FR3075079A1 - METAL ADDITIVE MANUFACTURING WORKSHOP - Google Patents

Abstract

 The metal additive manufacturing workshop (100) comprises, on the one hand, at least one main module (1), which can be handled and transported, to confine a metal additive manufacturing machine (16) and the metal powder for the machine and, on the other hand, additional modules (2 to 4), which can be handled and transported, to receive other equipment, from the workshop (100), said modules (1 to 4) being arranged from containers of the maritime type.

Description

The present invention relates to a metal additive manufacturing workshop, in particular for manufacturing metal parts individually or in small series, quickly remanufacturing broken parts, repairing and renovating them, adding shapes and functionality to an existing part, for example by adding one or more layers of metal, making prototypes and redesigning parts.

Metallic additive manufacturing, known as "FAM", uses metallic powders. It has benefited from advances in metallurgy which have made it possible to obtain atomized metals in a pulverulent form which is suitable for manufacturing by layers. It has also benefited from the applications of laser welding to layer manufacturing and from advances in layer fusion by electron beams displaced by electromagnetic deflection. This production appeared in the 1990s by applying to metal powders the principle of laser fusion of polymer powders. The range of available materials has grown considerably over time. By way of example, mention may be made of titanium alloys, nickel-based superalloys, chromium-cobalt alloys, aluminum, steels, stainless steels or copper. Metal additive manufacturing is interesting for industry and has many applications, for example, in metallurgy, aeronautics, transport, energy and maintenance.

There are several metallic additive manufacturing technologies. The three main types of process used are:

- the wire deposition processes of linked metal powders;

- processes for spraying fused powders directly onto the part; and

- laser sintering processes on a powder bed.

[0004] The methods of depositing by wire bonded metal powders require post-treatment of the parts in a sintering furnace to allow the metal powder to melt. This technology is interesting in terms of prototyping and presents few industrial risks. The methods of spraying fused powders directly onto the part are advantageous for the modification of function or maintenance.

The laser sintering processes on a powder bed are the most common and the most promising for metal additive manufacturing. They benefit from advances in 3D printers and can produce parts made of high-quality steel, aluminum, pure titanium, a nickel-titanium-based alloy, and other metals.

For example, it is known in particular the process known as "SLM" ("Selective Laser Melting" in English and "selective laser fusion" in French) and that known as "DMLS" ("Direct Métal Laser Sintering" in English and "direct laser sintering of metal" in French). Also known is a selective fusion process carried out by electron beams called "EBM" ("Electron Beam Melting" in English).

These methods present the need to control the risks associated with the presence of metal powders. In particular, the formation of an explosive atmosphere must be prevented (ATEX risks). Otherwise, ignition sources must be eliminated and measures taken to mitigate the effects of such an explosion, which unlike a fire is instantaneous combustion. It is also necessary to prevent chemical risks (CMR risks) also linked to the presence of powders. These ATEX and CMR risks are the subject of standards whose compliance is imperative.

[0008] Metal additive manufacturing is constantly changing. Thus, originally the SLM process made it possible to melt powder particles made up of pure metal such as titanium or aluminum, while the DMLS process sintered powders pre-alloyed together, such as for example steels stainless or superalloys. Currently, the SLM process is also used for the manufacture of pre-alloyed metals.

FAM technology has reached maturity and has its place in the factory of the future. The interest aroused by the FAM is important, because an excellent metallurgical quality of the parts is obtained, a reduction in material losses, a reduction in the tools required and a direct digital transition from the model to the part, which can be optimized or be of complex shape without welding or assembly. Thus, for example, FAM can be used for the production of a single copy of a part or for micro-production. FAM technology provides an efficient response to the mechanical manufacturing needs of manufacturers, particularly in terms of maintenance and production of prototypes.

