US20180021855A1 - Method for managing a powder in an additive manufacturing facility comprising a plurality of machines - Google Patents

Method for managing a powder in an additive manufacturing facility comprising a plurality of machines Download PDF

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Publication number
US20180021855A1
US20180021855A1 US15/549,233 US201615549233A US2018021855A1 US 20180021855 A1 US20180021855 A1 US 20180021855A1 US 201615549233 A US201615549233 A US 201615549233A US 2018021855 A1 US2018021855 A1 US 2018021855A1
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Prior art keywords
powder
machines
volume
feedstock
facility
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US15/549,233
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Christophe De Lajudie
Jean-Luc Petit-Jean
Christian Geay
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Compagnie Generale des Etablissements Michelin SCA
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Compagnie Generale des Etablissements Michelin SCA
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Assigned to COMPAGNIE GENERALE DES ETABLISSEMENTS MICHELIN reassignment COMPAGNIE GENERALE DES ETABLISSEMENTS MICHELIN ASSIGNMENT OF ASSIGNORS INTEREST (SEE DOCUMENT FOR DETAILS). Assignors: DE LAJUDIE, Christophe, GEAY, Christian, PETITJEAN, Jean-Luc
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    • B22F3/1055—
    • 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
    • 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
    • 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
    • B22F10/00—Additive manufacturing of workpieces or articles from metallic powder
    • B22F10/30—Process control
    • B22F10/34—Process control of powder characteristics, e.g. density, oxidation or flowability
    • 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
    • B22F10/60—Treatment of workpieces or articles after build-up
    • B22F10/68—Cleaning or washing
    • 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
    • B22F10/70—Recycling
    • B22F10/73—Recycling of 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
    • B22F12/50—Means for feeding of material, e.g. heads
    • B22F12/52—Hoppers
    • 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
    • B22F12/80—Plants, production lines or modules
    • B22F12/82—Combination of additive manufacturing apparatus or devices with other processing apparatus or devices
    • 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
    • B29C64/35—Cleaning
    • 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
    • B29C64/357—Recycling
    • 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
    • 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
    • B33Y40/00—Auxiliary operations or equipment, e.g. for material handling
    • 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
    • B33Y40/00—Auxiliary operations or equipment, e.g. for material handling
    • B33Y40/10—Pre-treatment
    • 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
    • B22F10/30—Process control
    • B22F10/32—Process control of the atmosphere, e.g. composition or pressure in a building chamber
    • B22F2003/1056—
    • B22F2003/1059—
    • 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
    • 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 invention falls within the field of powder-based additive manufacturing in which particles of this powder are sintered or melted using a high-energy beam of electromagnetic radiation, such as, for example, a laser beam, and/or a particle beam, for example an electron beam.
  • a high-energy beam of electromagnetic radiation such as, for example, a laser beam, and/or a particle beam, for example an electron beam.
  • the invention relates to the management of a powder within an additive manufacturing facility comprising a plurality of additive manufacturing machines, this management comprising at least feeding the various machines with powder and recycling the powder layering excess generated by the additive manufacturing operations taking place within each machine.
  • an additive manufacturing machine comprises at least means of emitting a laser beam and/or a particle beam, a device for layering powder in the working zone of the laser and/or particle beam, and means feeding the layering device with powder.
  • the layering device comprises powder spreading means able to travel over the working zone so as to distribute the powder into a layer of a final thickness suited to the additive manufacturing, feed means able to transfer the powder under gravity to the spreading means and metering means able to control the quantity of powder transferred to the spreading means. It is precisely the means of spreading the powder and the principle by which they operate that cause the powder layering excess generated by each machine during an additive manufacturing cycle. Specifically, in order to obtain layers of powder of uniform thickness, these spreading means deposit a layer of powder of a thickness greater than the thickness required, then the excess thickness of powder deposited is removed by sweeping with a roller or a scraper.
  • the storage means comprise at least one mobile hopper able to move with the feed means, the metering means and the spreading means.
  • the hopper of the feed means may be filled with powder manually by an operator before each additive manufacturing cycle.
  • this manual first method is hardly attractive because it does not allow the machine feed means to be restocked as a parallel process, the machine needing to be shut down in order to allow the operator to access the hopper of the feed means.
  • the means of implementing this internal recycling are a source of vibrations and of impurities liable to impede the correct operation of the machine and of its powder layering device.
