Thus, for example, for a first portion of the component, a metallic material powder in a laser melting process and for a second portion of the component, a plastic-based material powder can be processed in a laser sintering process. Particularly diverse possibilities in the production of components can be provided in this way.

According to a third aspect of the invention, the object is achieved by a powder reservoir for a device according to the first and / or second aspect of the invention, the powder reservoir having a reservoir for receiving a material powder. A powder storage container according to the invention is characterized in that the powder storage container has an adapter section, which is adapted to the first docking area and / or the second docking area. By using a powder reservoir according to the invention in a device according to the first and / or second aspect of the invention can be achieved by a powder reservoir according to the invention according to the third aspect of the invention, the same advantages have already been described in detail with respect to a device according to the first and / or second aspect of the invention.

The stock dream of the powder reservoir can be filled in particular with a, in particular arbitrary, powder material. In this case, an inventive powder reservoir in particular an adapter section. Adapted to the first and / or second docking area in the sense of the invention may mean in particular that a gastight arrangement of the powder reservoir at the docking area can be provided by the adapter section. Preferably, the adapter portion is designed adapted to a corresponding sealing element of the docking area. In addition, the powder reservoir can also have an arrangement section, by means of which an arrangement of the powder reservoir in a supply device of a device according to the invention according to the first and / or second aspect of the invention can be made possible.

In addition, a powder reservoir according to the invention can be designed such that the powder reservoir has a data element for storing parameters of the material powder received in the reservoir and for transmitting these parameters to the device. A device according to the invention according to the first and / or second aspect of the invention is in particular designed so that it can use different powder materials in a manufacturing process. The internal processes during the actual production process may differ depending on the powder material used. Therefore, it is necessary or at least advantageous for a device according to the invention according to the first and / or second aspect of the invention that these, in particular their control unit, is supplied with the parameters of the powder material used. By means of a data element of a powder reservoir according to the invention, these parameters can be provided in a particularly demand-oriented manner. Thus, by the data element, the parameters of the powder material filled in the storage space can be transferred to the device in a particularly specific manner, for example when the corresponding powder storage container is arranged in a docking area of a device according to the invention. A device according to the invention also has the element required for receiving and processing the transmitted parameters, for example driven by a control unit. The transmission and evaluation can be carried out automatically, for example, at the same time or at least close to an arrangement of the corresponding powder reservoir in a docking area of the device according to the invention. An immediate use of the provided by the powder reservoir material powder for a production of a component by a device according to the invention can be made possible thereby. Overall, therefore, a set-up time can also be reduced by the data element during a changeover of a device according to the invention.

• – Materialart
• – Korngröße
• – Materialqualität
• – minimale Schichtdicke
• – maximale Schichtdicke
• – Einwirkdauer
• – Einwirkstärke

According to a further development of a powder reservoir according to the invention, it can further be provided that the parameters comprise at least one of the following information:

• - Material type
• - grain size
• - Material quality
• - minimum layer thickness
• - maximum layer thickness
• - duration of action
• - Impact strength

In this case, this list is not completed, so that, as far as technically feasible and possible, other parameters of the recorded in the pantry material powder may be stored in the data element. The parameters material type, grain size and material quality indicate direct properties of the powder material. The specified layer thicknesses allow control of the possible arrangement of the material powder on the powder bed in the installation space. The parameters duration of action and intensity of action relate to a control of the laser device for the actual formation of the component and influence, for example, a laser power of the laser device and / or an exposure time. In summary, the material powder received in the storage space can thus be comprehensively characterized by the stored parameters.

Particularly preferably, a powder storage container according to the invention can be configured in such a way that the powder storage container has a cover element for gas-tight sealing of a removal opening of the storage space, wherein in an arrangement of the powder storage container in the first docking area and / or second docking area the cover element releases the removal opening, in particular automatically releases it. By means of such a cover element, it can be made possible that the powder reservoir is internally already provided with a protective gas atmosphere during and / or after filling with a material powder. In this case, the cover element may preferably be designed such that, in particular in cooperation with the docking area of a device according to the invention, it allows a gas-tight arrangement of the powder reservoir in a docking area of a device according to the invention. In this way, a continuous maintenance of a protective gas atmosphere can be provided be, which in turn can be achieved a further reduction of set-up time when changing the powder reservoir. Analogously, the cover element can also interact with a filling device in order to be able to continuously provide this protective gas atmosphere even when the powder reservoir is being filled with a material powder.

