DE102019214802A1 - Coating device for use in an additive manufacturing process, manufacturing system for use in an additive manufacturing process and a housing for a coating device for use in an additive manufacturing process - Google Patents

Abstract

The invention relates to a coating device (18) for use in an additive manufacturing process and a production system (10) for use in an additive manufacturing process and a housing (64) for a coating device (18) for use in an additive manufacturing process it is provided that the application device (18) can be moved by means of a movement device (40) with the provided components in two opposite directions in respective different spaced positions in relation to a production area. In addition, the housing (64) comprises at least one aerodynamic sleeve element (66) so that turbulence behind the coater can be avoided during a coating process. In addition, a manufacturing system (10) for use in an additive manufacturing process, which comprises the coating device (18) and the housing (64), is provided.

Description

The invention relates to a coating device for use in an additive manufacturing process and a production system for use in an additive manufacturing process and a housing for a coating device for use in an additive manufacturing process.

The additive manufacturing processes are increasingly to be regarded as an established technology in industrial production. In this context, various types of processes are already to be regarded as known, which, based on previously created construction data, enable the production of three-dimensional objects from shapeless or form-neutral materials. The materials used for this can, for example, previously be in powder form. In addition to the general designation as an additive manufacturing process, other terms are also used to ultimately create an object by applying a starting material layer by layer. In addition to the term 3D printing, such processes are also referred to as additive manufacturing or manufacturing processes using rapid technologies. Depending on the fundamental orientation of the process used, variants with completely melted starting materials but also variants with only partially melted additives are to be regarded as already known.

In this context, the use of different laser technologies is widespread and increasingly represents a standard for industrial application. In order to further increase the productivity of all processes, continuous process concepts are increasingly the focus of technical development. The objects to be manufactured should above all automatically run through the intended manufacturing steps, with a respective transport to the individual processing stations being carried out continuously by means of correspondingly automated transport devices. When developing a continuous 3D printer in the inclined bed process, for example using selective laser sintering technology (SLS - process = selective laser melting process) or selective laser melting technology, the component to be manufactured is first produced in a first production area. This component is then removed in a second area after a cooling process.

In the SLS process of an additive manufacturing system, the process speed depends heavily on the coater speed, among other things. In order to minimize or eliminate the temporal influence, very fast movements are necessary. Because of the fluid displacement by the coater, there are high flow velocities and turbulence behind the coater. As a rule, the application of the coater is only based on the technical requirements of the coating process. From a fluid mechanical point of view, this design is not optimal. Since the detachment on the upper side is rather irrelevant, as it is far enough away from the powder bed, the flow speed on the underside must be minimized through geometric adjustments.

In the future, additive manufacturing processes will be further improved for use in industrial mass production, so that further tasks or more cost-effective alternatives to previous approaches will be required in the course of this technical development. First approaches are already known from the prior art, as will be shown below with the aid of a few examples.

So is from the pamphlet DE 10 2016 218 249 A1 a method for producing a workpiece by an additive manufacturing method and a device which is suitable for carrying out the method can be seen as known. In particular, a method for producing a workpiece by means of a powder-bed-based additive manufacturing method is presented. The workpiece is produced in the powder bed by using a slider to smooth the powder bed to a target level. If obstacles (for example splashes) prevent the powder bed from being smoothed by means of the slide, the slide moves into an evasive position, powder residues being removed according to the invention by a following brush. The bristles advantageously adapt exactly to the contour of the obstacle, which means that the powder residues can be removed. The invention also relates to a system for the additive manufacturing of workpieces, in which a slide and a brush are used simultaneously to smooth the powder bed.

From the pamphlet DE 10 2005 015 986 A1 a method and a device for heating and flattening a parked powder wave can be found as known. The method and the device are provided for the formation of three-dimensional objects by laser sintering. The required amounts of powder for two successive layers are deposited on one side of the process chamber and at the same time the first layer is distributed while the second amount of layer is transported to the opposite side of the process chamber. The concept presented includes steps of parking the powder quantities within sight of the partial bed heater in order to preheat the powder and to flatten the powder wave prior to the preheating step to improve preheating efficiency.