  • transportation in the dense phase does not allow the powder to be transported over long distances, something which may prove necessary in the case of a facility or workshop comprising a plurality of additive manufacturing machines.
  • U.S. Pat. No. 7,887,316 envisages the use of an inert carrier gas such as nitrogen, argon, or carbon dioxide
  • this document U.S. Pat. No. 7,887,316 also indicates that the carrier gas used is preferably air, but without specifying any particular treatment to be performed on the air used for carrying the powder. Therefore, water contained in this untreated air may moisten the powder being transported and lead to the manufacture of poor-quality components.
  • document DE-201 07 262 makes provision for centralizing the recycling of the excess and recovered powders, it disadvantageously multiplies the circuits used for collecting and distributing the various powders, thereby increasing the risks of powder leakage and therefore health risks, and making servicing and maintaining the facility more complex.
  • one subject of the invention is a method for managing a powder within an additive manufacturing facility comprising a plurality of additive manufacturing machines, the management method making provision for storing a volume of feedstock powder and for automatically feeding the various machines of the facility with powder from this volume of feedstock powder, the powder delivered to each machine undergoing at least one layering during an additive manufacturing cycle implemented in this machine, and this layering operation taking place with powder being deposited in excess and the excess portion of the powder deposited, referred to as excess powder, being moved away, the management method making provision for the excess powder moved away within each machine of the facility to be collected and the excess powder collected to be conveyed from each machine to the volume of feedstock powder, the management method also making provision for a recovered powder derived from the cleaning of the rough components manufactured by the machines of the facility to be reintroduced into the volume of feedstock powder.
  • the management method is characterized in that it makes provision for one and the same collection circuit to convey the excess powder and the recovered powder as far as the volume of feedstock powder.
  • pooling of the collection of the excess powder there is no longer any need for each additive manufacturing machine to be equipped with an internal recycling device which is a nuisance source of vibrations and of impurities, and which increases the cost of each machine.
  • pooling the collection of the excess powder and of the recovered powder it is also possible to centralize the treatment of these powders prior to their reuse.
  • the pooling of the collection of the various powders reduces the cost of the facility and the risks of powder leakage, and makes the installation easier to maintain.
  • the management method makes provision for the excess powder and the recovered powder to be transported pneumatically and under vacuum as far as the volume of feedstock powder.
  • the management method also makes provision for the powder collected to be transported in diluted phase as far as the volume of feedstock powder so as to avoid blockages appearing in the circuit used for transporting the collected powder.
  • the management method provides powder transportation under gravity or pneumatically and under vacuum. This then avoids the risks of powder leakages that might be associated with the use of compressed air in the circuit conveying the powder from the volume of feedstock powder to the various machines.
  • the pneumatic and vacuum transport of the powder between the volume of feedstock powder and the various machines is done using dry air or an inert gas, in order to avoid moistening the powder transported.
  • the management method also makes provision for the steps aimed at preparing the powder before it is distributed to the machines and used by these machines to be centralized. More specifically, the management method preferably makes provision for the powder to be dried and sifted upstream of its distribution to the various machines of the facility, namely between the volume of feedstock powder and each machine of the facility.
  • the management method also makes provision for fresh powder to be introduced into the volume of feedstock powder, this fresh powder being mixed with the excess powder collected and with the recovered powder, and therefore dried and sifted at the same time as these recycling-derived powders.
  • Another subject of the invention is a facility for implementation of this management method, this facility comprising a plurality of additive manufacturing machines, a device for storing a volume of feedstock powder and a feed device automatically feeding the various machines of the facility with powder from this volume of feedstock powder, each additive manufacturing machine comprising a device for layering the powder delivered to this machine, and each layering device of each machine depositing the powder in excess and moving away the excess portion of the powder deposited, referred to as the excess powder, the facility comprising a collection circuit for the excess powder moved away by each layering device of each machine, this collection circuit allowing the excess powder collected from each machine to be transported as far as the volume of feedstock powder, and the facility further comprising a cleaning device for cleaning the rough components manufactured by the machines of the facility and allowing a powder, referred to as recovered powder, to be recovered during the cleaning of these components.
  • the facility is characterized in that the cleaning device is connected to the collection circuit that collects the excess powder, so that the recovered powder is introduced into this collection circuit.