According to a fourth aspect of the invention, the object is achieved by a system comprising a device for producing a component in a powder-based layer construction method and at least two powder storage containers. An inventive system is characterized in that the device according to the first aspect and / or second of the invention and the at least two powder reservoirs are formed according to the third aspect of the invention. By using a device according to the first and / or second aspect of the invention or by the use of powder reservoirs according to the third aspect of the invention can also be achieved by an inventive system having such a device or such powder reservoir, the same advantages that already have been described in detail with respect to a device according to the first and / or second aspect of the invention or with respect to a powder reservoir according to the third aspect of the invention.

According to a fifth aspect of the invention, the object is achieved by a method for producing a component in a powder-based layer construction method, wherein the component is produced by the action of a laser device on layers of a powder bed. A method according to the invention is characterized in that the method is carried out by a device according to the first and / or second aspect of the invention and / or by a system according to the fourth aspect of the invention. By carrying out a method according to the invention by means of a device according to the first and / or second aspect of the invention or by a system according to the fourth aspect of the invention, the same can also be achieved by a method according to the invention which is performed by such a device or by such a system Benefits can be achieved, which have already been described in detail with respect to a device according to the first and / or second aspect of the invention or with respect to a system according to the fourth aspect of the invention.

In a method according to the invention, it may be particularly preferred that material powder of the first powder reservoir and of the second powder reservoir be used to form at least one layer of the powder bed during manufacture of the component. By using a device according to the invention according to the first and / or second aspect of the invention or a system according to the fourth aspect of the invention, this optional arrangement of layers of material powder of different powder storage containers can be provided particularly simple. As a result, for example, a component can be produced that consists of two or more different materials. For this purpose, the powder reservoir, from which the material powder is removed, is changed in the course of the manufacturing process. This can be carried out particularly simply in a device according to the invention or in a system according to the invention, for example by directly exchanging a powder reservoir arranged in a docking area and / or by changing the docking area approached by the coating element or the powder reservoir arranged therein. The optional arrangement of different material powders is not necessarily successive, but can also be done for a layer, for example, to make a mixture of two materials. Components of novel alloys can be produced in this way, for example by using two metallic material powder. In addition, there are also advantages in powder storage containers in which identical material powder are stored. In particular, for example, an exchange of an empty powder reservoir can be made particularly simple, since the manufacturing process can be easily continued with material powder from the other powder reservoir. If necessary, the emptied powder reservoir can also be replaced without interrupting the production process or at least without the production process having to be substantially interrupted. Overall, therefore, by using powder material from more than just one powder storage container, production of a component in a powder-based layer construction process can be further improved.

Further advantages, features and details of the invention will become apparent from the following description in which, with reference to the drawings, embodiments of the invention are described in detail. The features mentioned in the claims and in the description may each be essential to the invention individually or in any desired combination. Elements with the same function or mode of action are in the 1 to 6 each provided with the same reference numerals. They show schematically:

1 an inventive system in a schematic plan view,

2 possible embodiments of a delivery device,

3 an inventive system in a schematic side view,

4 a switch element,

5 an inventive powder reservoir, and

6 a manufactured by an inventive system component.

