EP1526964A1 - Dispositif et procede pour produire un objet tridimensionnel au moyen d'un procede de fabrication generatif - Google Patents

Dispositif et procede pour produire un objet tridimensionnel au moyen d'un procede de fabrication generatif

Info

Publication number
EP1526964A1
EP1526964A1 EP03784136A EP03784136A EP1526964A1 EP 1526964 A1 EP1526964 A1 EP 1526964A1 EP 03784136 A EP03784136 A EP 03784136A EP 03784136 A EP03784136 A EP 03784136A EP 1526964 A1 EP1526964 A1 EP 1526964A1
Authority
EP
European Patent Office
Prior art keywords
applied layer
carrier
material application
previously applied
application device
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Withdrawn
Application number
EP03784136A
Other languages
German (de)
English (en)
Inventor
Thomas Mattes
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
EOS GmbH
Original Assignee
EOS GmbH
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by EOS GmbH filed Critical EOS GmbH
Publication of EP1526964A1 publication Critical patent/EP1526964A1/fr
Withdrawn legal-status Critical Current

Links

Classifications

    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B22—CASTING; POWDER METALLURGY
    • B22F—WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
    • B22F3/00—Manufacture of workpieces or articles from metallic powder characterised by the manner of compacting or sintering; Apparatus specially adapted therefor ; Presses and furnaces
    • B22F3/004—Filling molds with powder
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B22—CASTING; POWDER METALLURGY
    • B22F—WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
    • B22F12/00—Apparatus or devices specially adapted for additive manufacturing; Auxiliary means for additive manufacturing; Combinations of additive manufacturing apparatus or devices with other processing apparatus or devices
    • B22F12/30—Platforms or substrates
    • B22F12/37—Rotatable
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C64/00—Additive manufacturing, i.e. manufacturing of three-dimensional [3D] objects by additive deposition, additive agglomeration or additive layering, e.g. by 3D printing, stereolithography or selective laser sintering
    • B29C64/10—Processes of additive manufacturing
    • B29C64/141—Processes of additive manufacturing using only solid materials
    • B29C64/153—Processes of additive manufacturing using only solid materials using layers of powder being selectively joined, e.g. by selective laser sintering or melting
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B33—ADDITIVE MANUFACTURING TECHNOLOGY
    • B33Y—ADDITIVE MANUFACTURING, i.e. MANUFACTURING OF THREE-DIMENSIONAL [3-D] OBJECTS BY ADDITIVE DEPOSITION, ADDITIVE AGGLOMERATION OR ADDITIVE LAYERING, e.g. BY 3-D PRINTING, STEREOLITHOGRAPHY OR SELECTIVE LASER SINTERING
    • B33Y10/00—Processes of additive manufacturing
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B33—ADDITIVE MANUFACTURING TECHNOLOGY
    • B33Y—ADDITIVE MANUFACTURING, i.e. MANUFACTURING OF THREE-DIMENSIONAL [3-D] OBJECTS BY ADDITIVE DEPOSITION, ADDITIVE AGGLOMERATION OR ADDITIVE LAYERING, e.g. BY 3-D PRINTING, STEREOLITHOGRAPHY OR SELECTIVE LASER SINTERING
    • B33Y30/00—Apparatus for additive manufacturing; Details thereof or accessories therefor
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B22—CASTING; POWDER METALLURGY
    • B22F—WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
    • B22F10/00—Additive manufacturing of workpieces or articles from metallic powder
    • B22F10/20—Direct sintering or melting
    • B22F10/28—Powder bed fusion, e.g. selective laser melting [SLM] or electron beam melting [EBM]
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B22—CASTING; POWDER METALLURGY
    • B22F—WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
    • B22F12/00—Apparatus or devices specially adapted for additive manufacturing; Auxiliary means for additive manufacturing; Combinations of additive manufacturing apparatus or devices with other processing apparatus or devices
    • B22F12/40—Radiation means
    • B22F12/44—Radiation means characterised by the configuration of the radiation means
    • B22F12/45—Two or more
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B22—CASTING; POWDER METALLURGY
    • B22F—WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
    • B22F12/00—Apparatus or devices specially adapted for additive manufacturing; Auxiliary means for additive manufacturing; Combinations of additive manufacturing apparatus or devices with other processing apparatus or devices
    • B22F12/50—Means for feeding of material, e.g. heads
    • B22F12/55—Two or more means for feeding material
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
    • Y02P—CLIMATE CHANGE MITIGATION TECHNOLOGIES IN THE PRODUCTION OR PROCESSING OF GOODS
    • Y02P10/00—Technologies related to metal processing
    • Y02P10/25—Process efficiency