The FAM offers many advantages, among which:

a weight gain of the parts produced, up to 60%;

- the creation of recesses in the rooms which allow weight gain and better cooling;

- the reduction in the number of parts to be assembled by welding up to 90%, which significantly reduces the fatigue of parts with aging;

- the possibility of integrating from the manufacturing of the internal pipes and of facilitating the heat exchanges and the passage of various fluids;

- the possibility of making unitary and specific parts (such as tools) allowing to increase the agility of the company, as well as production gains of more than 6 months compared to conventional processes;

- the design of very specific parts, impossible to achieve with traditional means;

- rapid repair and maintenance of broken parts and / or renovation thereof;

- redesign of the parts, in particular by adding functions or forms to an existing part;

- the production of industrial prototypes and micro-production.

Significant training needs exist for FAM technology. The FAM design, also called DFAM (“Design For Additivé Manufacturing” in English), must be integrated into existing training, in particular engineering training, with also lessons on ATEX and CMR risks, as well as on metallurgy of powders and condensed matter.

Access to FAM technology is however expensive, not only because of the high cost of the machine and FAM manufacturing means proper, but also because of the need to have suitable premises for the development of '' a workshop capable of accommodating several people and integrating a manufacturing enclosure, with the required levels of security.

It is desirable to offer economical solutions which can facilitate access to FAM technology, in particular to meet training needs, possibly by offering a possibility of pooling the facilities.

The invention relates to a metal additive manufacturing workshop in which there is provided, on the one hand, at least one main module, which can be handled and transported, to confine a metal additive manufacturing machine and the metal powder for the machine. metal additive manufacturing and, on the other hand, additional modules, which can be handled and transported, to receive other workshop equipment, in particular post-processing equipment for the parts produced and at least one computer for controlling the machine, and in which the modules are arranged from containers of the maritime type.

Thanks to the invention, a flexible, modular and transportable workshop is obtained, in particular by truck, from one place to another, which offers new possibilities in terms of pooling of facilities. In addition, the proposed solution is economical, because it is feasible with containers of the maritime type, which are easily and quickly stowed with each other and transportable in particular by truck.

According to other characteristics taken individually or in combination:

the manufacturing machine is a 3D printer having at least one laser for laser sintering of the metal powder;

- the other equipment in the additional modules is notably linked to ATEX risks, the main module comprising a vacuum zone;

- the additional modules are arranged to form a U-shaped configuration which surrounds the main module;

- a first wing of the U is a post-treatment zone for the raw parts manufactured by the machine, which accommodates additional equipment necessary for the finishing of the raw manufactured parts, in particular a sandblasting machine, a stress relieving oven for the parts manufactured by the machine, a milling machine, band saw or workbench;

- a bottom of the U is a visit and / or work area which includes at least one computer;

- the main module includes filters accessible from the outside and a second wing of the U has entry doors and is configured to form a protected area around the filters;

- it is added next to the second wing of the U an additional technical module of the maritime container type, which includes in particular a waste water plant of the main module, bottles of argon / nitrogen and an electrical cabinet for the electrical supply of equipment ;

- it is added next to the second wing of the U, comprising the post-processing area, an additional module of the maritime container type in particular for storing the parts produced and / or serving as a meeting room;

- airlocks may be provided to ensure circulation between the different modules;

- the equipment and connections of the various modules include quick and / or waterproof connection / disconnection means;

- the manufacturing machine is a 3D laser printer of the Formllp 350 type (registered trademark) marketed by the company ADDUP and the main module is of the ADDUP Flex Care System type (registered trademark) also marketed by the company ADDUP.

Thanks to these provisions, the workshop makes it possible to manage the entire industrial process of metal additive manufacturing, all the industrial risks are managed, in particular the ATEX and CMR risks, and the workshop is flexible, transportable and installable in different environments.

Other advantages and characteristics of the present invention will appear more clearly on reading the description below of several particular embodiments with reference to the accompanying drawings, in which:

- Figure 1 is a schematic view of the metal additive manufacturing workshop according to the invention; and

- Figure 2 is a partial view showing a variant of the workshop of Figure 1 in which we added an additional technical container including the electrical cabinet, the wastewater tank and the bottles of argon / nitrogen gas from figure 1 ; and

- Figure 3 is a partial view showing another variant of the workshop of Figure 1 in which we added an additional container for example for a meeting room.