From the pamphlet US 2019/0077079 A1 a device and a method for compacting material during additive production can be found as known. Embodiments of the present disclosure relate to a system for additive manufacturing, which can comprise a nozzle with an inlet for receiving a flowable material and an outlet for depositing the flowable material. An applicator head can surround at least a portion of a proximal region of the nozzle. The applicator head may include a housing, a cooling inlet for receiving coolant into the housing, a cooling outlet configured to allow coolant to exit the housing, and an air inlet. A roller can be attached to the applicator head on one side of the outlet of the nozzle. The roller may have an air outlet, with a flow path connecting the air inlet and the air outlet so that air enters the air inlet and leaves the air outlet. The roller can also have a plurality of holes which are arranged on an outer surface of the roller.

In previous technical solutions, coaters with low speeds are predominantly used. The problem of powder turbulence does not arise with these slow coaters. In this respect, higher coater speeds cannot be achieved. Maximum horizontal speeds are around 0.3 m / s. So far, a slow coating process has therefore often been carried out. A coating process from both sides is also to be regarded as known alternately.

The invention is now based on the object of providing a coating device and a production system for use in an additive manufacturing process and a housing for the coating device, with which a process speed can be increased and regulated for respective process operations.

In a preferred embodiment of the invention it is provided that a coating device is provided for use in an additive manufacturing process. Such a coater device comprises a coater unit, a material feed unit arranged on the coater unit, the coater unit and the material feed unit being at least partially arranged in a housing, the coater unit arranged at least partially in the housing and the material feed unit together by means of a movement device in two opposite directions respective different spaced positions can be moved in relation to a production area, so that different feed speeds of the coating device can be provided. In this way, a respective process speed can be increased and regulated for respective process operations. For example, an increased feed rate can thus be selected depending on the set spacing position. For example, the application unit can be raised in such a way that the distance to a powder bed is significantly increased. This can be> 10 mm, for example. With such an air gap, very high speeds of the coater unit or the coater can be achieved without adversely affecting the quality of the powder bed. For example, the mechanism for lifting the coater can be constructed so simply that no additional drives are required for this. In this way, for example, in the case of an increased distance position, a return travel can be achieved at a very high speed of the coater, which can be, for example,> 1 m / s.

In a further preferred embodiment of the invention it is provided that a housing is provided for a coating device for use in an additive manufacturing process. The housing is designed to at least partially accommodate a coater unit and a material feed unit, the housing comprising at least one aerodynamic sleeve element, so that turbulence behind the coater in relation to a direction of travel can be avoided during a coating process. In this way, an aerodynamic shape can be provided which, in particular, enables increased speeds or travel speeds of the coater. In other words, the coater can thus be provided or installed or arranged in such a way that it is designed aerodynamically so that turbulence behind the coater is avoided by a flow-favorable shape, for example similar to a wing. In this respect, the coater is designed in such a way that the influence of the flow in the process chamber is influenced as little as possible.

In a further preferred embodiment of the invention, it is provided that a manufacturing system is provided for use in an additive manufacturing process. Such a production plant comprises a coating device according to claims 1 to 6, wherein the coating device comprises a housing according to claims 7 to 9. The advantages mentioned above also apply to the production system presented, insofar as they can be transferred.

Further preferred embodiments of the invention emerge from the other features mentioned in the subclaims.

In a further embodiment of the invention, it is provided that the movement device is arranged on at least one side of the coating unit and comprises at least one first entrainment element which is designed to interact with a first cam element of the movement device during a coating process, so that the coating unit moves from a first spaced position can be moved into a raised spaced position in relation to the production area, wherein a holding device of the moving device is designed to hold the coating unit in this raised spaced position and wherein the moving device comprises at least one second entrainment element, which is designed with a second cam element of the moving device during a travel of the To interact coater device in the raised spaced position, so that the coater unit can be moved into the first spaced position, the holding device from is placed to be operated by means of the second cam element, so that the holding process of the application unit can be canceled in the raised spaced position. For example, the mechanism for lifting the coater can be constructed so simply that no additional drives are required. For this purpose, for example, the application device moves by means of the movement device when traveling up to the first cam element, which thus indirectly lifts the application device. The application device locks in the raised position by the holding device, for example in the form of a spring or a corresponding mechanism. After the return journey, a second cam element pushes the coater back into a work plane. This process is repeated, for example, with every cycle. A very high speed can thus be achieved or driven when traveling back with an increased distance position, so that an overall increased process speed can be achieved. In this way, the process times can be reduced overall, so that a more cost-effective overall process can be achieved without having a negative impact on the process chamber or the powder bed.