  • the collection circuit comprises a single collecting duct connecting each machine of the facility to the volume of feedstock powder and vacuum generating means making it possible to transport the excess powder collected pneumatically and under vacuum in this collecting duct.
  • the vacuum generating means allow the excess powder collected to be transported in a dilute phase in the collecting duct.
  • the feed device comprises a first, powder-preparation, circuit, followed by a second, powder-distribution, circuit distributing the prepared powder to the various machines of the facility, the preparation circuit connecting the volume of feedstock powder to the distribution circuit, and the distribution circuit connecting the preparation circuit to each machine of the facility.
  • At least one portion of the preparation circuit is set out in such a way as to transport the powder under gravity, and the preparation circuit also comprises vacuum-generating means allowing the powder to be transported pneumatically and under vacuum in at least one portion of this preparation circuit.
  • the distribution circuit comprises a distribution duct connected to the preparation circuit and to each machine of the facility, and vacuum-generating means allowing the powder to be transported pneumatically and under vacuum in this distribution duct.
  • this distribution circuit takes the form of a closed circuit.
  • the preparation circuit comprises a powder drying device and a powder sifting device.
  • the installation further comprises a device for storing a volume of fresh powder, which is connected to the device for storing the volume of feedstock powder.
  • FIG. 1 is a simplified schematic depiction of a plurality of additive manufacturing machines fed with powder within a facility according to the invention
  • FIG. 2 is a more detailed schematic depiction of a plurality of additive manufacturing machines fed with powder within an installation according to the invention.
  • the invention relates to a facility 10 comprising a plurality of additive manufacturing machines M 1 ,M 2 which are to be fed with powder.
  • the facility 10 comprises a device 12 for storing a volume of feedstock powder VPA and a supply device 14 automatically supplying powder to the various machines Ml,M 2 of the facility from this volume of feedstock powder VPA.
  • an additive manufacturing machine M 1 ,M 2 comprises at least means of emitting a laser and/or particle beam, a device for layering powder in the work zone of the laser and/or particle beam, and means feeding the layering device with powder, for example from the powder delivered to this machine by the feed device 14 .
  • each layering device of each machine M 1 ,M 2 applies the powder in excess and moves away the excess part of the powder deposited, referred to as excess powder, in order to obtain a layer of powder that is as uniform as possible.
  • the rough components PB are extracted from the machine M 1 ,M 2 to be cleaned and separated from the unconsolidated powder surrounding them.
  • the rough components PB are generally extracted from a machine M 1 ,M 2 in the container in which they were manufactured, and therefore immersed in the middle of the powder not set aside by the layering device and not consolidatable by the laser and/or particle beam.
  • the facility 10 comprises a device 16 for cleaning the rough components PB manufactured by the machines M 1 ,M 2 of the facility.
  • This cleaning device 16 allows the rough components PB to be separated from the non-consolidated powder surrounding them and therefore allows this powder, referred to as recovered powder, to be recovered during the cleaning of these rough components PB.
  • the cleaned components PN are sent away to a storage site or to another device.
  • the facility 10 further comprises a device 18 for storing a volume of fresh powder VPN which is connected to the storage device 12 that stores the volume of feedstock powder VPA.
  • This volume of fresh powder VPN is used to restock the volume of feedstock powder VPA as necessary.
  • the volume of fresh powder VPN is used almost solely to compensate for the volume of powder converted into rough components PB by the machines M 1 ,M 2 of the facility.
  • the invention also makes provision to sift the mixture of powder derived from the volume of feedstock powder VPA before this mixture is used to feed the various machines M 1 ,M 2 of the facility, the volume of fresh powder VPN is also used to compensate for the clumps of powder rejected as waste by this sifting operation.
  • this fresh powder storage device 18 is preferably arranged outside this space 19 to make it easier to restock or to handle with a view to replacing it with another storage device full of fresh powder.
  • the facility 10 comprises a collecting circuit 20 for collecting excess powder swept aside by each layering device of each machine M 1 ,M 2 , this collecting circuit 20 allowing the excess powder collected to be transported from each additive manufacturing machine M 1 ,M 2 as far as the volume of feedstock powder VPA of the storage device 12 .
  • the collecting circuit 20 allows the creation of a facility 10 with machines M 1 ,M 2 which are less expensive and which remain cleaner for longer because they do not incorporate an internal system for recycling the excess powder moved aside by their layering device.
