WO2018141476A1

WO2018141476A1 - Automated separation of support structures from a powder-bed-based additively manufactured component

Info

Publication number: WO2018141476A1
Application number: PCT/EP2018/000039
Authority: WO
Inventors: Vasily Ploshikhin
Original assignee: Amsis Gmbh
Priority date: 2017-01-31
Filing date: 2018-01-29
Publication date: 2018-08-09
Also published as: DE102017101834A1

Abstract

The invention relates to a method for the powder-bed-based additive manufacturing of at least one component, wherein powder, from which at least one component is to be made, is applied to a construction platform in layers as a powder bed, the at least one component is produced in layers by locally melting the powder, and a support structure is produced together with the at least one component, which supports the at least one component at support points, wherein a structure is produced from the at least one component, the support structure and the construction platform having at least one hollow space, which is configured such that, when the hollow space is supplied with an active medium at a predefinable pressure, this hollow space withstands the pressure load without breaking until at least one connection point between the component or one of the components and the support structure, or at least one connection point between the construction platform and the support structure, or at least one connection point between different parts of the support structure is broken by the pressure load.

Description

Automated separation of support structures from a powder bed-based additive-fabricated component

The present invention relates to a method for powder bed-based additive manufacturing of at least one component, one or more powder bed-based additively manufactured component (s) having a support structure, a method for automatically separating a support structure from one or more powder bed-based Additive manufactured component (s), a method for automatically separating a support structure of one or more powder bed-based additively manufactured component / components of a construction platform, a method for automatically separating a support structure of one or more powder bed-based additively manufactured component (s) and from a construction platform as well as a plant for carrying out the process for powder bed-based additive production of at least one component and / or for carrying out the method for automatically separating a support structure from one or more powder bed-based additively manufactured component (s), a construction platform, a method for calculating geometry description data of one or more component (s) having a support structure and a corresponding computational product.

Support structures are intended as an additional building material to prevent a lowering of components in the space or their delay. The danger for lowering and delay is particularly great as long as the components have not yet reached their final strength. Distortion can be caused, for example, by uneven cooling or uneven drying or setting of a component. The delay primarily means the loss of dimensional accuracy of a component.

CONFIRMED GS OPIE The lowering of a component or a component portion can lead to form deviation or in the worst case to a release layer. A separating layer means the interruption of the layer composite and thus also of the component.

The support structures usually bind directly to the component. After completion of the construction process, the support structures must be removed in the post process.

Support structures are predominantly used in processes in which the building material is liquid or flowable during the application. In powder processing systems, the unbound powder primarily supports the components. If the component density increases during manufacture, the components can sink in the powder bed. Therefore, supporting structures can also be used here. In the thermal production of large components or components with unfavorable cross-sectional jumps made of powder material support structures can prevent distortion. In metal-powder-based processes, heat can be dissipated into the build platform via the support structure.

The construction data of the support structures as part of the geometry description data are automatically created by the machine software in the pre-process and can be optimized by the operator.

In the indirectly constituting methods, e.g. selective fusion or sintering of surface-applied powder with high-energy radiation, e.g. Laser sintering, selective bonding of sheet applied powder with a binder printhead, e.g. 3D printing, and selectively polymerizing a photosensitive resin with UV radiation, e.g. Stereolithography or Digital Light Processing (DLP), formless building material is applied flat and then selectively cured. The building material can be both liquid or pasty and powdery.

In indirectly constituting processes, the support structures are constructed from the same building material as the component itself. The support structure can be both a fine column structure and a statically optimized grid construction. As a rule, the support structures do not rest on the entire surface of the component. They are mainly used in the production of so-called "down-faces" (overhangs) in components.

The support structure can also end in the powder bed. It then serves more for heat dissipation.

The support structure does not necessarily have to be connected to the build platform, but may also be connected to both ends with the component.

The support structure does not have to end up at the bottom of a component. It can also be attached to one side and / or top of the component.

The separation of the support structures of a powder bed-based additively manufactured component is currently carried out in a post-processing step (post process) by a very complex manual labor. For example, the support structures are broken out, cut off, sawn off, ground or etched. This is a significant part of the total production time and thus significant (additional) manufacturing costs.

The present invention is therefore based on the object, an automated separation of the support structures of one or more powder bed-based additive manufactured component (s) and / or allow the build platform.

According to the invention, this object is achieved by a method for powder bed-based additive manufacturing of at least one component, in which

Powder, from which at least one component is to be produced, is applied in layers as a powder bed on a building platform,

- The at least one component by local melting of the powder is produced in layers and - A support structure is produced together with the at least one component, which supports the at least one component at support points, wherein a structure of the at least one component, the support structure and the building platform is produced with at least one cavity which is designed so that when acted upon the cavity with an active medium with a predetermined pressure of this cavity, the pressure load so long without breakage, until at least one connection point between the component or one of the components and the support structure or at least one connection point between the building platform and the support structure or at least one connection point between different parts the support structure is broken by the pressure load. Both the support points and the connection points can also be surfaces. The active medium or the active media or at least one of the active media can / can, for example

- Oil, especially high temperature stable oil

- Air, in particular compressed air;

- Gas, in particular inert gas, such as argon, helium or carbon dioxide (C0 ₂ )

- Gas, strongly cooled

be.

