DE102019201494A1 - Plant for the additive manufacturing of a component and process - Google Patents

Abstract

Plant 1 for the generative production of a component 2 from a material powder, with a building platform 11 for building the component 2, with at least one application section for applying a powder layer 12 to the building platform 11, with at least one irradiation section 17 for selectively irradiating the powder layer 12, with a Transport unit 7, the transport unit 7 being designed to move and / or move the construction platform 11 in a plant room 4 along a transport path, the application section and the irradiation section 13 being spaced apart and / or adjacent along the transport path.

Description

State of the art

Plant for the additive manufacturing of a component from a powdery material powder, with a building platform for building the component, with at least one application section for applying a powder layer to the building platform, with at least one irradiation section for selective irradiation of the powder layer.

Powder bed-based systems for the additive construction of components, for example 3D printing, are known in the prior art. Such systems have a linear structure, which means that the powder coating works translationally within the process chamber and causes downtimes that significantly reduce the overall productivity of additive manufacturing processes. To increase the selectivity, multi-laser systems are used in the prior art, for example, in which several laser beams are used simultaneously to build up several components in a process chamber.

The publication DE 10 2016 211 799 Al, which is probably the closest prior art, describes a device for producing workpieces from a powder material. The device has a carrier device with at least one build-up container for the powdery material, from which the workpieces can be produced by selective melting and subsequent solidification by means of a processing beam within the build-up container. At least one storage container has a separate distribution element which can be rotated about an axis relative to the fixedly arranged carrier device.

One consideration of the invention is to provide a system in which the construction times of the component and the idle and waiting times of the system are reduced.

Disclosure of the invention

A system for the additive manufacturing of a component with the features of claim 1 is proposed. Furthermore, a method for additive manufacturing of a component with the features of claim 15 is proposed. Preferred and / or advantageous embodiments of the invention result from the subclaims, the description and the attached figures.

A system for the additive manufacturing of a component from a powder material powder is proposed. The system is designed in particular to carry out a powder bed-based build-up process, preferably powder bed-based print process. The system forms, for example, a 3D printing system. The component and / or the material powder can comprise and / or form a metal, ceramic and / or plastic material. In particular, the system is designed as a selective laser melting system (SLM), as an electron beam-based assembly system (EBM) or an ion beam assembly process. The plant has in particular a plant room. The plant room can be surrounded and / or limited, for example, by a housing of the plant. The component is preferably a layer component and comprises more than two layers and / or less than 100 layers. The component preferably forms a flat component. The powdered material powder is, for example, a metal powder, a ceramic powder or a plastic powder. In particular, the material powder can comprise a binder.

The system comprises at least one construction platform for building the component. The construction platform has at least one flat section. The construction platform and / or its flat section is preferably flat. In particular, the construction platform can form a metal support. For example, the construction platform is designed as a metal, plastic or ceramic plate.

In particular, the construction platform can be designed as an endless material, for example as a sheet metal from a roll.

The system has at least one application section. The application section is in particular a flat or a volume section of the plant room. In particular, the application section and a construction platform have an overlap at least temporarily. A powder layer can be applied to the construction platform in the application section. In particular, the powder layer can be applied to an intermediate layer between the building platform and the free surface. For example, a previous powder layer has already been irradiated and / or cured, so that this powder layer is applied to the previous one. For example, the system has a powder application device for this purpose. The powder application device can have a reservoir for the material powder and / or the powder. The powder layer is created in particular from the material powder. For this purpose, the material powder in powder form is applied in particular over a large area. For this purpose, the application device in particular has a doctor blade and / or a smoothing knife. The powder layer can completely fill the building platform, alternatively the powder layer is applied only over a partial area of the building platform. The powder layer in particular has a powder layer thickness. The application section is arranged in particular in the plant room.

