NL2018849B1 - Apparatus for producing an object by means of additive manufacturing and method of using the apparatus - Google Patents
Apparatus for producing an object by means of additive manufacturing and method of using the apparatus Download PDFInfo
- Publication number
- NL2018849B1 NL2018849B1 NL2018849A NL2018849A NL2018849B1 NL 2018849 B1 NL2018849 B1 NL 2018849B1 NL 2018849 A NL2018849 A NL 2018849A NL 2018849 A NL2018849 A NL 2018849A NL 2018849 B1 NL2018849 B1 NL 2018849B1
- Authority
- NL
- Netherlands
- Prior art keywords
- heating element
- build plate
- support
- heating
- building
- Prior art date
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Classifications
-
- 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
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- 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]
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- 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
- B22F12/90—Means for process control, e.g. cameras or sensors
-
- 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
- B29C64/20—Apparatus for additive manufacturing; Details thereof or accessories therefor
- B29C64/245—Platforms or substrates
-
- 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
- B29C64/20—Apparatus for additive manufacturing; Details thereof or accessories therefor
- B29C64/295—Heating elements
-
- 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
- B29C64/30—Auxiliary operations or equipment
- B29C64/379—Handling of additively manufactured objects, e.g. using robots
-
- 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
-
- 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
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- Engineering & Computer Science (AREA)
- Chemical & Material Sciences (AREA)
- Materials Engineering (AREA)
- Physics & Mathematics (AREA)
- Manufacturing & Machinery (AREA)
- Optics & Photonics (AREA)
- Mechanical Engineering (AREA)
- Analytical Chemistry (AREA)
- Automation & Control Theory (AREA)
- Plasma & Fusion (AREA)
- Robotics (AREA)
Abstract
Apparatus for producing an object by means of additive manufacturing, comprising: - a process chamber for receiving on a build surface of a build plate a bath of powdered material which can be solidified; - a support for supporting on a supporting surface thereof said build plate and positioning said build plate in relation to a surface level of said bath of powdered material; - a solidifying device for solidifying a selective part of said material; and - a heating element arranged for contacting a surface of said build plate for directly heating said build plate supported on said supporting surface. Method of producing an object by means of additive manufacturing
Description
Title: Apparatus for producing an object by means of additive manufacturing and method of using the apparatus
Description
According to a first aspect the invention relates to an apparatus for producing an object by means of additive manufacturing.
According to a second aspect the invention relates to a method of producing an object by means of additive manufacturing on a build surface of a build plate, using an apparatus according to the first aspect. 3D printing or additive manufacturing refers to any of various processes for manufacturing a three-dimensional object. The three-dimensional object may be produced by selectively solidifying, in a layer-like fashion, a powder, paper or sheet material to produce a three-dimensional, 3D, object. In particular, a computer controlled additive manufacturing apparatus may be used which sequentially sinters a plurality of layers to build the desired object in a layer-by-layer fashion.
One of the challenges in the manufacturing of three dimensional objects, in particular in additive manufacturing of metal objects, is achieving a relative high reproducibility of manufactured objects as regards geometric variations and mechanical properties such as residual stress. According to prior art practice, an object is manufactured on a build plate, wherein the build plate is heated to temperatures of about 200 °C by placing the build plate on a piston that can be heated.
It is an object of the invention to provide an apparatus for reducing residual stress differences between manufactured objects.
Thereto, the invention provides an apparatus according to claim 1. The apparatus comprises, a process chamber for receiving on a build surface of a build plate a bath of material which can be solidified, in particular a bath of powdered material that can be solidified in order to make metal products. A support is provided for supporting on a supporting surface thereof said build plate and positioning said build plate in relation to a surface level of the bath of material. A solidifying device, such as a laser device, for solidifying a layer of the material on the surface, in particular by means of electromagnetic radiation, is provided. To reduce residual stress differences between the manufactured objects a heating element arranged for contacting a surface of said build plate is provided for directly heating said build plate supported on said supporting surface. According to the invention the variation of residual stress is reduced by heating a surface of said build plate directly, by the heating element, supported on the supporting surface of the support. Direct heating of the build plate in this manner allows for a more uniform thermal profile within a single build plate, but additionally allows for a more uniform thermal contact between different build plates and the heating element, thereby allowing for a more uniform heat transfer between the heating element and the various build plates. It is an insight of the applicant that residual stress variations between objects are at least partly due to non-uniform temperature profiles in the build plate. Additionally, it was found that differences in thermal contact between the heated piston and different build plates causing temperature differences between the different build plates also plays a role. Differences in thermal contact are for instance due to geometric variations of the build plate and/or geometric variations of supporting surfaces between different apparatuses. A more uniform thermal contact between the heating element and a surface of the build plate reduces the variation of residual stress between manufactured objects.