1 shows a possible embodiment of a system according to the invention 100 in a schematic plan view. The system according to the invention 100 in particular has a device according to the invention 101 on. A construction section 20 the device 101 is in this preferred embodiment as a separate module above a space 10 arranged, in particular the space 10 below a construction area 24 of the construction section 20 in which a laser device 21 is arranged, is arranged. The laser device 21 is there to act on a in the space 10 arranged powder bed 11 (not shown with), whereby in the powder bed 11 layer by layer a component 1 (not shown) arises. In particular, the construction section 20 is also gas-tight against an environment formed and filled with a protective gas atmosphere. Unwanted oxidation processes, especially in the powder bed 11 can be prevented. Furthermore, the illustrated device according to the invention 101 a first docking area 30 and a second docking area 31 on. Alternatively, in a device according to the invention 101 also be provided that these only a first docking area 30 has (not shown). In the first docking area 30 is a first powder reservoir 50 arranged in which a first material powder 60 is stored. This first material powder 60 can through a coater element 23 a coater device 22 (each not shown) and as a material layer in a powder bed 11 in the installation space 10 to be ordered. Essential to the invention, the illustrated device according to the invention 101 another, second docking area 31 on. In this second docking area 31 is a second powder reservoir 51 arranged in which a second material powder 61 is stored. This can be the first material powder 60 and the second material powder 61 as shown, different or alternatively identical (not shown). Also from this second powder reservoir 51 can through the coater element 23 the device according to the invention 101 the second material powder 61 taken and as a layer in the powder bed 11 to be ordered. In particular, by this optional removal of material powder 60 . 61 from the first powder reservoir 50 and / or from the second powder reservoir 51 can be provided that a set-up time when changing the powder reservoir used 50 . 51 can be significantly reduced. This is especially true even if in both powder reservoirs 50 . 51 same material powder 60 . 61 is stored. Thus, by an inventive system 100 be provided that, for example, when in a first powder reservoir 50 in the first docking area 30 no first material powder 60 more is available, this simply from a second powder reservoir 51 can be removed, in the second docking area 31 the device according to the invention 101 is arranged. A manufacturing process of the component 1 in the installation space 10 does not have to be interrupted for this or at least only insignificantly. In the illustrated embodiment of a system according to the invention 100 are the first material powder 60 and the second material powder 61 differently. In this way, by an inventive system 100 or by a device according to the invention 101 be provided that components 1 from different material powders 60 . 61 can be made in one piece and in particular monolithic in a manufacturing process. For this, the material powder used is changed during the manufacturing process. components 1 For example, having a metal material and a plastic material can be made particularly easy in this way. Elaborate, especially multi-stage and time-consuming production processes can be avoided.

In the in 1 illustrated embodiment, the inventive device 101 Further, a feeder 40 on whose feed element 41 as one around a rotation axis 45 swiveling swivel element 42 is trained. The feeder 40 is the first docking area 30 assigned. In alternative embodiments of a device according to the invention 101 can also use both docking areas 30 . 31 such or equivalent delivery devices 40 be assigned. Next to the first powder reservoir 50 in the first docking area 30 the device 101 is arranged, is at the opposite end of the pivot member 42 another first powder reservoir 50 arranged with the second material powder 61 is filled. By a rotation of the pivoting element 42 around the axis of rotation 45 can thus in the first docking area 30 arranged first powder reservoir 50 and especially in the first docking area 30 through the first powder reservoir arranged there 50 provided material powder 60 . 61 change. This can preferably be made gas-tight in such a way that in the construction section 20 prevailing protective gas atmosphere is maintained. In particular, thus, in this way an exchange of the powder reservoir used 50 . 51 be made without any production process of the component 1 interrupted or at least not substantially interrupted. In the present embodiment, in particular, provision of a replenishment of used second material powder 61 be enabled. The production of a component 1 in a powder-based layer construction process by a system according to the invention 100 can be further improved.