Definitions

  • the present invention relates to an apparatus and a method for producing a three-dimensional object by means of a generative production method.
  • the three-dimensional object is produced in layers by applying layers of a construction material and connecting them at the points corresponding to the cross section of the object.
  • a device for the layer-by-layer production of a three-dimensional object by selective laser sintering is known for example from EP 0 734 842.
  • a first layer of a powdery material is applied to a lowerable carrier and irradiated at the locations corresponding to the object, so that the material sinters there.
  • the carrier is then lowered and a second layer is applied to this first layer and in turn selectively sintered, which is bonded to the first layer. This creates the object in layers.
  • the application of layers of a building material does not mean an independent flow of the material into the space between the container bottom and the carrier, as is described, for example, in DE 199 57 370.
  • the object of the present invention is to increase the production speed of a device for the layer-by-layer production of three-dimensional objects and the productivity of an associated method. This object is achieved by the device characterized in claim 1 and the method characterized in claim 17.
  • Fig. 1 is a side view of a device according to a first embodiment of the present invention.
  • FIG. 2 shows a top view of a device according to a second embodiment of the present invention
  • FIG. 3 shows a perspective illustration of a device according to a second embodiment of the invention
  • FIG. 4 shows a top view of a device according to a third embodiment of the present invention.
  • FIG. 5 shows a perspective illustration of a device according to a third embodiment of the invention.
  • FIG. 1 shows a cross-sectional view of a device for the layer-by-layer production of three-dimensional objects according to a first embodiment of the invention.
  • the device does not necessarily have a construction area 2 shaped cross section. This is occupied by a construction container 4 which is open at the top and has an outer boundary surface 17 and an inner boundary surface 16.
  • a construction platform 6 serves as the lower limit of the construction container 4 and is designed in such a way that it completely fills the area between the inner boundary surface 16 and the outer boundary surface 17.
  • the construction platform 6 has on its inner edge a seal 19 for sealing the gap between the inner boundary surface 16 and the construction platform 6.
  • the construction platform 6 has on its outer edge a seal 18 for sealing the gap between the outer boundary surface 17 and the construction platform 6.
  • the provision of an inner boundary surface 16 is not absolutely necessary. If there is only an outer boundary surface 17, the building container 4 has no recess in its center and the building platform 6 has no hole in the middle.
  • the construction platform 6 is connected to a vertical drive 15, which enables the construction platform 6 to move up and down in the vertical direction.
  • the entire building container 4 is connected to a drive 20 which sets the building container 4 in motion about an axis of rotation 3 coinciding with the axis of symmetry of the building container 4.
  • the connection between the construction container 4 and the drive 20 is designed so that it can be released immediately below the construction container 4, so that the construction container 4 can be removed from the construction area 2.
  • a material application device 7 for applying the material to be applied to the building platform. arranged terials. This extends in the radial direction over the maximum radial extent of the building container.
  • a solidification device in the form of a laser 21 and a deflection unit 22 is arranged above the material application device 7.
  • the deflection unit is suitable for directing the laser beam to any location within a consolidation area 11.
  • the deflection unit is preferably an xy scanner.
  • the consolidation area 11 is a partial area that is stationary relative to the position of the material application devices within the construction area 2 and is located at the level of the layer deposited by the material application devices.
  • the laser 21, the deflection unit 22, the vertical drive 15 and the drive 20 are connected to a controller 23. 1 shows a formed object 24, which is surrounded by non-solidified material 25.
  • the building platform 6 is first positioned so that its top surface is flush with the upper edge of the building container 4. Thereafter, the controller 23 starts the movement of the building container 4 about the axis of rotation 3 at a uniform speed by the drive 20, the material application device 7 applying material to be solidified to the building platform 6. Then the exposure process is started by the laser. This solidifies the material at selective locations within a fixed solidification area 11, under which the building container 4 moves. The material is applied by the material application device 7 in such a way that the applied layer when it enters the laser radiation covered hardening area 11 has a predetermined thickness d and can take place automatically without the involvement of the controller.
  • controller 23 controls the vertical drive 15 in such a way that the building platform is lowered by the amount of the layer thickness d during a full revolution of the building container. During each revolution of the building container 4, the material applied at points outside the solidification area 11 is now solidified in the solidification area 11.
  • the advantage of this embodiment is that during the solidification of the applied material in one surface area of the object (s) to be manufactured, new material is applied in other surface areas of the object (s) to be manufactured.
  • the parallelization of material application and consolidation increases productivity when manufacturing objects. There are no idle times during which the material is dosed, stored and tempered and no solidification can take place.
  • the relative movement of the application device 7 to the building container 4 is always only in one direction. Among other things, this results in a higher temperature constancy, which leads to a number of advantages, e.g. a higher process reliability and a higher precision as well as the distortion and tension free of the components.