  • the operation of the machines M 1 ,M 2 is not disrupted by vibrations in an internal recycling system.
  • the collecting circuit preferably comprises a single collecting duct 22 connecting each machine M 1 ,M 2 of the facility to the volume of feedstock powder VPA and vacuum generating means 23 allowing the excess powder collected to be sent pneumatically and under vacuum into this collection duct 22 .
  • Vacuum transportation of the excess powder is more reliable because, in the event of a leak from the collecting duct 22 , the powder being transported, which may be toxic, is kept inside the collecting circuit 20 and cannot escape to an environment in which it could be inhaled by an operator or an individual situated near the leak.
  • the excess powder collected is transported under atmospheric air vacuum.
  • the invention also makes provision for drying the mixture of powder derived from the volume of feedstock powder VPA before this mixture is used to feed the various machines M 1 ,M 2 of the facility; there is no need to use dry air or a pure gas containing no water vapour.
  • the vacuum generating means 23 allow the space 25 of this device to be depressed.
  • the space 25 comprises an opening 27
  • the vacuum generating means 23 comprise a filter for placing under depression 29 installed on the opening 27 and connected to a vacuum pump 31 .
  • a feed duct 33 connecting the space 35 of the fresh powder storage device 18 to the space 25 of the feedstock powder storage device 12 , the vacuum generating means 23 also allow the fresh powder to be carried pneumatically and under vacuum from the volume of fresh powder VPN toward the volume of feedstock powder VPA.
  • a new powder flow regulating device 37 such as a valve is provided between the space 35 of the fresh powder storage device 18 and the fresh powder supply duct 33 .
  • each discharge opening 24 of each machine M 1 ,M 2 is connected to the collecting duct 22 by its own discharge line 26 .
  • the excess powder is removed from each machine M 1 ,M 2 under gravity via its discharge opening 24 and is transported under gravity in the discharge line 26 connected to this opening.
  • each discharge line 26 from each machine M 1 ,M 2 comprises a powder flow regulating device 28 interposed between the discharge opening 24 of this machine and the collecting duct 20 .
  • the various regulating devices 28 allow the transfer of excess powder from the machines M 1 ,M 2 to the collecting circuit 20 to be halted in order to limit the running times of the vacuum generating means 23 and the electrical power consumption thereof.
  • the flow regulating devices 28 take the form of an endless screw conveyor.
  • these regulating devices 28 may also be simple valves, sluice gates or any other device able to regulate the flow of a pulverulent product being transported under gravity.
  • each discharge line 26 comprises an upstream duct 30 connecting a discharge outlet 24 of a machine M 1 ,M 2 to the inlet of the regulating device 28 and a downstream duct 32 connecting the outlet of the flow regulating device 28 to the collecting duct 22 .
  • vacuum generating means 23 allow the excess powder collected to be transported in the dilute phase in the collecting duct 22 .
  • transport in the dilute phase is transport with a gas circulating at a high speed in excess of 9 m/s and, for example, comprised between 15 and 35 m/s, and with a low concentration of powder, for example representing less than 10 kg of powder/kg of gas.
  • This transportation of the excess powder in a dilute phase is advantageous because it makes it possible to prevent blockages of powder appearing in the collecting duct 22 .
  • the gas flow rate associated with this type of transportation makes it possible to remove a bed of powder that may have settled at the bottom of the collecting duct 22 .
  • the additive manufacturing facility 10 comprises a device 16 for cleaning the rough components PB manufactured by the machines M 1 ,M 2 of the facility, and this cleaning device 16 allows powder, referred to as recovered powder, to be recovered during the cleaning of these rough components PB.
  • the cleaning device 16 is connected to the collecting circuit 20 that collects the excess powder in such a way as to introduce the recovered powder into this collecting circuit 20 .
  • the collecting duct 22 and its vacuum-generating means 23 allow the excess powder and the recovered powder to be transported towards the volume of feedstock powder VPA.
  • the cleaning device 16 is connected to the collecting duct 22 by a discharge line 34 in which the recovered powder is transported under gravity.
  • this discharge line 34 also comprises a regulating device 36 regulating the flow of recovered powder interposed between the recovered-powder discharge opening 38 of this cleaning device 16 and the collecting duct 22 .
  • the device 36 for regulating the flow of recovered powder also makes it possible to limit the operating time and electrical power consumption of the vacuum-generating means 23 of the collecting circuit 20 .