2 shows further possible embodiments of feeding devices 40 used in a device according to the invention 101 or a system according to the invention 100 (each not shown) can be used. In this case, the embodiment shown on the left side has a feed element 41 on that as a revolver element 43 is trained. Like that in 1 shown and as a pivoting element 42 trained feeding element 41 is also this turret element 43 around a rotation axis 45 rotatably mounted. The revolver element 43 However, more than two powder reservoirs can be used 50 . 51 take in the illustrated embodiment, six powder reservoir 50 . 51 , These powder reservoirs 50 . 51 can do this with any material powders 60 . 61 (not pictured), resulting in a particularly wide range of manufacturing capabilities of components 1 (not shown) by a device according to the invention 101 or a system according to the invention 100 can be provided. The same advantage can be achieved with the alternative embodiment of a delivery device 40 be achieved on the right side of the 2 is shown. In this embodiment, the feeding element 41 as a magazine element 44 educated. The magazine element 44 in particular has a magazine tape 46 on, on which the individual powder reservoir 50 . 51 are arranged. The magazine tape 46 can, as exemplified, via pulleys 47 of the magazine element 44 be guided. Depending on the place of use and in particular depending on an existing installation space 10 can thus be a feeder 40 be formed adapted to demand, with always several, in particular more than two, powder reservoir 50 . 51 at least one of the docking areas 30 . 31 can be supplied.

In 3 is a further embodiment of a system according to the invention 100 shown in a schematic side view. In this case, the illustrated inventive system 100 a device according to the invention 101 with a construction section 20 on, the central of a construction area 24 having. In the construction sector 24 there is a laser device 21 , which is used to emit laser light 26 is trained. The laser device 21 can be designed or used to carry out both a laser sintering process and a laser melting process. In both cases, the laser light acts 26 on a powder bed 11 in a space 10 in which layer by layer a component 1 will be produced. A coater element 23 a coater device 22 ensures a supply of material powder 60 . 61 , This can be the coater element 23 driven along a coater path 25 inside the construction section 20 the device according to the invention 101 move. On both sides of the construction area 24 are also a first docking area 30 and a second docking area 31 arranged. In these docking areas 30 . 31 are a first powder reservoir 50 with a first material powder 60 or a second powder reservoir 51 with a second material powder 61 arranged. The powder reservoir 50 . 51 have each adapter sections 52 on, the respective docking area 30 . 31 adapted trained. The docking areas 30 . 31 in turn are with sealing elements 32 equipped, which in particular a gas-tight docking or arranging, both with regard to a docking operation as well as with regard to the whereabouts of the powder reservoir 50 . 51 in the respective docking area 30 . 31 , can be ensured. One inside a device according to the invention 101 , especially in the construction phase 20 the device 101 , prevailing protective gas atmosphere can be maintained thereby. A set-up time when changing a powder reservoir 50 . 51 can be reduced. Feeding devices can be used for such a change 40 (not shown). When docking a powder reservoir 50 . 51 at a docking area 30 . 31 gives a cover element 54 of the powder reservoir 50 . 51 a removal opening 55 (not pictured) freely, making it in a pantry 53 Powder reservoir 50 . 51 arranged material powder 60 . 61 through the coater element 23 taken up and as the topmost layer of the powder bed 11 in the installation space 10 can be arranged. By a local action of the laser light 26 the laser device 21 becomes the component 1 added another layer by a sintering process or a melting process. By a lifting device 15 in the installation space 10 becomes the powder bed 11 and the component to be manufactured 1 lowered by one layer thickness and then the powder bed 11 by adding a new layer of powdered material 60 . 61 refilled.