In a further embodiment of the invention it is also provided that the holding device comprises a spring and latching device, so that the coating unit can be held in the raised spaced position by means of the spring and latching device. In this way, the raised spaced position can be reliably maintained over a longer distance without an unintentional lowering being able to lead to a loss of quality.

Furthermore, in a further embodiment of the invention it is provided that the first cam element is provided in the form of a ramp and the first driver element is provided in the form of a round rod. This mechanical expression of the interaction elements can thus ensure a reliable mode of operation, so that an overall cost-effective process is possible.

In addition, a further embodiment of the invention provides that the second cam element is provided in the form of a projection element and the second driver element is provided in the form of a ramp. The advantages mentioned above can thus be achieved even better.

In a further embodiment of the invention, it is also provided that the movement device comprises an electric drive so that the coating unit can be reversibly moved from a first spaced position into at least one raised spaced position in relation to the production area. In this way, user-defined operation can be guaranteed at any time without the need for additional mechanics.

Furthermore, a further embodiment of the invention provides that at least two aerodynamic sleeve elements are provided, one aerodynamic sleeve element each being arranged on opposite sides of the coating unit, the aerodynamic sleeve elements each having a parabolic side surface with respective outer vertices. The advantages mentioned above can thus be achieved even better, insofar as they are transferrable.

Finally, in a further embodiment of the invention, it is provided that the at least two aerodynamic sleeve elements each have a flat and a curved outer surface, the curved outer surface extending away from the application unit and having an arched course with at least one turning point.

The advantages mentioned above can thus be achieved even better, insofar as they are transferrable.

For example, the solutions presented can be used in any form in the automotive industry. A use in the armaments industry, in medical technology or in the aerospace industry is at least partially conceivable. For example, the solutions presented can be used in the production of printed plastic parts, as well as printed components made of metal, ceramic or the like. This is preferably a so-called powder bed process.

The various embodiments of the invention mentioned in this application can advantageously be combined with one another, unless stated otherwise in the individual case.

• 1 eine schematische Seitenansicht von einer Fertigungsanlage für den Einsatz in einem additiven Fertigungsverfahren;
• 2 eine schematische Ansicht einer Pulverzuführung mit einer Beschichtungseinheit gemäß dem Stand der Technik;
• 3 eine perspektivische Draufsicht auf eine Fertigungsanlage von 1;
• 4 eine weitere perspektivische Draufsicht auf eine Fertigungsanlage von 1;
• 5 eine schematische Teilansicht auf eine Beschichtervorrichtung mit einer Bewegungsvorrichtung;
• 6 eine weitere schematische Teilansicht auf eine Beschichtervorrichtung mit einer Bewegungsvorrichtung;
• 7 eine weitere schematische Teilansicht auf eine Beschichtervorrichtung mit einer Bewegungsvorrichtung;
• 8 eine weitere schematische Teilansicht auf eine Beschichtervorrichtung mit einer Bewegungsvorrichtung;
• 9 eine schematische Darstellung von einem Gehäuse für eine Beschichtervorrichtung für die Verwendung in einem additiven Fertigungsverfahren; und
• 10 eine schematische Darstellung von einem weiteren Gehäuse für eine Beschichtervorrichtung für die Verwendung in einem additiven Fertigungsverfahren.