The system also has at least one radiation section. The radiation section is preferably a flat section in the plant room, alternatively the radiation section is a volume section of the radiation room. The construction platform and / or the applied powder layer is preferably arranged and / or can be arranged at least temporarily in the irradiation section. The system has, for example, an irradiation device which can selectively irradiate the powder layer. The irradiation can take place, for example, as irradiation with a laser, an ion or an electron beam. For this purpose, for example, the irradiation device has a laser, an ion source or an electron source. By selective irradiation, the powder layer is melted in a selective, punctiform, linear and / or flat manner. A solidification step is preferably carried out after the irradiation, so that the melted powder layer can solidify and solidify.

The system has a transport unit. The transport unit is designed to move, move and / or move the construction platform in the plant room. The construction platform can be moved and / or moved along a transport path by means of the transport unit. The transport path is preferably a straight path, alternatively and / or in addition, the transport path can form an angled, curved and / or branched transport path. The transport route is preferably arranged entirely in the plant space. Alternatively, it can be provided that parts of the transport route are arranged outside the plant room. The transport unit is designed to transport the construction platform from the application section to the irradiation section. If the system has a plurality of application sections and / or a plurality of irradiation sections, the transport unit is in particular designed to transport the construction platform from one application section to one irradiation section and from the irradiation section on to further application sections and / or irradiation sections.

According to the invention, it is provided that the application section and the irradiation section are spaced apart, in succession and / or adjacent to one another. In particular, the application section and the irradiation section are spaced apart along the transport path. Application section and irradiation section can be separated from one another by a further section, alternatively the irradiation section and application section are adjacent to one another without a transition.

It is a consideration of the invention to provide a system for the more effective and / or faster production of a component by means of a generative manufacturing process. In particular, it is a consideration to reduce downtime, changeover times and / or preparation times and / or to combine them. This is achieved in particular by the fact that coating and radiation are decoupled from one another in time and / or space. Instead of leaving the construction platform in a fixed position during the construction process and possibly only lowering the plate, by moving the construction platform during construction, powder can be applied within the system and exposure can be arranged and used sequentially. In particular, the duration of the assembly per component is no longer given as the mere sum of all coating and exposure processes, but is only determined from the duration of the individual exposure processes.

One embodiment of the invention provides that the system has a plurality of application sections and a plurality of irradiation sections. The number of application sections preferably corresponds to the number of irradiation sections. For example, all application sections and all irradiation sections are arranged within a common housing of the system and thus in a common system room. The application sections and irradiation sections are arranged along the transport route. In particular, application sections and irradiation sections are arranged alternately along the transport route. The transport route leads in particular from a first application section to a first irradiation section, from the first irradiation section to the second application section and, with possible further irradiation sections and application sections, to a last irradiation section. The irradiation sections and application sections are arranged in particular along a linear and / or straight transport path. The transport unit connects the plurality of application sections to the plurality of irradiation sections.

It is particularly preferred that at least one application section is arranged in each case between two irradiation sections. Alternatively, it can be provided that an irradiation section is followed by a further irradiation section, for example in order to further process, melt and / or structure the powder layer by means of a further laser beam, for example with a different wavelength or power.

It is particularly preferred that the system has a first application device for applying the powder layer with a first material powder and a second application device for applying the powder layer in a second Application section with a second material powder. In particular, the system can be designed such that different material powders are used in the first application section and in a second application section. The first material powder and the second material powder have different physical properties, chemical properties and / or compositions. This embodiment is based on the consideration of providing a system in which a component can be produced from different powder layers, in particular material powders, the different material powders being applied to different application sections which are spaced apart from one another via the transport path. In particular, mixing of the material powders can be avoided in this way.

In particular, the component forms a multilayer component comprising a number of layers. The number of layers corresponds in particular to the number of powder layers that are required to build up the component. The number of layers is preferably greater than two and in particular greater than five. Furthermore, it is preferably provided that the number of layers is less than twenty. Optionally, the system has a number of radiation sections and / or application sections that is equal to the number of layers of the component. This embodiment is based on the consideration of providing a production system in such a way that all the layers required for the construction of the component can be generated and / or generated in one line.