  • the device 36 for regulating the flow of recovered powder takes the form of an endless screw conveyor.
  • this regulating device 36 could also be a simple valve, a sluice gate or any other device capable of regulating the flow of a pulverulent product transported by gravity.
  • the recovered-powder discharge line 34 also comprises a buffer reservoir 40 interposed between the recovered-powder flow-regulating device 36 and the collecting duct 22 , another recovered-powder flow regulating device 42 being provided at the outlet of this buffer reservoir 40 so as to control the flow of recovered powder leaving this buffer reservoir 40 and transferred toward the collecting duct 22 .
  • the recovered-powder discharge line 34 comprises an upstream duct 44 connecting the discharge outlet 38 of the cleaning device 16 to the inlet of the regulating device 36 , an intermediate duct 46 connecting the outlet of the regulating device 36 to the inlet of the buffer reservoir 40 , and a downstream duct 48 connecting the outlet of the regulating device 42 to the collecting duct 22 .
  • the invention makes provision for distributing to the various machines M 1 ,M 2 of the facility a mixture of fresh powder, recovered powder, and excess powder. So, because the recovered powder and the excess powder may contain clumps of powder or have a certain moisture content, the invention makes provision for preparing the powder derived from this mixture before distributing it to the machines M 1 ,M 2 of the facility.
  • the feed device 14 of the facility 10 comprises a first, powder-preparation, circuit 50 , followed by a second, powder-distribution, circuit 52 distributing the prepared powder to the various machines M 1 ,M 2 of the facility, the preparation circuit 50 connecting the volume of feedstock powder VPA to the distribution circuit 52 , and the distribution circuit 52 connecting the preparation circuit 50 to each machine M 1 ,M 2 of the facility.
  • At least a portion PG 1 ,PG 2 of the preparation circuit 50 is set out in such a way as to transport the powder under gravity, and the preparation circuit 50 also comprises vacuum-generating means, not illustrated in FIG. 2 , allowing the powder to be transported pneumatically and under vacuum, preferably using dry air, into another portion PSV of this preparation circuit 50 .
  • the preparation circuit 50 comprises a powder-drying device 54 .
  • the preparation circuit 50 comprises a powder-sifting device 56 .
  • the sifting device 56 is situated downstream of the drying device 54 in the preparation circuit 50 because a powder containing a certain moisture content could cause malfunctioning of the sifting device 56 and, for example, slow the flow of the powder through the sifting device 56 .
  • the drying device 54 may take the form of a mixer/dryer with a vertical rotor and insulating double walls. This drying device 54 may be equipped with an oil bath or hot water heating unit and with a vacuum-creating unit 58 .
  • creating a vacuum in the dryer makes it possible to lower the temperature at which water vaporizes and to save time in removing the vaporized moisture.
  • the sifting device 56 comprises a vibrating belt with a mesh opening of 50 microns, the clumps or particles of powder larger than this mesh opening being removed by the sifting device 56 as waste D.
  • the preparation circuit 50 comprises a first powder-flow regulating device 60 interposed between an outlet 62 of the space 25 of the device 12 for storing the volume of feedstock powder VPA and the inlet of the drying device 54 , and a second powder-flow regulating device 64 interposed between the outlet of the drying device 54 and the inlet of the sifting device 56 .
  • the drying device 54 operates in powder batches of around 100 litres.
  • the batch of powder is transferred to the sifting device 56 via the pneumatic vacuum powder transportation portion PSV.
  • the powder is transported in the PSV portion of the preparation circuit 50 as a dense phase.
  • transport as a dense phase is transportation with a gas flowing at a low speed of below 9 m/s and, for example, of between 1 and 8 m/s, and with a high powder concentration, for example higher than 30 kg of powder/kg of gas.
  • the prepared powder is transferred to the distribution circuit 52 via a second portion PG 2 in which the powder is transported under gravity.
  • this second portion PG 2 of transport under gravity of the preparation circuit 50 there is a first prepared-powder buffer reservoir 66 and a second prepared-powder metering reservoir 68 , a first powder-flow regulating device 70 being interposed between the first buffer reservoir 66 and the second metering reservoir 68 , and a second powder regulating device 72 being provided at the outlet of the second metering reservoir 68 and connected to the distribution circuit 52 .