In the figures, identical or similar elements will have the same references.

Referring to Figure 1, we see in 100 the metal additive manufacturing workshop according to the invention, which is a flexible workshop, modular and transportable, in particular by truck, from one place to another. This workshop is configured to be waterproof and implantable on an outdoor site.

The workshop 100 may use one of the aforementioned metal additive manufacturing technologies, in particular the laser sintering technology on a powder bed.

Thus, as shown in Figure 1, the workshop 100 uses metal powder and a metal additive production machine 16, such as a 3D printer with at least one laser. This machine 16 makes it possible to make the workshop flexible, that is to say quickly reconfigurable according to production constraints. It allows in particular a micro-production, a diversification of the products to be manufactured and a rapid change of production, which can be unitary for example to remake a part, repair it or manufacture a prototype. With this machine 16, the workshop 100 has the aforementioned advantages.

According to one characteristic, this workshop 100 comprises at least one main module 1, in which the machine 16 is mounted and the metal powder is stored for the machine 16. The module 1 can be handled and transported and here in a standardized format of sea container. The module 1 may advantageously have an area that is entirely under vacuum to prevent powder leaks to the outside, and thus encapsulate the ATEX risk. Machine 16 can work in module 1 under an inert atmosphere (argon / nitrogen) to prevent ATEX risks. This module 1, ATEX standards, will also be configured to be CMR standards, as described below. It follows from these provisions, according to another characteristic, that the machine 16 and the metal powder are confined inside the module 1 which is similar to a confinement enclosure. The arrangements around the machine 16 and the metal powder, and including these, form the heart of the workshop 100.

According to yet another characteristic, there is provision (FIG. 1) for another structure of complementary modules 2 to 4 which can be manipulated and transported to receive the other equipment of the workshop 100 not linked to those of module 1, such as the post processing of the manufactured parts and at least one computer or computer station 31 for controlling the machine 16. These modules are also arranged from containers of the maritime type.

Thus, in combination, there is provided on the one hand at least one main module 1, which can be handled and transported, to confine a metal additive manufacturing machine 16 and the metal powder for the machine 16 and, on the other hand, additional modules 2 to 4, which can be handled and transported, to receive other equipment from the workshop 100, in particular for post-processing of the manufactured parts, and at least one computer 31 intended in particular for controlling the machine 16, said modules 1 to 4 being containers of the maritime type.

More specifically, the additional modules 2 to 4 can receive the other equipment in the workshop 100 not related to ATEX risks, such as computers 31, as well as the post-processing of the manufactured parts, and also secure access to main module 1.

This structure of additional modules 2 to 4 will secure access, manage traffic for maintenance and deliveries. It will make it possible to comply with fire safety standards (abbreviation SSI), in particular to manage automatic extinction, smoke extraction, stopping the machine 16 and / or electrical installations, door release and evacuation people.

Thus, the modules 1 to 4 equipped make it possible to manage and control the entire industrial process of metal additive manufacturing up to post-treatment, which may be contained in module 2 of Figures 1 and 3. This module constitutes a area which can accommodate the additional equipment necessary for the finishing of the raw parts manufactured by the machine 16.

The complementary modules 2 to 4 may be arranged in the shape of a U. The main module 1 is located inside the U formed by the complementary 2 to 4. Alternatively, as shown in Figures 2 and 3, additional modules 5 and 6 which can be handled and transported can be added. These additional modules 5, 6 are also arranged from shipping containers, as described below. Thus, the workshop 100 is expandable via these additional modules 5, 6. Airlocks may be provided to ensure circulation between the different modules.

According to one characteristic, these additional modules 2 to 4 and additional 5, 6, are configured at the level of their structure to be assembled and dismountable, on the one hand, between themselves and on the other hand with the structure of module 1 containment of the machine 16.

Thus, the workshop building is based on an economical modular structure which is advantageously made from shipping containers. As is known, a sea container, generally of parallelepiped shape, is waterproof, easy to handle, transportable and stackable, and is suitable for being assembled and stowed quickly with other containers. The shipping container is standardized and is sized and configured to be transportable by truck and boat.