An embodiment of the invention provides that the construction platform is encompassed by the transport unit and / or the construction platform forms the transport unit. For example, the construction platform is connected by means of a mechanism, for example a linkage or ropes, in such a way that they can be moved, moved and / or moved in the plant space. In particular, the construction platforms that are encompassed by the transport unit are reusable construction platforms that can be used again after the construction of a component to build a new further component. For example, a building platform is provided and / or used again at the start of the transport route after the component has been successfully built.

It is particularly preferred that the transport unit and / or the construction platform forms a conveyor belt. For example, the construction platform forms a metal strip, on which the powder layers are applied and the component is built on it. The construction platform and / or the conveyor belt thus form in particular an endless belt which is arranged in a loop and / or closed. It is particularly preferred that the construction platform is designed for direct application and / or construction of the component on it. For example, the construction platform and / or the conveyor belt form a base material and / or a base layer of the component. For example, the assembled component can then be punched out of the construction platform and / or the conveyor belt and / or separated therefrom.

The system preferably has a processing chamber. The processing chamber is formed, for example, by the housing of the system. In particular, the plant space is arranged within the processing chamber. For example, it is provided that at least and / or all of the radiation sections are arranged in the processing chamber. Furthermore, it is preferably provided that at least one or all application sections are arranged in the processing chamber. In particular, it is provided that a protective gas atmosphere prevails within the processing chamber. For this purpose, the system has, for example, an atmosphere preparation device which supplies and / or discharges protective gas. The processing chamber in particular forms a barrier for the protective gas atmosphere from the environment and / or the atmosphere. It is preferably provided that the transport path and / or the entire transport path is arranged within the processing chamber.

One embodiment of the invention provides that the processing chamber has an entrance lock section and an exit lock section. The transport route preferably extends from the entrance lock section to the exit lock section. The entrance lock section and / or the exit lock section is designed, for example, as a slot in the housing and / or the processing chamber. The height of the slot is preferably dimensioned such that the construction platform can enter the transport unit at the entrance lock section and the component can exit at the exit lock section. The entrance lock section and the exit lock section serve to open the processing chamber from the surroundings, while at the same time causing a protective gas atmosphere to be maintained. For example, a protective gas overpressure prevails in the processing chamber, so that the inlet lock section and the output lock section serve to discharge the excess pressure and / or the protective gas, so that the protective gas atmosphere always prevails within the processing chamber.

It is particularly preferred that the plant has at least one depulping unit. The depulping unit is designed, for example, as a suction unit or as a magnetization unit or unit for generating an electric field. The depulping unit is preferably arranged after an irradiation section. Powder which has not melted and / or is not used can be removed and / or suctioned off by means of the depulping unit. In particular, it can be provided that instead of and / or in addition to suctioning off the powder in the case of metallic and / or other powders, the removal can take place by means of electrical charging and / or separation and by magnetization. This configuration is based on the consideration of providing a resource-saving system so that, for example, the powdered material powder that was not used can be reused and used later.

It is optionally provided that the depulping unit is arranged between application sections in which different material powders or material powders are used. For example, a first material powder is used in a first application section and another material powder is used in the second application section, wherein after the irradiation section for the first material powder, the depulping unit sucks up the unused first material powder and only then does the further material powder be applied. This embodiment is based on the consideration that, when changing the material powder within the system, it is possible to avoid a mixture of the material powders, so that each material powder can in particular be used and / or recycled.

It is particularly preferred that the transport unit is designed to carry out the transport of the construction platform continuously. For example, the construction platform is continuously conveyed at a constant speed along the transport route. This embodiment is based on the consideration of enabling continuous processing and / or of being able to prevent the powder layer from shifting, slipping and / or smearing. Alternatively, it is provided that the transport unit is designed to transport the construction platform discontinuously, for example step by step. For example, the construction platform is transported along a given translation path with a given and / or adjustable length.