  • the size and the number of objects to be manufactured are not limited by the area covered by the deflection unit. The device is therefore suitable for the series production of large numbers of components with the same properties
  • Second embodiment A second embodiment differs from the first embodiment in that a plurality of consolidation devices 1 and a plurality of material application devices 7 are present. Each consolidation device is assigned to a material application device 7 and a consolidation area within the construction area 2. 2 shows an example of a plan view of a device with four solidification areas 11, 12, 13, 14, which are each present between the material application devices 7 and 8 or 8 and 9 or 9 and 10 or 10 and 7.
  • the operation of a device according to the second embodiment of the invention differs from the operation of a device according to the first embodiment in that the applied layer of material is solidified in all areas of consolidation at the same time.
  • the material applied by the material application device 7 is solidified in the consolidation area 11
  • the material applied by the material application device 8 is solidified in the consolidation area 12
  • the material applied by the material application device 9 is solidified in the consolidation area 13
  • the material applied by the material application device 10 is solidified in the solidification area 14.
  • Each of the material application devices deposits the material with a layer thickness d.
  • n denotes the number of consolidation areas present
  • FIG. 3 shows only one of the consolidation devices 1.
  • a first modification of the device according to the first or second embodiment has a drive 20 which is able to change the circulating speed in stages or continuously during the circulation of the building container.
  • the rotational speed of the building container about the axis of rotation 3 is increased if material of an applied layer that is not to be solidified passes through the hardening area 11.
  • the production speed can thereby be increased since the time period during which no building material is solidified is shortened.
  • the circulating speed of the building container is preferably varied as a function of the expansion of the partial areas of the applied layer to be solidified. The result of this is that the current rotational speed is determined by the expansion of the largest partial area of the applied layer to be selectively solidified within one of the hardening areas. If this maximum possible circulation speed is always set as the circulation speed of the building container, this leads to an increase in the production speed. Modification 2 of the first and second embodiments
  • the mode of operation is changed such that the thickness d of the layer deposited by the material application devices is varied.
  • the lowering speed of the building platform 6 is adapted to the thickness d 'of the layer deposited in a partial area of the building area 2.
  • the layer thickness can thus be adapted to the local geometric requirements of the part to be built. If, for example, an increased detail resolution is required locally, one or more layers with a smaller thickness can be applied. The building process can thus be optimized.
  • the drive 20 is not connected to the building container 4 but to the consolidation devices 1 and the material application devices 7, 8, 9, 10.
  • the building container 4 therefore maintains its position, while the drive 20 allows the consolidation devices 1 and the material application devices 7, 8, 9, 10 to move with respect to the building container 4 about the axis of rotation 3. It is of course also conceivable that both the consolidation devices 1 and the material application devices 7, 8, 9, 10 and the construction container 4 execute a movement against one another.
  • Modification 4 of the first and second embodiments In the case of a fourth modification of the first and second embodiment, the building platform cannot be lowered continuously, but in stages, ie the lowering takes place, for example, after solidification has been completed. This has the advantage that the focusing of the laser beam on the layer to be solidified is simplified since the layers applied are thereby parallel to the horizontal plane.
  • Figures 4 and 5 show a third embodiment of the invention.
  • the third embodiment differs from the second embodiment in that the building container 4 is replaced by a plurality of building containers.
  • the construction area is exemplarily occupied by four construction containers 4a, 4b, 4c, 4d.
  • Each of the construction containers 4a or 4b or 4c or 4d has a construction platform 6a or 6b or 6c or 6d and has an outer boundary surface 17, an inner boundary surface 16 and lateral boundary surfaces 26.
  • a construction platform 6a or 6b or 6c or 6d serves as the lower boundary of the building container 4a or 4b or 4c or 4d and extends between the outer boundary surface 17, the inner boundary surface 16 and the lateral boundary surfaces 26.
  • the gap between the construction platform and the boundary surfaces are sealed by a seal analogous to the previous embodiments.
  • the horizontal cross-sectional areas of the individual building containers can have any shape and do not necessarily have to be identical.
  • a plurality of material application devices 7, 8, 9, 10 for applying building material to the building platforms 4a, 4b, 4c, 4d are arranged about the axis of rotation 3 above the building area 2.
  • the number of material application devices preferably corresponds to the number of building containers.
  • a plurality of deflection units 22 and / or lasers 21 are arranged above the material application devices 7, 8, 9, 10. Each of the deflection units is suitable for directing the laser beam to any location within a solidification area assigned to the deflection unit.
  • Each deflection unit is assigned to a hardening area within the construction area 2.
  • the number of building containers preferably corresponds to the number of consolidation areas.
  • 4 shows an example of a plan view of a device with four solidification areas 11, 12, 13, 14, which are each present between the material application devices 7 and 8 or 8 and 9 or 9 and 10 or 10 and 7.