The invention is explained below in exemplary embodiments with reference to the accompanying drawings. Show it:

• 1 a schematic side view of a manufacturing system for use in an additive manufacturing process;
• 2 a schematic view of a powder feed with a coating unit according to the prior art;
• 3 a perspective top view of a manufacturing plant of FIG 1 ;
• 4th a further perspective top view of a manufacturing plant from FIG 1 ;
• 5 a schematic partial view of a coating device with a movement device;
• 6th a further schematic partial view of a coating device with a movement device;
• 7th a further schematic partial view of a coating device with a movement device;
• 8th a further schematic partial view of a coating device with a movement device;
• 9 a schematic representation of a housing for a coater for use in an additive manufacturing process; and
• 10 a schematic representation of a further housing for a coating device for use in an additive manufacturing process.

1 shows a schematic side view of a manufacturing plant 10 for use in an additive manufacturing process. In this greatly simplified representation, the individual stations of a production plant of this type are only roughly outlined 10 operated procedure. In relation to the image plane, the first step is to print on the left. There is a laser device for that 12th in a process chamber 14th shown schematically, which by means of a laser beam 16 one beforehand by a coater 18th Applied powder processed so that an object 20th can be printed in layers. The laser beam 16 encounters an object that has not yet been completed 20th which is in a powder bed area 22nd is provided. The powder bed area 22nd can for example in an at least partially closed in the process chamber 14th arranged powder chamber 24 be provided. The object 20th is from left to right during the printing process on a transport system provided for this purpose 26th emotional. During this movement, the coating device 18th correspondingly the next layer on the object 20th coat, which then or during the application by means of the laser device 12th is processed. The process chamber 14th is shown here only schematically and can have other shapes. In particular, this process chamber 14th separate from the powder bed area 22nd be provided, as will be better explained in the following figures. Following the printing, the item becomes 20th outside the process chamber 14th unpacked, leaving excess manufacturing material 27 in one below the transport system 26th positioned collector 28 falls. After unpacking, the steps for handling and cleaning follow in the right-hand area of the screen.

2 shows a schematic view of a powder feed 30th with a coating unit 32 according to the state of the art for use in an additive manufacturing process. In relation to the image plane, powder is used 34 below the powder feed 30th shown before a subsequent process step by means of the coating unit 32 is carried out. Because of the fluid displacement by the coater, there are high flow velocities and turbulence behind the coater. As a rule, the application of the coater is only based on the technical requirements of the coating process. From a fluid mechanical point of view, this design is not optimal.

3 shows a perspective top view of a manufacturing plant 10 of 1 . The same reference numbers are used so that they are not introduced separately at this point. At the coater 18th is a material feed unit 36 arranged. The coater 18th is also shown to be above the powder bed area 22nd is arranged to be movable. Two parallel drive axles shown opposite one another 38 of a movement device not shown in detail are provided for this movement process. In other words, is the coater 18th can be moved in at least two opposite directions by means of the movement device, which is not shown in detail, with a certain distance position from the powder bed area depending on the direction of movement and process operation 22nd or is generally provided for a production area.

4th shows a further perspective top view of a manufacturing plant 10 of 1 . The same reference symbols are used as before, so that they are not introduced separately at this point. At the coater 18th is a material feed unit 36 arranged. The coater 18th is also shown to be above the powder bed area 22nd is arranged to be movable. Two parallel drive axles shown opposite one another 38 of a movement device not shown in detail are provided for this movement process. In other words, is the coater 18th can be moved in at least two opposite directions by means of the movement device, which is not shown in detail, with a certain distance position from the powder bed area depending on the direction of movement and process operation 22nd or is generally provided for a production area.