Preferably said heating element is arranged for contacting said build plate at a side of said build plate opposite said build surface of said build plate. This allows for direct heating of said build plate supported on said supporting surface without interfering with the build surface of said build plate and allowing heating of the build plate during manufacturing of an object.
It is beneficial if said support comprises a push element for pushing said heating element against said surface of said build plate supported on said supporting surface. Said pushing element may be a spring element, such as a compression spring or an extension spring, for example, or any other means that is able to move said heating element onto said surface of said build plate supported on said supporting surface. With the term push element it is meant any element that is suitable for urging said heating element onto said surface, and explicitly comprises pulling elements as well. Pushing (or pulling) said heating element against said build plate is beneficial for realising a relatively high and predictable heat transfer between the heating element and the build plate, thereby reducing the variation of thermal contact between the heating element and different build plates.
It is beneficial if said heating element comprises an electrical heating element. An electrical heating element is beneficial for realising a relative large heating capacity in a relative compact way.
It is advantageous if said apparatus comprises a temperature measurement element for measuring the temperature of said build plate supported on said supporting surface. This is beneficial for determining temperature variations of the build plate before and during production of the object.
It is beneficial if said heating element comprises a temperature measurement element for measuring the temperature of said heating element. This allows for a direct feedback of the temperature of said heating element, with which the temperature of the build plate may also be better controlled.
In an embodiment, said support comprises an urging element for urging said temperature measurement element against said surface of said build plate supported on said supporting surface. Said urging element may be a spring element, such as an extension spring or a compression spring. Said temperature measurement element may be a temperature sensor that is connected to said support. The temperature measurement element may be connected to said support by means of said urging element. The urging element is arranged for urging said temperature measurement element away from said support, and towards said build plate. This way, the temperature measurement element is always in good thermal contact with said build plate, which provides more accurate results.
In this regard it is beneficial if said apparatus comprises a control unit, coupled for communication with said temperature measurement element and coupled for communication with said heating element, for controlling said heating element based on a temperature measurement of said temperature measurement element. This is beneficial for improving temperature control before and during production of the object to realise a more accurate temperature of the build plate, thereby reducing the variation of residual stress between manufactured objects.
In a practical embodiment said control unit is further arranged to control said heating element based on said temperature measurement and a predefined temperature of said build plate. This arrangement is beneficial for realising a relative accurate control of the temperature of said build plate. Preferably said control unit is a proportional-integral-derivative controller.
It is advantageous if said support comprises a cooling unit for cooling said support at a lower end of said support for reducing thermal expansion of thereof. Cooling said support by said cooling unit is beneficial for reducing thermal expansion of said support by said heating of said build plate. Reducing thermal expansion of said support allows for a more accurate positioning of said build surface of said build plate in relation to said surface level of said bath of powdered material.
In a practical embodiment said supporting surface comprises said heating element. Supporting said build plate at least partly by said heating element by comprising said heating element in said supporting surface allows for a further improvement of a more uniform thermal contact between different build plates and the heating element, thereby allowing for a more uniform heat transfer between the heating element and the various build plates.
It is beneficial if said apparatus comprises two or more of said heating elements for directly heating on two or more positions said build plate supported on said supporting surface. Heating said build plate on two or more positions allows for a more controlled temperature profile in said build plate. A more uniform temperature distribution in said build plate may thus be obtained, thereby allowing for a reduction of variation of residual stress between manufactured objects.
In this regard it is beneficial if said supporting surface is formed by said two or more of said heating elements. Supporting said build plate by said two or more heating elements by forming said supporting surface by said two or more heating elements allows for a further improvement of a more uniform thermal contact between different build plates and the heating element, thereby allowing for a more uniform heat transfer between the heating element and the various build plates.
It is advantageous if said apparatus comprises two or more of said temperature measurement elements for measuring the temperature of said build plate supported on said supporting surface on two or more positions. Measuring the temperature of said build plate at two or more positions allows for measurement of temperature variations over the build plate. It is additionally beneficial if said apparatus comprises two or more of said heating elements for directly heating on said two or more positions said build plate supported on said supporting surface. Heating said build plate on said two or more positions, i.e. on said two or more positions where said two or more temperature measurement elements are provided, allows for a more accurately controllable temperature profile in said build plate. This leads to an even more uniform temperature distribution in said build plate that may be obtained.
In a practical embodiment said temperature measurement element comprises a thermal imaging camera. A thermal imaging camera allows for measuring a temperature distribution over a surface of said build plate.