The maritime container has a lower structure, forming its base, comprising, on the one hand, a lower metal frame, generally rectangular in shape, consisting of lower side members and lower end cross members and, on the other hand, a floor, especially of wood, covering the lower frame. On some models, the lower beams have passages for forklifts. Additional sleepers are also provided to support the floor. The container also has an upper structure comprising an upper metal frame, generally rectangular in shape, consisting of upper side members and upper end cross members. This upper frame is covered with a corrugated iron roof. Metal uprights, side walls made of corrugated sheets for better strength of the containers, and doors constitute the mechanical connection between the lower structure and the upper structure. Eight corners, called ISO corners or "Corner Casting" in English, are distributed to the eight corners of the container. These corners are generally in the shape of a perforated steel cube so that the container can be transported, moved or stowed easily with other containers. Thus, the container can be moved using forklifts, a gantry crane or a jumper. It can be quickly stowed with other containers, on the platform or chassis of a truck, on the deck of a boat or placed on a ground support on an outdoor site.

In their original state, the shipping containers have watertight doors at the front. They can also have watertight doors on the back. These waterproof maritime containers can be converted and it is known to use them for the construction of houses and buildings. The container walls are then provided with windows, doors, glass walls and the like. Containers can be fitted internally with electrical circuits, water circuits, heating, air conditioning, etc.

The invention recommends using available shipping containers and transforming them to carry out the workshop 100 economically. As a variant, the containers will not be transformed, but will be manufactured new and supplied fitted out of the factory.

In general, modules 1 to 6 therefore have the standardized structure of shipping containers. It should be noted however that for certain embodiments the containers may be made to measure with specific dimensions.

Depending on the applications, modules 1 to 6 will be placed directly outside on the ground or on a slab. As a variant, modules 1 to 6 can be placed on elevation means, for example, to prevent risks of flooding or to meet specific constraints relating to the condition of the soil.

With these modules 1 to 6 of the maritime type, the workshop 100 can be transportable and installable outside in several types of environment, for example, in different manufacturing sites of a company, training centers technical or otherwise. The metal additive manufacturing workshop according to the invention can thus be shared by being transportable from one geographic site to another.

To offer these advantageous characteristics of flexibility and transportability, the workshop 100 must be designed, in terms of its equipment, connections, in particular hydraulic and electrical supply, fire safety system (SSI) and others, so as to guarantee easy disassembly and reassembly. The connections will preferably be provided outside of modules 1 to 6 and will be chosen and arranged so as to allow rapid connections / disconnections, while ensuring the necessary seals. Temporary fixed and mobile installations such as power stations for communities, campsites, marinas, markets, fairgrounds and others can be used. In these installations, the electrical equipment, in particular the electrical sockets, must imperatively be ATEX 22 standardized, and the same applies to valves and fluid circulation conduits. The fluid conduits may include hoses.

In order to be able to be transported without mechanical bending liable to cause damage, the modules 1 to 6 can incorporate cross braces of the Saint Andrew's cross type, in particular at the level of the fluid valves and the connections of the hoses so as to ensure their stability. The various equipment can be securely stowed directly on the containers, reinforcements can be attached for travel.

First embodiment In this embodiment (FIG. 1), the workshop 100 uses laser sintering technology on a powder bed and comprises modules 1 to 4 in the form of containers 1 to 4 of the type which are assembled together at their corners. The equipment, connections and supplies of the various containers being, as mentioned above, configured to be separable and reassociable easily and quickly between them.

The workshop 100 includes for this purpose the module 1, which contains and confines the additive manufacturing machine 16. The additive manufacturing machine 16 is here for example a 3D printer, with at least one laser, such as the Formllp 350 printer (registered trademark) sold by the company ADDUP. Such a 3D printer allows fast, reliable and precise manufacturing from CAD (computer-aided design) data. Module 1, of the maritime container type, comprises, projecting outwards, filters 18 responsible for filtering particles in the air, relative to the ATEX risk.