  • the construction platform 6a or 6b or 6c or 6d is each connected to a vertical drive 15a or 15b or 15c or 15d, not shown in the figures, which enables the construction platform to move up and down in the vertical direction.
  • a vertical drive 15a or 15b or 15c or 15d not shown in the figures, which enables the construction platform to move up and down in the vertical direction.
  • the connection between the vertical drive and the construction container is detachable immediately below the construction container, so that each of the construction containers can be removed from the construction area 2 independently of the other construction containers.
  • a single vertical drive 15 can also be present, to which all construction platforms 6a, 6b, 6c, 6d are connected.
  • All building containers 4a, 4b, 4c, 4d are connected to a drive 20, which can set the building containers 4a, 4b, 4c, 4d in synchronism with each other in a movement around the axis of rotation 3.
  • the lasers 21, the deflection units 22, the vertical drives 15a, 15b, 15c, 15d, and the drive 20 are connected to a controller 23.
  • the controller 20 causes the drive 20 to move the building containers 4a, 4b, 4c, 4d synchronously at a constant speed around the axis of rotation 3.
  • the material application devices 7, 8, 9, 10 apply material to be solidified to the construction platforms 6a, 6b, 6c and 6d.
  • the applied material layer is solidified in all areas of consolidation at the same time.
  • the material applied by the material application device 7 is solidified in the consolidation area 11
  • the material applied by the material application device 8 is solidified in the consolidation area 12
  • the material applied by the material application device 9 is solidified in the consolidation area 13
  • the material applied by the material application device 10 is solidified in the solidification area 14.
  • Each of the material application devices deposits the material with a layer thickness d.
  • the drives 15a, 15b, 15c, 15d are controlled in such a way that each of the construction platforms 4a, 4b, 4c, 4d is lowered four times the layer thickness 4 xd during one revolution of the associated construction container.
  • n denotes the number of consolidation areas present, then the respective construction platforms must be reduced by n times the layer thickness nxd during one revolution of the associated construction container.
  • the advantage of the third embodiment results from increased flexibility.
  • the device can be used with only a subset of the building containers, even with only one building container operate.
  • the construction platforms cannot be lowered continuously, but in stages, i.e. the lowering takes place, for example, after solidification is complete in all hardening areas.
  • This has the advantage that the focusing of the laser beam on the layer to be solidified is simplified since the layers applied are thereby parallel to the horizontal plane.
  • the layer thickness of the applied layer in the different building containers can be selected differently. This goes hand in hand with a different lowering speed of the building platforms in the different Bau josern. This allows objects with different layer thicknesses to be produced in parallel.
  • the building containers do not execute a rotational movement with respect to an axis of rotation 3. Instead, a guide drive 27 guides the building containers synchronously around the axis of rotation 3 only on a closed, not necessarily circular path. If the device has n material application devices and n consolidation areas, the web preferably corresponds to the edge of an n-corner. Optionally, each building container executes an additional rotary movement on its path around the axis of rotation 3 about an axis of rotation 3 ′ passing through it and parallel to the axis of rotation 3.
  • Modification 5 of the third embodiment in a fifth modification of the third embodiment, analogously to modification 1 described above, the device has a drive 20 which is able to change the rotational speed in stages or continuously during the rotation of the building container.
  • the current rotational speed can be adapted to the extent of the largest partial area of the applied layer to be selectively solidified within one of the hardening regions. If this maximum possible rotational speed is always set as the rotational speed of the building container, this leads to an increase in the production speed.
  • the drive 20 is not with the building containers 4a, 4b, 4c, 4d, but with the deflection units 22 and the material application devices 7,
  • the laser and the deflection unit instead of the laser and the deflection unit, other radiation sources, such as a Electron beam, microwave radiation, a lamp in connection with a mask, LEDs and other exposure arrays etc. or other solidification devices such as binder and adhesive applicators can be used.
  • a Electron beam microwave radiation
  • a lamp in connection with a mask LEDs and other exposure arrays etc.
  • solidification devices such as binder and adhesive applicators
  • the device and methods described above can also be used in various additive manufacturing processes, such as. B. selective laser sintering, especially of polymers, stereolithography, the LOM process (Laminated Object Manufacturing), the FDM process (fused model deposition) or three-dimensional printing (solidifying powdery material by means of an adhesive or by means of a chemical reaction, in particular by using multicomponent systems made of binder / hardener or by melting thermoplastic), in which the three-dimensional object is produced in layers by applying layers of a construction material and connecting them at the points corresponding to the cross section of the object.
  • B. selective laser sintering especially of polymers, stereolithography, the LOM process (Laminated Object Manufacturing), the FDM process (fused model deposition) or three-dimensional printing (solidifying powdery material by means of an adhesive or by means of a chemical reaction, in particular by using multicomponent systems made of binder / hardener or by melting thermoplastic), in which the three-dimensional object is produced in layers by applying layers of a construction material and connecting