Essential to the invention is that by the coater element 23 optionally a first material powder 60 from the first docking area 30 arranged first powder reservoir 50 or a second material powder 61 from the second docking area 31 arranged second powder reservoir 51 for filling the powder bed 11 can use. The two material powders can 60 . 61 be formed identical. As a result, for example, an exchange of an empty powder reservoir 50 . 51 without or at least without substantial interruption of the manufacturing process of the component 1 done because of material powder 60 . 61 in this case from the other, still at least partially filled, powder reservoir 51 . 50 can be removed. A particularly great advantage of a system according to the invention 100 or a device according to the invention 101 can also be provided when in the powder reservoirs 50 . 51 different material powder 60 . 61 are arranged. components 1 from these different material powders 60 . 61 can be produced in this way in a single, monolithic manufacturing process. In particular, thereby novel material combinations for components 1 be provided in conventional devices 101 can not be produced for powder-based layer construction process or only at great expense, such as components 1 in which a metal material is bonded to a plastic material. In order to simplify the production, have the powder reservoir used in this embodiment 50 . 51 data elements 56 in which parameters of the pantry 53 of the respective powder reservoir 50 . 51 contained material powder 60 . 61 For example, a type of material, a grain size or parameters for an action of the laser device 21 , are stored. The data element 56 transmits these parameters to the device according to the invention 101 , For example, to a control unit of the device according to the invention 101 , whereby a use of the respective material powder 60 . 61 in a device according to the invention 101 especially immediately after the arrangement of the powder reservoir 50 . 51 in the docking area 30 . 31 can be enabled. This also leads to a reduction of a required setup time. To prevent contamination between the material powders used 60 , 61 to prevent, has the illustrated device 101 cleaning devices 33 on that in the first docking area 30 and in the second docking area 31 are arranged. By appropriate switch elements 34 in the coater path 25 can these cleaning devices 33 targeted by the coater element 23 be approached. Impurities of the material powder 60 . 61 can be avoided. To unnecessarily high stress on the cleaning devices 33 There are also surplus spaces to avoid 12 provided, in the excess, so after an arrangement of a new layer in the powder bed 11 still in the coater element 23 existing, material powder 60 . 61 can be delivered.

In summary, it is thus possible to use a system according to the invention 100 or a device according to the invention 101 a set-up time when manufacturing a component 1 be reduced in a powder-based layer construction process. Furthermore, novel components 1 in a wide range of useable materials and material combinations in a monolithic manufacturing process.

4 shows a detailed view of a switch element 34 a device according to the invention 101 , The switch element 34 is in this embodiment above a surplus space 12 arranged. It is clearly recognizable that there is a coater path 25 in the area of the switch element 34 forks, and that through the switch element 34 that of the coater element 23 (Not shown with imprinted) coater path 25 is adjustable. Targeted conduction of the coater element 23 For example, to a cleaning device 33 or to a removal opening 55 a powder reservoir 50 . 51 (each not shown), can be achieved. The switch element 34 can be selectively controlled and driven, for example pneumatically, hydraulically and / or spring-mechanically. Furthermore, it is shown that a receiving opening 13 the excess space 12 through a cover 14 is formed coverable. The cover element 14 In this case, it can likewise be designed to be driveable, preferably even coupled to the switch element 34 , In this way it can be prevented, for example, that the excess space 12 for a coater element 23 open, the freshly taken up material powder 60 . 61 to the powder bed 11 (not shown) transported. Unnecessary losses of material powder 60 . 61 can be avoided. On the other hand, by the cover 14 the receiving opening 13 the excess space 12 be released when the coater element 23 from the installation space 10 comes and still excess material powder 60 . 61 carries in itself. An impurity of the material powder 60 . 61 in the powder reservoir 50 . 51 and / or unnecessarily high stress on the cleaning device 33 can be avoided.

In 5 is a powder reservoir according to the invention 50 . 51 shown in the pantry 53 a first material powder 60 is arranged. The cover element 54 is half open in this figure, leaving the removal opening 55 partially accessible. Furthermore, also the adapter sections 52 recognizable, the one, in particular gas-tight, arranging or docking of the powder reservoir 50 . 51 to a docking area 30 . 31 a device according to the invention 101 (not shown) allow or at least support. A data element 56 for storing and providing parameters of the storage room 53 arranged first material powder 60 is also shown with. In operation, by a coater element 23 (not shown) the first material powder 60 in the area of the removal opening 55 added. In this area continuously and continuously the first material powder 60 to be able to provide, has the illustrated powder reservoir 50 . 51 Furthermore, a lifting element 57 on. By this lifting element 57 becomes the first material powder 60 in the storeroom 53 raised. A removal of the first material powder 60 through the coater element 23 can thus be independent of a level in the storage room 53 be ensured.