5 shows a schematic partial view of a coating device 18th with a movement device 40 . The movement device 40 is in several parts and, for example, partially by means of a connecting element 42 the movement device 40 on at least one side of an illustrated coater unit 44 arranged. For example, this can be provided by means of fastening means not shown in detail. This movement device 40 can, for example, with the drive axles explained above 38 interact or be technically connected with them. The movement device 40 is also with a separate support element 46 shown, which is the side of the connecting element 42 is provided and is fixed in the position shown and is therefore provided immovably. On this carrier element 46 is a first cam element based on the image plane at the upper limit 48 shown, this first cam element 48 in the form of an inclined plane and with a substantially rectangular base 50 is shown. In relation to the image plane, the inclined plane increases from front to back. On the connecting element 42 is also a first driving element 52 arranged, which has a substantially cylindrical basic shape. This first take-away element 52 is designed with the first cam element 48 the movement device 40 interact during a coating process, so that the coater unit 44 can be moved from a first spaced position into a raised spaced position in relation to a production area, which can be a powder bed area, for example. In other words, it becomes the first entrainment element 52 via the first cam element 48 moved upwards in relation to the image plane, the connected connecting element 42 from the movement device 40 and thus also the coater unit 44 is moved from a first spaced position to a raised spaced position. A holding device 54 from the movement device 40 the coater unit is designed 44 hold in this raised distance position. This holding device 54 can for example be a spring mechanism with, for example, a spring. This holding device 54 is in this embodiment based on the image plane above the first entrainment element 52 arranged.

6th shows a further schematic partial view of a coating device 18th with a movement device 40 . The same reference symbols are used as before, so that they are not introduced separately at this point. In this 6th is the driving element 52 via the first cam element 48 has already been moved so that the coater unit 44 from a first spaced position to a raised spaced position in relation to a production area, which for example is a powder bed area 22nd can be raised.

7th shows a further schematic partial view of a coating device 18th with a movement device 40 . It is from the movement device 40 in this 7th only one more detail shown. The movement device 40 is with a support frame 56 shown, which is provided statically at this position. On the support frame 56 is a second cam element 58 arranged. This second cam element 58 is shown essentially with a rectangular basic shape, with a rounded area being provided on the lower boundary side in relation to the image plane. The movement device 40 is also with a holding element 60 shown, with this holding element 60 a second driver element 62 is arranged. This second entrainment element 62 is shown in the form of an inclined plane. The driving element 62 is designed with a second cam element 58 the movement device 18th during a journey of the coater 18th in the raised spaced position so that the coater unit 44 can be moved into the first spaced position. In other words, it is thus possible to resolve the previously reached raised spacing position again. Here is the holding device 54 designed by means of the second cam element 58 to be operated, so that the holding process of the coater unit 44 can be canceled in the raised spaced position.

8th shows a further schematic partial view of a coating device 18th with a movement device 40 . The same reference numbers are used as before, so that these not be introduced separately at this point. In this 8th is the second cam element 58 already on the second driver element 62 moved so that the coater unit 44 moved from the raised clearance position to the first clearance position.

9 shows a housing 64 for a coater 18th for use in an additive manufacturing process. It is from the coater 18th only one coater unit 44 shown. This coater unit 44 is essentially in the center of the housing 64 intended. In relation to the image plane is to the right of the application unit 44 a powder feeder 30th shown. This embodiment of the housing 64 has an essentially elliptical basic shape. In this respect, this case is 64 designed with an aerodynamic shape, so that turbulence behind the coater unit 44 based on a direction of travel are avoidable during a coating process. In particular, the housing 64 for a coater 18th provided and thus suitable for use in an additive manufacturing process, the housing 64 a coater unit is designed at least in part 44 and a material feed unit 36 take up, with the housing 64 at least one aerodynamic sleeve element 66 includes, so that turbulence behind the coater in relation to a direction of travel can be avoided during a coating process. Of course, other aerodynamic profiles are also conceivable or conceivable. The drop shape is largely considered to be particularly low in turbulence.

10 shows another housing 64 for a coater 18th for use in an additive manufacturing process. It is from the coater 18th only one coater unit 44 shown. This coater unit 44 is essentially in the center of the housing 64 intended. In relation to the image plane is to the right of the application unit 44 a powder feeder 30th shown. This embodiment of the housing 64 has an essentially hill-shaped basic shape. In other words, there are left and right of the coater unit 44 arcuate courses of an outer surface of the housing 64 provided so that an aerodynamic shape results, so that turbulence behind the coater unit 44 based on a direction of travel are avoidable during a coating process. In particular, the housing 64 for a coater 18th provided and thus suitable for use in an additive manufacturing process, the housing 64 a coater unit is designed at least in part 44 and a material feed unit 36 take up, with the housing 64 at least one aerodynamic sleeve element 66 includes, so that turbulence behind the coater in relation to a direction of travel can be avoided during a coating process. Of course, other aerodynamic profiles are also conceivable or conceivable.