It is optionally provided that the component forms a flat component, the system forming a system for producing a flat component. In particular, the system is designed and / or set up such that the exit lock section and / or the entrance lock section are set up on flat components. Examples of flat components are, for example, components with less than ten layers and / or with a height of less than five centimeters. In particular, it is provided that the component forms a structural component, a surface and / or a heat sink.

It is particularly preferred that the component forms a bipolar plate and / or a flow field for a fuel cell. For example, the component is a bipolar plate for PEM fuel cells. For example, flow fields and / or bipolar plates for PEM fuel cells have five to ten layers. It is a consideration here, for example, to be able to produce fuel cell parts and / or bipolar plates in a system with a cycle time of one to two seconds per bipolar plate.

Another object of the invention is a method for producing a component in a generative manufacturing process. In particular, the method is carried out with the system as previously described. To produce the component, a powder layer is applied to a construction platform and the powder layer is then selectively irradiated. The method provides for the powder application to be carried out spatially separated and / or at a distance from the radiation. For this purpose, for example, the construction platform is transported from an application section to an irradiation section. According to the method, it is provided, for example, to spatially separate the powder application and the exposure, so that a shorter processing time is possible.

• 1 ein Ausführungsbeispiel einer Anlage zur generativen Fertigung eines Bauteils;
• 2 ein weiteres Ausführungsbeispiel einer Anlage zur generativen Fertigung eines Bauteils;
• 3 eine dritte Ausführungsform einer Anlage zur generativen Fertigung eines Bauteils.

Further advantages, effects and configurations result from the attached figures and their description. Show:

• 1 an embodiment of a system for additive manufacturing of a component;
• 2nd a further embodiment of a system for the additive manufacturing of a component;
• 3rd a third embodiment of a system for the additive manufacturing of a component.

1 shows schematically a first embodiment of a system 1 for additive manufacturing of a component 2nd . The system is designed as a system for carrying out a powder bed-based production process and / or additive production process. For example, the facility 1 designed as a system for selective laser melting. The attachment 1 is here as a system like a manufacturing system for linear conveying and / or manufacturing of the component 2nd educated. The component 2nd preferably forms a flat component which is constructed from a plurality of layers. The layers can have the same or a different material composition. The component 2nd forms a 3D component, which in particular has three-dimensional structures. For example, the component forms 2nd a bipolar plate for a fuel cell.

The attachment 1 has a housing 3rd which defines a processing chamber. The housing defines a plant room 4th which is inside the case 3rd located. The housing 3rd has an entrance lock section 5 and an exit lock section 6 on.

The entrance lock section 5 and the exit lock section 6 are openings in the housing 3rd formed, and preferably formed in slots. The dimensioning of the exit lock opening 6 is chosen in particular so that the height of the slot is greater than the height of the component to be manufactured 2nd , but preferably has a lower height than twice the height of the component 2nd .

The attachment 1 has a transport unit 7 on. The transport unit 7 is designed as a conveyor belt. The conveyor belt is operated by a conveyor 8th promoted. The actual conveyor belt is preferably conveyed continuously at a uniform speed. The conveyor belt and / or the transport unit 7 extends in particular from the entrance lock section 5 to the exit lock section 6 . In the case 3rd and thus in the plant room 4th there is a protective gas atmosphere. For this purpose, protective gas is regularly generated using an inert gas generation device 9 supplied so that there is a continuous protective gas atmosphere in the processing chamber and / or in the plant room. In particular, the protective gas atmosphere and / or the supply of the protective gas 9 chosen so that there is an overpressure, so that a slight escape of the protective gas at the entrance lock section 5 and the exit lock section 6 he follows.