6 shows a by a method according to the invention in a system according to the invention 100 or a device according to the invention 101 manufactured component 1 , It is clearly visible that different materials for the manufacture of the component 1 were used, in particular a first 60 , a second one 61 and a third material powder 62 , In this case, for example, the first material powder 60 a dense and stable metal material layered in a laser melting process. Such solid and stable areas of a component 1 are for example for a later attachment of the component 1 advantageous. As a second material powder 61 For example, the same metal material may have been used, except that the second material powder 61 one compared to the first material powder 60 has larger grain size. A density in the finished component 1 can thus be influenced in a targeted manner, in the present example diminished. As a result, for example, a lower weight of the manufactured component 1 be enabled. As a third material powder 62 In this example, a plastic material has been used, whereby the middle region of the component 1 can provide a damping characteristic. Overall, therefore, by an inventive method in a system according to the invention 100 or a device according to the invention 101 components 1 be provided with a variety of properties.

LIST OF REFERENCE NUMBERS

1

component

10

space

11

powder bed

12

Excess space

13

receiving opening

14

cover

15

hoist

20

construction phase

21

laser device

22

Beschichtervorrichtung

23

application element

24

construction industry

25

Beschichterpfad

26

laser light

30

first docking area

31

second docking area

32

sealing element

33

cleaning device

34

soft member

40

feeder

41

feeding

42

pivoting element

43

turret member

44

magazine member

45

axis of rotation

46

Magazine strip

47

guide rollers

50

first powder reservoir

51

second powder reservoir

52

adapter section

53

pantry

54

cover element

55

removal opening

56

data element

57

lifting member

60

first material powder

61

second material powder

62

third material powder

100

system

101

contraption

Claims (17)