Abstract

L'invention concerne un dispositif et un procédé pour la production générative par couches d'objets tridimensionnels par solidification sélective d'un matériau structurel liquide ou poudreux pouvant être solidifié. Grâce à un mouvement de rotation de la zone de réalisation (2), dans laquelle les objets doivent être produits, par rapport à un dispositif d'application de matériau (7) servant à appliquer des couches du matériau structurel et à un dispositif de solidification (1), il est possible d'utiliser le dispositif d'application de matériau (7) et le dispositif de solidification (1) simultanément à des emplacements différents de la zone de réalisation.
EP03784136A 2002-08-02 2003-07-31 Dispositif et procede pour produire un objet tridimensionnel au moyen d'un procede de fabrication generatif Withdrawn EP1526964A1 (fr)

Applications Claiming Priority (3)

Application Number Priority Date Filing Date Title
DE10235434 2002-08-02
DE10235434A DE10235434A1 (de) 2002-08-02 2002-08-02 Vorrichtung und Verfahren zum Herstellen eins dreidimensionalen Objekts mittels eines generativen Fertigungsverfahrens
PCT/EP2003/008520 WO2004014637A1 (fr) 2002-08-02 2003-07-31 Dispositif et procede pour produire un objet tridimensionnel au moyen d'un procede de fabrication generatif

Publications (1)

Publication Number Publication Date
EP1526964A1 true EP1526964A1 (fr) 2005-05-04

Family

ID=30128673

Family Applications (1)

Application Number Title Priority Date Filing Date
EP03784136A Withdrawn EP1526964A1 (fr) 2002-08-02 2003-07-31 Dispositif et procede pour produire un objet tridimensionnel au moyen d'un procede de fabrication generatif

Country Status (7)

Country Link
US (1) US8172562B2 (fr)
EP (1) EP1526964A1 (fr)
JP (1) JP4790264B2 (fr)
CN (1) CN1678448B (fr)
DE (1) DE10235434A1 (fr)
HK (1) HK1081489A1 (fr)
WO (1) WO2004014637A1 (fr)

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US20060108712A1 (en) 2006-05-25
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HK1081489A1 (en) 2006-05-19
WO2004014637A1 (fr) 2004-02-19

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