There are provided, as mentioned above, three additional modules 2, 3, 4 of the maritime container type which are arranged in a U-shape. The modules 2 and 4 constitute the wings of the U, while the module 3 constitutes the bottom of the U. The module 1 containing the machine 16 is located inside the U. Passages (not referenced) exist between the wings 2, 4 and the bottom 3 of the U. Thus, the modules 2 to 4 surround the faces side panels and the front face of module 1. In this example, modules 2 and 4 have the same standard container length. As a variant, one of the modules 2, 4 could have a standard length of container different from the other.

As mentioned above, the module 2 is a post-processing area for the raw parts produced by the machine 16, which will be able to accommodate additional equipment necessary for the finishing of the raw manufactured parts, such as a sandblaster used in particular for takeoff of the manufactured parts from their metal plate, a stress relieving oven for the parts manufactured by the machine 16, here in an inert atmosphere (argon / nitrogen), a milling machine, a band saw or a workbench.

The module 3 is a visit and / or work area and can host a work area with computers 31. CAD software, CFAM and / or control of the machine 16 can be installed in the computers 31. The module 3 is provided with doors (not referenced) located on either side of the computers 31. The front face 32, or storefront, of the module 3 is preferably glazed, for example at the level of the work where computers are installed 31.

The module 4 has entry doors 41 and is configured to constitute a protected area around the filters 18, which are subject to regular maintenance and replacement operations for compliance with the ATEX standard. The doors of zone 3 and doors 41 are secure, and ordered to open automatically in the event of a fire. These doors allow controlled access to workshop 100, for example using badges. Doors 41 are the main entrance to workshop 100 here. They are used to manage entrances for maintenance and deliveries.

According to a particular embodiment, the module 1 incorporating the machine 16 and the filters 18 is a system of the type sold under the registered trademark ADDUP Flex Care System by the company ADDUP, which is of the shipping container type. This type of system makes it possible to "encapsulate" and manage the ATEX risk around the machine 16 while avoiding any leakage of powder, and has the advantage of being modular and transportable.

Thus, module 1 essentially contains the following sub-assembly and equipment:

- a first airlock 11, which allows the operator to dress in safety equipment;

- a second airlock 12 equipped with a sink that can be used by operators, in particular to free themselves from powder residues on their hands;

- a vacuum zone 13, in one piece, which is an ATEX risk encapsulation zone and which in particular receives the following equipment: the machine 16, a powder sieve shaker (not referenced) for reusing the recovered powder in production , an ATEX vacuum cleaner 14 to eliminate during maintenance the released powders, an ATEX powder storage cabinet (not referenced), a washing machine 15 arranged in a flat pass for discharging the metal trays of the parts manufactured by the machine 16;

- a glazed box 17 which makes it possible to go around the machine 16; and

- filters 18.

Note that the module 1 is preferably equipped with dual-flow air conditioning.

The ADDUP Flex Care System is designed to be installed inside a production workshop. When such a system is adopted for module 1 and is integrated into the workshop according to the invention, it is the subject of an adaptation to allow its use on an outdoor site, in particular in terms of sealing.

At the rear of module 1, a central 19 air treatment unit (CTA) is installed, in particular for air renewal and heating, a tank 20 for recovering waste water from module 1, bottles 21 of argon / nitrogen gas, a sealed electrical cabinet 22 for 220 V single-phase and 400 V three-phase electrical supply of the various equipment, an oxygen meter (not shown) for safety control. There is also a grid 23 for accessing these external equipment 19 to 22.

Securing access to module 1 is carried over to module 4.

The workshop 100 includes various sensors linked to the security and technical management systems of the workshop, such as, for example, RFID badge access sensors, fire, temperature and filling level sensors. tank 20 sewage, etc. An autonomous fire safety system (SSI) and a dual-flow air conditioning system equip the workshop here. This module 1 meets ATEX standards and health and safety standards, in particular CMR standards.