The attachment 1 comprises three application facilities 10th which in the plant room 4th are arranged and are located along the transport route. The transport route is through the transport unit 7 and in particular defined and / or defined by the conveyor belt. The transport route extends from the entrance lock section 5 to the exit lock section 6 . The application facilities 10th are formed, a material powder as a layer of powder on the transport unit and in particular on a construction platform 11 to apply. The construction platforms are, for example, metal, plastic or ceramic plates, which form the basis for the component 2nd serve. The construction platforms 11 are arranged on the conveyor belt and are carried by the transport unit 7 transported along the transport route. The application facilities 10th each carry a layer of powder 12th on. The first application facility on the transport route 10th applies the powder layer to the build platform, the subsequent application devices 10th apply the powder layer on a previous powder layer and optionally on a melted powder layer. The height profile of the powder layers increases from the entrance lock section to the exit lock section with each application device 10th to, in particular, these are arranged stepwise in the height profile. For example, the material powder is applied using the application devices 10th continuously, for example when the building platforms 2nd continuously at a constant speed from the transport unit 7 be promoted.

The attachment 1 has an irradiation unit 13 on. The radiation unit 13 is designed here as a laser that has a main laser beam 14 issues. The laser beam 14 is at least in sections within the housing 3rd and / or in the plant room 4th headed. The attachment 1 has a scanner device 15 on that is formed the laser beam 15 in partial laser beams 16 to divide. The partial laser beams, also called laser beams for short, are divided into radiation sections 17th headed. The radiation sections 17th are in particular each after an application section. In the radiation section 17th becomes the powder layer 12th from the laser beam 16 selectively melted. The melted powder is then cooled and allowed to solidify. The cooled and / or solidified sections and the unmelted powder layer are applied in a subsequent application device 10th the next powder layer is applied and then in the next radiation section 17th irradiated and / or melted. By arranging the application sections and irradiation sections 17th one after the other and the use of several radiation sections and / or several application sections can result in faster processing and / or production of the component 2nd respectively.

The attachment 1 comprises a depulping unit 18th . The de-powdering unit 18th is in the housing 3rd arranged. In particular, the depulping unit 18th along the transport route after the last radiation section 17th arranged. The de-powdering unit 18th is designed to extract unused, melted and / or recyclable material powder. This exposes and / or cleans the component 2nd . Furthermore, suction and / or removal of the application powder takes place by means of the de-powdering unit 18th recycling of the material powder, which can be returned to the application devices 10th .

2nd shows another version of the system 1 . The attachment 1 is essentially the same as the system 1 out 1 educated. The attachment 1 in the 2nd differs essentially in that the construction platform 11 directly as a conveyor belt of the transport unit 7 serves. A base plate is used as the construction platform 12th right along the Transport route promoted. The base plate 2nd is through the application facilities 10th performed, with the first application device 10th the powder layer is applied directly to the conveyor belt, here the base plate. In the radiation section 17th after the first application facility 10th the powder layer is melted. In particular, the melted powder layer partially connects to the base plate and thus to the construction platform 12th . The base plate then forms part of the component to be produced 2nd . The subsequent application of further powder layers and the further melting takes place on the previously applied powder layers and / or melted sections. After the last melting section, the component 2nd with the depulping unit 18th powdered. The component 2nd is then led out of the processing chamber along the transport path. After the powder removal and removal, the component 2nd isolated from the base plate or from the construction platform. For example, the component 2nd punched out, cut out or otherwise separated. In particular, the separation, cutting and / or punching out is carried out in such a way that part of the base plate or the construction platform is part of the component 2nd remains. This embodiment is based on the consideration of directly promoting the construction platform, for example by driving with motors, a pulling or pushing device. This saves you from having to wear a separate conveyor belt. In particular, the base plate can be provided as an endless material and the components can then be obtained by singling and / or punching / cutting.