According to a second aspect the invention relates to a method of producing an object by means of additive manufacturing on a build surface of a build plate, using an apparatus according to the first aspect of the invention. The method comprises at least one of the steps of: placing said build plate onto said supporting surface of said support; heating said build plate by said heating element.
The advantages of the method according to the second aspect of the invention are analogue to the benefits of the apparatus according to the first aspect of the invention.
Embodiments of the invention will be described in the following wherein:
Fig. 1 is a schematic overview of an apparatus according to the present invention for additive manufacturing an object;
Fig. 2 is a schematic overview of a part of the apparatus of Fig. 1 in a first state;
Fig. 3 is a schematic overview of a part of the apparatus of Fig. 1 in a second state;
Fig. 4 is a schematic overview of an apparatus according to the present invention for additive manufacturing an object.
Fig. 1 shows an overview of an apparatus 1 for producing an object by means of additive manufacturing. The apparatus 1 comprises a process chamber 5 for receiving a bath of powdered material which can be solidified. The bath of powdered material is receivable on a build surface 7 of a build plate 9. As can be seen in Fig. 2, the build plate 9 is on a supporting side 27 opposite of the build surface 7 thereof removably connected to a supporting surface 21 of a support 13. The supporting surface 21 is provided with an alignment protrusion 31 designed to cooperate with an alignment recess 33 provided on the supporting side 27 of the build plate 9. Referring back to Fig. 1, the support 13 is movably provided in a piston 11, such that after solidifying a layer, the support 13 may be lowered, and a further layer of material may be solidified on top of the part of the object already formed. A solidifying device 15 is provided for solidifying a selective part of the material. In the embodiment shown, the solidifying device 15 is a laser device, which is arranged for producing electromagnetic radiation in the form of laser light, in order to melt a powdered material provided on the build surface 7, which then, after cooling forms a solidified part of the object to be produced. However, the invention is not limited to the type of solidifying device.
The apparatus 1 comprises, in the embodiment shown in Fig. 2, a build plate takeover device 17. The build plate takeover device 17 comprises three movable supporting organs 19a, 19b, 19c. The three supporting organs 19a, 19b, 19c are provided with an alignment profile 25 at an end face for supporting said build plate 9 at the supporting side 27. The supporting side 27 is provided with three supporting organ recesses 29a, 29b, 29c for receiving the three supporting organs 19a, 19b, 19c. In a first position (Fig. 3), the movable supporting organs 19a, 19b, 19c are largely retracted into the support 13 for supporting said build plate 9 on said supporting surface 21. In a second position (Fig. 2), the movable supporting organs 19a, 19b, 19c extend outward of the supporting surface 21 to a larger extent than in the first position thereof to make the build plate 9 free from support of the supporting surface 21 of the support 13. The takeover device 17 further comprises a robot element 23 (see Fig. 1). The robot element 23 is provided with a build plate manipulation organ 33 for placing and removing the build plate 9 onto and from the three moveable supporting organs 19a, 19b, 19c when the three moveable supporting organs 19a, 19b, 19c are in the second position. In a practical embodiment, the manipulation organ 33 may be moved in the cavity formed between the build plate 9 and the support 13 when the supporting organs 19a, 19b, 19c are in the second position. Then the supporting organs 19a, 19b, 19c may be retraced towards the first position until the manipulation organ 33 carries the build plate 9. Then the manipulation organ 33 may move the build plate 9 away from the support 13.
An exemplary embodiment of the takeover device 117 is shown in Figure 4, which shows a further preferred embodiment of an apparatus 101. The reference numerals used to indicate components in Fig. 4 comparable to the components shown in figures 1-3 are incremented by 100. Build plate 109 is provided with a build plate takeover recess 150. Apparatus 101 comprises an actuating element 123 for moving a build plate takeover organ 152 between a first position wherein said build plate take over organ 152 is disposed at least partly into said build plate takeover recess 150 and a second position wherein said build plate takeover organ 152 is outside said build plate takeover recess 150.
As best shown in Fig. 2, the support 13 is provided with a cavity 39 for receiving a movable heating element 35 and a spring 37. The spring 37 pushes the heating element 35 upwards, wherein the heating element 35 at least partly extends above the supporting surface 21 when said supporting organs 19a, 19b, 19c are in the second position of the supporting organs 19a, 19b, 19c. The spring 37 will push the heating element 35 against the supporting side 27 of the build plate 9 when the build plate 9 is placed on the supporting surface 21. The support 13 is further provided with an inflatable bag element 43 and a cooling unit 51 (Fig. 1). The inflatable bag element 43 seals a space present between the support 13 and the wall 41 of the process chamber 5 in the inflated state thereof.