Second embodiment As shown in Figure 2, it is added next to module 4 an additional technical module 5, which can integrate different equipment such as the central 19, the tank 20, the bottles 21 and the cabinet 22, as well as the oxygen meter, mentioned with reference to FIG. 1. The module 5 is of the maritime container type as mentioned above. A communication passage (not referenced) is present between modules 4 and 5. Modules 4 and 5 may be the same size or, alternatively, may be of different size. In FIG. 2, a tank 51 for recovering the waste water from module 1 is shown, bottles of argon / nitrogen 52 and an electrical cabinet 53.

Third embodiment As shown in Figure 3, it is added, next to module 2, an additional module 6 of the maritime container type to in particular store the parts produced and / or serve as a meeting room. The modules 2, 6 may have the same size and, as a variant, be of different size. A communication passage (not referenced) is present between modules 2 and 6. Module 6 can also be added in the embodiment of FIG. 1 and / or in the embodiment of FIG. 2.

Other embodiments The manufacturing machine 16 may also be an electron beam machine or a machine implementing methods of wire deposition of bonded metal powders or projection of fused powders directly on the part.

The workshop may include at least two modules, each comprising a manufacturing machine 16. In this case, the modules can be stacked on top of each other.

Given the modular construction of the workshop 100, we can only move module 1 and transfer it to a place where modules 2 to 4 or 2 to 5 or 2 to 6 are already present.

In the embodiments of Figures 1 to 3, we can use modules 1 to 6 all having the same standard length or having different standard lengths. Thus, for example, modules 2 and 4 to 6 could each be formed with a container having the same standard outside length of 20 feet, while module 3 could be formed with a single container having a standard outside length of 40 feet or well two contiguous containers each having the same standard length of 20 feet.

Of course, the invention is not limited to the embodiments which have been described more particularly here by way of example. Those skilled in the art, depending on the applications of the invention, may make various modifications and variants which fall within the scope of the appended claims.

Claims (10)

1. Workshop (100) of metal additive manufacturing in which there is provided, on the one hand, at least one main module (1), which can be handled and transported, to confine a metal additive manufacturing machine (16) and the metal powder for said metal additive manufacturing machine (16) and, on the other hand, additional modules (2 to 4), which can be handled and transported, to receive other workshop equipment (100), in particular post-processing equipment for the parts produced and at least one computer (31) for controlling said machine (16), and in which said modules (1 to 4) are arranged from containers of the maritime type. 2. Workshop (100) according to claim 1, wherein said machine (16) is a 3D printer having at least one laser ensuring laser sintering of said metal powder. 3. Workshop (100) according to claims 1 or 2, wherein said other equipment of the additional modules (2 to 4) includes equipment related to so-called ATEX risks, said main module (1) comprising a zone (13) in depression. 4. Workshop (100) according to any one of claims 1 to 3, wherein said additional modules (2 to 4) are arranged so as to form a U-shaped configuration which surrounds said main module (1). 5. Workshop (100) according to claim 4, wherein a first wing (2) of the U is a post-treatment area of the raw parts manufactured by said machine (16), which accommodates equipment necessary for finishing the manufactured parts rough, in particular a sandblasting machine, a stress relieving furnace for the parts manufactured by said machine, a milling machine, a band saw or a workbench. 6. Workshop (100) according to claim 5, wherein a bottom (3) of the U is a visit and / or work area which comprises at least one computer (31). 7. Workshop (100) according to claim 6, wherein said main module (1) comprises filters (18) accessible from outside of said main module (1) and in which a second wing (4) of the U has doors inlet (41) and is configured to form a protected area around said filters (18). 8. Workshop (100) according to claim 7, wherein it is added next to said second wing (4) of the U an additional technical module (5) of the type 5 maritime container, which includes in particular a central unit (51) for wastewater from the main module (1), bottles (52) of argon / nitrogen and an electrical cabinet (53) for the electrical supply of equipment. 9. Workshop (100) according to claim 5, wherein it is added next to said first wing (2) of the U, comprising said post-treatment area, a 10 additional module (6) of the maritime container type, in particular for storing produced parts and / or serving as a meeting room. 10. Workshop (100) according to any one of claims 1 to 9, in which the equipment and the connections of the different modules (1 to 6) comprise quick and / or waterproof connection / disconnection means.