3rd shows a third embodiment of a system 1 for additive manufacturing of a component 2nd . The attachment 1 in 3rd is essentially similar to the other two embodiments 2nd and 1 educated. A major difference from the previous embodiments is that the application devices 10a , 10b and 10c are designed to apply a different material powder. So the first application facility bears 10a a first material powder as a layer of powder. This powder layer is melted in the radiation section. After this irradiation, the first material powder that is not used is sucked off with the depulping unit 18a . By the depulping unit 18a the material powder that was not used is removed and is thus sorted by type of the application device 10a traceable. On the de-powdered section is with the application device 10b after the depulping unit 18a applied a second powder material. The second material powder differs in its composition and / or in its physicochemical properties from the material powder that was used previously. The powder layer of the second material powder applied in this way is melted, in particular selectively melted, in a subsequent irradiation. After melting and possibly cooling, unused second material powder is removed from the depulping unit 18b away. The removed material powder with the depulping unit 18b is sorted again and can be used by the application facility 10b to be led back. In a subsequent application facility 10c a third material powder is applied as a powder layer. The composition and / or the physicochemical properties of the third material powder are in particular different from those of the second material powder. The applied powder layer of the third material powder is then also selectively melted and / or irradiated. Unused third material powder is used with the depulping unit 18c away. The removed third material powder can be removed from the depulping unit 18c the application facility 10c to be led back.

This embodiment is based on the consideration of being able to produce components with multiple layers generatively, the layers having different material compositions and / or properties. By arranging application devices one after the other 10a , 10b and 10c powder and / or material change can be saved and the process can be carried out continuously. Sucking off unused powder after the respective melting process ensures that the powder can be reused according to type.

QUOTES INCLUDE IN THE DESCRIPTION

This list of documents listed by the applicant has been generated automatically and is only included for the better information of the reader. The list is not part of the German patent or utility model application. The DPMA assumes no liability for any errors or omissions.

Patent literature cited

• DE 102016211799 [0003]

Claims (15)

Plant (1) for the additive manufacturing of a component (2) from a material powder, with a building platform (11) for building the component (2), with at least one application section for applying a powder layer (12) to the building platform (11), with at least an irradiation section (17) for selectively irradiating the powder layer (12), characterized by a transport unit (7), the transport unit (7) being designed to move the construction platform (11) in a plant space (4) along a transport path and / or to move, the application section and the irradiation section (13) being spaced apart and / or adjacent along the transport path. Annex (1) to Claim 1 , characterized by a plurality of application sections and a plurality of irradiation sections (13), the application section and the irradiation sections (13) being spaced apart along the transport path. Annex (1) to Claim 2 , characterized in that at least one application section is arranged in each case between two irradiation sections (13). System (1) according to one of the preceding claims, characterized by a first application device (10, 10a, 10b) for applying a first material powder in a first of the application sections and a second application device (10, 10b, 10c) for applying a second material powder in one second of the application sections, the first and second material powders being differently designed and / or composed. System (1) according to one of the preceding claims, characterized in that the component (2) forms a multi-layer component and is constructed from a number of layers, the system (1) having at least a number of layers of radiation sections (13) and / or at least has a number of layers of application sections. System (1) according to one of the preceding claims, characterized in that the construction platform (11) is encompassed by the transport unit (7) and / or the construction platform (11) forms the transport unit (7). System (1) according to one of the preceding claims, characterized in that the transport unit (7) and / or the construction platform (11) forms a conveyor belt. System (1) according to one of the preceding claims, characterized by a processing chamber, at least one of the irradiation sections (13) and at least one of the application sections being arranged in the processing chamber. Annex (1) to Claim 8 , characterized in that the processing chamber has an entrance lock section (9) and an exit lock section (10), the transport path leading from the entrance lock section (9) to the exit lock section (10). Plant (1) according to one of the preceding claims, characterized by at least one depulping unit (18, 18a-c) for removing unused material powder. Annex (1) to Claim 10 , characterized in that the depulping unit (18, 18a-c) is arranged between two application sections for material change. System (1) according to one of the preceding claims, characterized in that the transport unit (7) is designed to move the building platform (11) continuously and / or to move at a constant speed. System (1) according to one of the preceding claims, characterized in that the component (2) forms a flat component. System (1) according to one of the preceding claims, characterized in that the component (2) forms a bipolar plate. Method for producing a component (2), in particular with the system (1) according to one of the preceding claims, wherein a powder layer (12) is applied to a construction platform (11), the powder layer (12) subsequently being selectively irradiated, application the powder layer and radiation of the powder layer (12) take place spatially separated.

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