  • the various devices and reservoirs of the preparation circuit 50 are connected by suitable pipes, and the preparation circuit 50 thus formed is arranged in such a way as to allow the powder to flow under gravity in the relevant portions PG 1 ,PG 2 .
  • all the powder flow regulating devices 60 , 64 , 70 of the preparation circuit 50 are endless screw conveyors with the exception of the regulating device 72 provided at the outlet of the second metering reservoir 68 which takes the form of a sluice gate.
  • these regulating devices 60 , 64 , 70 , 72 may also adopt the form of other means known to those skilled in the art and allowing regulation of the flow of a pulverulent product.
  • the regulating device 72 provided at the outlet of the second metering reservoir 68 has the function of delivering a dose of prepared powder to the distribution circuit 52 so that this dose, for example of 2.5 litres, is carried to a machine M 1 ,M 2 of the facility 10 by the distribution circuit 52 .
  • the distribution circuit 52 comprises a distribution duct 74 connected to the preparation circuit 50 and to each machine M 1 ,M 2 of the facility 10 , and vacuum generating means 76 allowing the powder to be transported pneumatically and under vacuum in this distribution duct 74 .
  • the powder is transported pneumatically and under vacuum of dry air or of a pure and inert gas such as nitrogen in this distribution duct 74 so as to avoid any degradation of the hygrometric and particle size characteristics of the dried and sifted powder.
  • the distribution circuit 52 is preferably a closed circuit.
  • the distribution duct 74 forms a closed loop to which the outlet of the regulating device 72 provided at the outlet of the second metering reservoir 68 of the preparation circuit 50 is connected and to which the various machines M 1 ,M 2 of the facility are connected.
  • the distribution duct 74 forms a closed loop starting at and returning to a buffer tank 78 passing via the vacuum-generating means 76 .
  • the buffer tank 78 is double-walled allowing it to condense any water that might be contained in the carrier gas and remove it from the distribution circuit 52 .
  • the distribution circuit 52 is a closed circuit, a carrier-gas feed 80 to the buffer tank 78 is also provided.
  • the powder is also transported in dilute phase in the distribution circuit 52 .
  • the powder is transported in this distribution circuit 52 in small volumes, such as for example when the regulating device 72 provided on the outlet of the preparation circuit 50 delivers 2.5-litre doses of powder to the distribution duct 74 , transportation in a semi-dilute phase is conceivable.
  • a transport in a semi-dilute phase is transportation with a gas circulating at an intermediate speed, being situated for example at around 9 m/s, and with an intermediate powder concentration for example comprised between 10 and 30 kg of powder/kg of gas.
  • each machine M 1 ,M 2 of the facility is connected to this duct 74 via a separation device 82 allowing the powder to be separated from the carrier gas.
  • such a separation device 82 comprises a distributor 84 inserted into the distribution circuit 52 , a receiving hopper 88 receiving the mixture of powder and of carrier gas, and a depressurizing filter 90 .
  • the distributor 84 may adopt two positions: a divert position in which it diverts the mixture of powder and of carrier gas to the receiving hopper 88 via a bypass duct 92 and a neutral position in which it allows this mixture of powder and of carrier gas to circulate in the distribution duct 74 and toward the other machines M 1 ,M 2 of the facility.
  • the receiving hopper 88 comprises means allowing the powder to be separated from the carrier gas through a cyclone effect, the carrier gas being conveyed back to the distribution duct 74 via a coupling 94 , and the powder being stored in this receiving hopper 88 to be fed into the additive manufacturing machine to which it is connected by a powder flow regulating device 96 .
  • the invention also covers a method for managing a powder within an additive manufacturing facility 10 as has just been described for example.
  • this management method offers the same advantages as the facility 10 which has just been described.
  • this facility 10 comprises a plurality of additive manufacturing machines M 1 ,M 2
  • the management method makes provision for storing a volume of feedstock powder VPA and for automatically feeding powder to the various machines M 1 ,M 2 of the facility from this volume of feedstock powder VPA.
  • the management method makes provision for collecting the excess powder moved aside within each machine M 1 ,M 2 of the facility 10 and for conveying the excess powder collected from each machine M 1 ,M 2 to the volume of feedstock powder VPA.
  • the management method makes provision for the excess powder collected at each machine M 1 ,M 2 to be transported pneumatically and under vacuum as far as the volume of feedstock powder VPA, and preferably under atmospheric air vacuum because the management method also makes provision for the powder feeding the machines of the facility to be dried.