The support 13 is further provided with a temperature measurement element 45 for measuring the temperature of build plate 9 and a control unit 47. The control unit 47 is coupled for communication with said temperature measurement element 45 and coupled for communication with said heating element 35. An urging element (not shown) in the form of a spring may be connected to this temperature measurement element 45 in order to urge said temperature measurement element 45 to the build plate 9. This increases the thermal contact, and ensures a more accurate measurement.
Furthermore, it is advantageous when the heating element 35 itself is provided with a temperature measurement element (not shown in Fig. 2). In that case, more precise information on the temperature of the heating element itself is obtained, which allows for more precise control of the temperature of the build plate.
It will be understood by those skilled in the art that a plurality of heating elements may be provided. In an embodiment (not shown) the support 13 may be provided with a plurality of cavities 39, each for receiving a movable heating element 35 and a spring 37 therein. As stated before, each spring 37 pushes the respective heating element 35 upwards. Each spring 37 will push the respective heating element 35 against the supporting side 27 of the build plate 9 when the build plate 9 is placed on the supporting surface. By providing a pluratlity of heating elements 35 a more precise and local control of the temperature profile of the build plate 9 will be possible.
Using the apparatus 1 an object can be manufactured as follows. The supporting organs 19a, 19b, 19c are moved to their first position. The robot element 23 holds a build plate 9 with the build plate manipulation organ 33 thereof. The robot element 23 moves the build plate 9 in a position wherein the build plate 9 rests with the supporting organ recesses 29a, 29b, 29c thereof on the supporting organs 19a, 19b, 19c. Subsequently robot element 23 moves the build plate manipulation organ 33 free from the build plate 9 and the supporting organs 19a, 19b, 19c are moved to their first position wherein the build plate 9 rests on the supporting surface 21. When the supporting organs 19a, 19b, 10c are in their first position the inflatable element 43 is inflated. After building the object on the build surface 7 of the build plate 9, the inflatable element 43 is deflated and the support organs 19a, 19b, 19c are move to their second position. The robot element 23 moves the build plate manipulation organ 33 towards a position wherein the build plate manipulation organ 33 can lift the build plate 9 free from the supporting organs 19a, 19b, 19c. Subsequently the robot element 23 lifts the build plate 9 from the supporting organs 19a, 19b, 19c.
Claims (16)
Priority Applications (1)
Application Number | Priority Date | Filing Date | Title |
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NL2018849A NL2018849B1 (en) | 2017-05-05 | 2017-05-05 | Apparatus for producing an object by means of additive manufacturing and method of using the apparatus |
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NL2018849A NL2018849B1 (en) | 2017-05-05 | 2017-05-05 | Apparatus for producing an object by means of additive manufacturing and method of using the apparatus |
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Citations (5)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
WO2001085386A2 (en) * | 2000-05-09 | 2001-11-15 | Optomec Design Company | Forming structures from cad solid models |
WO2005025781A1 (en) * | 2003-09-15 | 2005-03-24 | Trumpf Werkzeugmaschinen Gmbh + Co. Kg | Substrate sheet for a 3d-shaping method |
DE102013001374A1 (en) * | 2013-01-28 | 2014-07-31 | Cl Schutzrechtsverwaltungs Gmbh | Device for producing three-dimensional object by compacting powdered layers of compositional material, comprises carrier arranged in construction chamber, application device for applying compositional material layers and irradiating device |
DE102015205314A1 (en) * | 2015-03-24 | 2016-09-29 | Siemens Aktiengesellschaft | Plant for an additive manufacturing process with a heater for the powder chamber |
DE102015211170A1 (en) * | 2015-06-17 | 2016-12-22 | Eos Gmbh Electro Optical Systems | Device and method for producing a three-dimensional object |
-
2017
- 2017-05-05 NL NL2018849A patent/NL2018849B1/en active
Patent Citations (5)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
WO2001085386A2 (en) * | 2000-05-09 | 2001-11-15 | Optomec Design Company | Forming structures from cad solid models |
WO2005025781A1 (en) * | 2003-09-15 | 2005-03-24 | Trumpf Werkzeugmaschinen Gmbh + Co. Kg | Substrate sheet for a 3d-shaping method |
DE102013001374A1 (en) * | 2013-01-28 | 2014-07-31 | Cl Schutzrechtsverwaltungs Gmbh | Device for producing three-dimensional object by compacting powdered layers of compositional material, comprises carrier arranged in construction chamber, application device for applying compositional material layers and irradiating device |
DE102015205314A1 (en) * | 2015-03-24 | 2016-09-29 | Siemens Aktiengesellschaft | Plant for an additive manufacturing process with a heater for the powder chamber |
DE102015211170A1 (en) * | 2015-06-17 | 2016-12-22 | Eos Gmbh Electro Optical Systems | Device and method for producing a three-dimensional object |
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