Contraption ( 101 ) for producing a component ( 1 ) in a powder-based Layer construction method, comprising a construction space ( 10 ) and a construction section ( 20 ) with a laser device ( 21 ), whereby in the construction space ( 10 ) Material powder ( 60 . 61 ) as a powder bed ( 11 ) can be arranged in layers and the component ( 1 ) by an action of the laser device ( 21 ) on the material powder ( 60 . 61 ) can be produced in layers, characterized in that in the construction section ( 20 ) a first docking area ( 30 ) for docking at least one first powder storage container ( 50 ) with a first material powder ( 60 ) and a coating device ( 22 ), wherein the coater apparatus ( 22 ) a driven and movably mounted coater element ( 23 ) for removing material powder ( 60 . 61 ) from the first powder reservoir ( 50 ) and for arranging the removed material powder ( 60 . 61 ) in the installation space ( 10 ) as a layer of the powder bed ( 11 ), and wherein the device ( 101 ) at least one feeding device ( 40 ) with a feed element ( 41 ), in which at least two powder reservoirs ( 50 . 51 ) are arranged for selectively feeding each one of the powder reservoir ( 50 . 51 ) to the first docking area ( 30 ). Contraption ( 101 ) for producing a component ( 1 ) in a powder-based layer construction method, comprising a construction space ( 10 ) and a construction section ( 20 ) with a laser device ( 21 ), whereby in the construction space ( 10 ) Material powder ( 60 . 61 ) as a powder bed ( 11 ) can be arranged in layers and the component ( 1 ) by an action of the laser device ( 21 ) on the material powder ( 60 . 61 ) can be produced in layers, characterized in that in the construction section ( 20 ) a first docking area ( 30 ) for docking at least one first powder storage container ( 50 ) with a first material powder ( 60 ), a second docking area ( 31 ) for docking at least one second powder reservoir ( 51 ) with a second material powder ( 61 ) and a coating device ( 22 ), wherein the coater apparatus ( 22 ) a driven and movably mounted coater element ( 23 ) for removing material powder ( 60 . 61 ) optionally from the first powder reservoir ( 50 ) or from the second powder reservoir ( 51 ) and for arranging the removed material powder ( 60 . 61 ) in the installation space ( 10 ) as a layer of the powder bed ( 11 ). Contraption ( 101 ) according to claim 2, characterized in that the device ( 101 ) at least one feeding device ( 40 ) with a feed element ( 41 ), in which at least two powder reservoirs ( 50 . 51 ) are arranged for selectively feeding each one of the powder reservoir ( 50 . 51 ) to the first docking area ( 30 ) or to the second docking area ( 31 ). Contraption ( 101 ) according to claim 1 or 3, characterized in that the feed element ( 41 ) a pivoting element ( 42 ) and / or a turret element ( 43 ) and / or a magazine element ( 44 ) having. Contraption ( 101 ) according to one of the preceding claims, characterized in that the first docking area ( 30 ) and / or the second docking area ( 31 ) a sealing element ( 32 ) for gas-tight docking of the respective powder reservoir ( 50 . 51 ) having. Contraption ( 101 ) according to one of the preceding claims, characterized in that at least the first docking area ( 30 ) and / or the second docking area ( 31 ) a cleaning device ( 33 ) for cleaning the coating element ( 23 ) having. Contraption ( 101 ) according to claim 6, characterized in that the at least one docking area ( 30 . 31 ) an adjustable switch element ( 34 ) for guiding a movement of the coater element ( 23 ) to the cleaning device ( 33 ) or to the respective powder container ( 50 . 51 ) having. Contraption ( 101 ) according to one of the preceding claims, characterized in that the construction section ( 20 ) and / or the installation space ( 10 ) a surplus space ( 12 ) for at least partially receiving excess material powder ( 60 . 61 ) having. Contraption ( 101 ) according to claim 8, characterized in that the excess space ( 12 ) a movable cover element ( 14 ) for closing a receiving opening ( 13 ) of the excess area ( 12 ) having. Contraption ( 101 ) according to one of the preceding claims, characterized in that the laser device ( 21 ) is designed to perform a laser sintering process and / or to perform a laser melting process. Powder reservoir ( 50 . 51 ) for a device ( 101 ) according to one of the preceding claims, the powder reservoir ( 50 . 51 ) having a storage space ( 53 ) for receiving a material powder ( 60 . 61 ), characterized in that the powder reservoir ( 50 . 51 ) an adapter section ( 52 ) facing the first docking area ( 30 ) and / or the second docking area ( 31 ) adapted adapted. Powder reservoir ( 50 . 51 ) according to claim 11, characterized in that the powder reservoir ( 50 . 51 ) a data element ( 56 ) for storing parameters of the storage room ( 53 ) received material powder ( 60 . 61 ) and for transmitting these parameters to the device ( 101 ) having. Powder reservoir ( 50 . 51 ) according to claim 12, characterized in that the parameters comprise at least one of the following information: - material type - grain size - minimum layer thickness - maximum layer thickness - exposure time - impact strength Powder reservoir ( 50 . 51 ) according to one of claims 11 to 13, characterized in that the powder reservoir ( 50 . 51 ) a cover element ( 54 ) for gas-tight closing of a removal opening ( 55 ) of the storage room ( 53 ), wherein in an arrangement of the powder container ( 50 . 51 ) in the first docking area ( 30 ) and / or second docking area ( 31 ) the cover element ( 54 ) the removal opening ( 55 ) releases, in particular automatically releases. System ( 100 ) from a device ( 101 ) for producing a component ( 1 ) in one powder-based layer construction method and at least two powder storage containers ( 50 . 51 ), characterized in that the device ( 101 ) is designed according to one of claims 1 to 10 and the powder reservoir ( 50 . 51 ) are formed according to one of claims 11 to 14. Method for producing a component ( 1 ) in a powder-based layer construction method, wherein the component ( 1 ) by acting on a laser device ( 21 ) on layers of a powder bed ( 11 ), characterized in that the method is characterized by a device ( 101 ) according to one of claims 1 to 10 and / or by a system ( 100 ) is carried out according to claim 15. Method for producing a component ( 1 ) according to claim 16, characterized in that during the manufacture of the component ( 1 ) Material powder ( 60 . 61 ) of the first powder reservoir ( 50 ) and the second powder reservoir ( 51 ) to form at least one layer of the powder bed ( 11 ) is used.

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