  • the management method makes provision for the excess powder collected at each machine M 1 ,M 2 to be transported in dilute phase as far as the volume of feedstock powder VPA.
  • the management method also makes provision for reintroducing a recovered powder derived from the cleaning of the rough components PB manufactured by the machines M 1 ,M 2 of the facility into the volume of feedstock powder VPA.
  • the management method makes provision for the powder to be transported under gravity or pneumatically and under vacuum from the volume of feedstock powder VPA as far as each machine M 1 ,M 2 of the facility.
  • the method makes provision for the use of dry air or an inert gas as a carrier gas in order to avoid increasing the moisture content of the powder.
  • the management method makes provision for introducing fresh powder into the volume of feedstock powder VPA.
  • the management method according to the invention makes provision for various machines M 1 ,M 2 of a facility to be fed with a mixture of fresh powder, recovered powder derived from the cleaning of the rough components PB manufactured by these various machines, and of excess powder removed by the various machines of the facility.
  • the management method makes provision for sifting the powder between the volume of feedstock powder VPA and each machine M 1 ,M 2 of the facility.
  • the management method makes provision for sifting the powder between the volume of feedstock powder VPA and each machine M 1 ,M 2 of the facility. cm 1 - 18 . (canceled)

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  • Physics & Mathematics (AREA)
  • Mechanical Engineering (AREA)
  • Optics & Photonics (AREA)
  • Life Sciences & Earth Sciences (AREA)
  • Sustainable Development (AREA)
  • Plasma & Fusion (AREA)
  • Automation & Control Theory (AREA)
  • Filling Or Emptying Of Bunkers, Hoppers, And Tanks (AREA)
  • Powder Metallurgy (AREA)
US15/549,233 2015-02-16 2016-02-15 Method for managing a powder in an additive manufacturing facility comprising a plurality of machines Abandoned US20180021855A1 (en)

Applications Claiming Priority (3)

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FR1551277A FR3032637A1 (fr) 2015-02-16 2015-02-16 Procede de gestion d'une poudre dans une installation de fabrication additive comprenant une pluralite de machines
FR1551277 2015-02-16
PCT/EP2016/053198 WO2016131785A1 (fr) 2015-02-16 2016-02-15 Procede de gestion d'une poudre dans une installation de fabrication additive comprenant une pluralite de machines

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CN109774148A (zh) * 2019-02-28 2019-05-21 共享智能铸造产业创新中心有限公司 一种增材制造粉料集成处理装置及粉料处理方法
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CN112743104A (zh) * 2019-10-29 2021-05-04 通用电气公司 用于多个金属粉末处理装置的粉末回收系统
US11794256B2 (en) * 2019-10-29 2023-10-24 General Electric Company Powder reclamation system and operating method
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CN112743103A (zh) * 2019-10-29 2021-05-04 通用电气公司 使用宽频过滤器的粉末筛分系统
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US12017277B2 (en) 2020-10-20 2024-06-25 Sodick Co., Ltd. Additive manufacturing apparatus
WO2022122295A1 (en) 2020-12-08 2022-06-16 SLM Solutions Group AG Resource management system and additive manufacturing facility with such
US20220226888A1 (en) * 2021-01-21 2022-07-21 Xerox Corporation Method and system for operating a metal drop ejecting three-dimensional (3d) object printer to shorten object formation time
US20220331874A1 (en) * 2021-04-15 2022-10-20 Hewlett-Packard Development Company, L.P. Reconditioning used build material powder for a 3d printer
US20220339706A1 (en) * 2021-04-21 2022-10-27 Hewlett-Packard Development Company, L.P. Loading build material powder for a 3d printer
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JP2018506651A (ja) 2018-03-08
US20200230698A1 (en) 2020-07-23
EP3259086A1 (fr) 2017-12-27
FR3032637A1 (fr) 2016-08-19
US11130179B2 (en) 2021-09-28
JP6803858B2 (ja) 2020-12-23
WO2016131785A1 (fr) 2016-08-25
CN107249791A (zh) 2017-10-13
EP3259086B1 (fr) 2020-04-01
KR102406898B1 (ko) 2022-06-10
KR20170118070A (ko) 2017-10-24
CN107249791B (zh) 2021-03-30

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