List of reference symbols

10

Manufacturing facility

12th

Laser device

14th

Process chamber

16

laser beam

18th

Coater device

20th

object

22nd

Powder bed area

24

Powder chamber

26th

Transport system

27

Manufacturing material

28

Collector

30th

Powder feed

32

Coating unit

34

powder

36

Material feed unit

38

Drive axle

40

Movement device

42

Connecting element

44

Coater unit

46

Support element

48

first cam element

50

Floor space

52

first take-away element

54

Holding device

56

Support frame

58

second driver element

60

Retaining element

62

second cam element

64

casing

66

Sleeve element

QUOTES INCLUDED IN THE DESCRIPTION

This list of the documents listed by the applicant was generated automatically and is included solely 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 102016218249 A1 [0006]
• DE 102005015986 A1 [0007]
• US 2019/0077079 A1 [0008]

Claims (10)

Coater device (18) for use in an additive manufacturing process comprising a coater unit (44), a material supply unit (36) arranged on the coating unit (44), the coating unit (44) and the material supply unit (36) at least partially in a housing (64) ), characterized in that the coater unit (44), which is at least partially arranged in the housing (64), and the material feed unit (36) can be moved together by means of a movement device (40) in two opposite directions in respective different spaced positions in relation to a production area, so that different feed speeds of the coating device (18) can be provided. Coater device (18) after Claim 1 , wherein the movement device (40) is arranged on at least one side of the application unit (44) and comprises at least one first entrainment element (52) which is designed to interact with a first cam element (48) of the movement device (40) during a coating process, so that the coater unit (44) can be moved from a first spaced position to a raised spaced position in relation to the production area, a holding device (54) being designed by the moving device (40) to hold the coater unit (44) in this raised spaced position and wherein the moving device ( 40) comprises at least one second entrainment element (58) which is designed to interact with a second cam element (62) of the movement device (40) while the application device (18) is moving in the raised spaced position, so that the application unit (44) moves into the first Distance position is movable, wherein the Haltevo The device (54) is designed to be operated by means of the second cam element (62), so that the holding process of the application unit (44) in the raised spaced position can be canceled. Coating device (18) according to one of the preceding claims, wherein the holding device (54) comprises a spring and latching device, so that the coating unit (44) can be held in the raised spaced position by means of the spring and latching device. Coater device (18) according to one of the preceding claims, wherein the first cam element (48) is provided in the form of a ramp and the first entrainment element (52) is provided in the form of a round rod. Coater device (18) according to one of the preceding claims, wherein the second cam element (62) is provided in the form of a projection element and the second entrainment element (58) is provided in the form of a ramp. Coater device (18) after Claim 1 wherein the movement device (40) comprises an electric drive so that the coating unit (44) can be reversibly moved from a first spaced position into at least one raised spaced position in relation to the production area. Housing (64) for a coating device (18) for use in an additive manufacturing process, the housing (64) being designed to at least partially accommodate a coating unit (44) and a material feed unit (36), characterized in that the housing (64) comprises at least one aerodynamic sleeve element (66), so that turbulence behind the coater can be avoided in relation to a direction of travel during a coating process. Housing (64) Claim 7 , at least two aerodynamic sleeve elements (66) being provided, one aerodynamic sleeve element (66) each being arranged on opposite sides of the application unit (44), the aerodynamic sleeve elements (66) each having a parabolic side surface with respective outer vertices. Housing (64) Claim 7 wherein the at least two aerodynamic sleeve elements (66) each have a flat and a curved outer surface, the curved outer surface extending away from the application unit (44) and having an arcuate course with at least one point of inflection. Manufacturing plant (10) for use in an additive manufacturing process, comprising a coating device (18) according to FIGS Claims 1 to 6th , wherein the application device (18) comprises a housing (64) according to FIGS Claims 7 to 9 includes.

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