Furthermore, this object is achieved by a powder bed-based additively manufactured component (s) having a support structure which supports the at least one component at support points, wherein a structure comprising at least one component, a support structure and a build platform has at least one cavity, which is designed so that when exposed to the cavity with an active medium with a predetermined pressure of the cavity, the pressure load so long without break tolerates at least one connection point between the component or one of the components and the support structure or at least one connection point between the build platform and the support structure or at least one joint between different parts of the support structure is broken by this pressure load. Furthermore, this object is achieved by a method for automatically separating a support structure of one or more powder bed-based additively manufactured component (s), in particular according to one of claims 21 to 26 and / or a construction platform, wherein the support structure with the component or the Components or the construction platform is connected and comprises a structure of the at least one component, a support structure which supports the at least one component at support points, and a construction platform at least one cavity comprises

Acting on the at least one cavity with an active medium with a predetermined pressure such that at least one connection point between the component or one of the components and the support structure or at least one connection point between the building platform and the support structure or at least one connection point between different parts of the support structure by the pressure load is broken.

Furthermore, this object is achieved by a system for carrying out a method according to one of claims 1 to 20 and 27, comprising

a construction space housing with a construction platform for supporting one or more powder bed-based additive to be manufactured component / components,

a layer preparation device for preparing respective powder layers on the building platform,

an irradiation device for irradiating the respectively last-prepared powder layer on the construction platform in accordance with geometry description data of the component or components to be manufactured and the associated support structure and

a control device for controlling the irradiation device in accordance with the geometry description data. In addition, the object is achieved by a system or a system module for the automatic separation of a support structure of one or more powder bed-based additive manufactured component (s), in particular according to one of claims 21 to 26, and / or a construction platform, wherein the support structure with the Component or the components or construction platform is connected and a structure of the at least one component, a support structure, which supports the at least one component at support points, and a building platform at least one cavity, comprising a Wirlanediumversorgungseinrichtung, which for controlling the loading of the cavity or at least one of the cavities with at least one active medium with a Wirkmediumanschlusseinrichtung of the component or at least one of the components and / or the support structure can be brought into fluid communication.

Furthermore, this object is achieved by a method for calculating geometry description data of one or more component / components with a support structure according to one of claims 21 to 26, wherein for a predefinable pressure, the geometry of the support structure is designed so that the expansion of each point of the wall of the Cavity or one of the cavities under pressure load is lower than the value of the breaking elongation of a material from which the component is to be built, and at least one connection point between the component or one of the components and the support structure or at least one connection point between the building platform and the support structure an elongation is reached which is equal to or higher than the value of the elongation at break of the material from which the component is to be built.

Finally, the present invention provides a computer program product that includes computer readable instructions that, when executed on a suitable system, perform a method according to any one of claims 1 to 20 and 32 to 36.

In the method for powder bed-based additive manufacturing of at least one component can be provided that the cavity or at least one of the cavities partially from at least one component, in particular its underside or a part thereof, a part of the support structure, in particular a wall, the the build platform and the component connects, and the build platform is limited and in which there are support elements that connect the build platform and the component at the support points.

Furthermore, it can be provided that the cavity or at least one of the cavities is bounded in part by the at least one component, in particular by its underside or a part thereof or by the construction platform or a part thereof and a component, in particular a wall, of the support structure Surface of the component of the support structure on the side of the cavity with the component or with the building platform directly and / or is connected by support elements.

In a further particular embodiment of the present invention, the wall or the walls of the cavity or at least one of the cavities is / are completely a component of a support structure, in particular a support element, which connects the construction platform and the component at the support points.

Advantageously, the wall (s) of the cavity or at least one of the cavities has / have at least one resilient wall portion which, upon pressurization of the cavity, has a greater deformation without break than the remaining wall of the cavity.

In particular, it can be provided that the at least one resilient wall section in sectional view has a symmetrical or asymmetric zigzag line course or a symmetrical or asymmetrical curved line course.

Expediently, the at least one connection point between the component or one of the components and the support structure and / or the at least one connection point between the construction platform and the support structure and / or the at least one connection point between different parts of the support structure has / have a predetermined breaking point. Advantageously, the connecting surface of the at least one connection point between the support structure and the component or at least one of the components and / or between the support structure and the building platform in sectional view parallel to the surface of the at least one component or the building platform in one direction, preferably continuously, for control the process of disconnecting.

Furthermore, it can be provided that the connecting surfaces of at least two connection points between the support structure and the component or at least one of the components and / or between the support structure and the construction platform in sectional view parallel to the surface of the component or the build platform are designed uniquely large, so that at the same pressure load, the joint with a smaller joint surface breaks earlier than the joint with a larger joint surface.

According to another particular embodiment of the present invention, the pressurization takes place in stages, wherein in a first stage, a first pressure is used and in a second stage and all other stages, an ever higher pressure is used.

In particular, it may be provided that in the first stage of the pressurization only a first part of the connection points between the support structure and the component or one of the components and / or between the support structure and the build platform is broken and in the second and the further stages of pressurization a second part and further parts of the joints are broken.

Advantageously, the wall or the walls of the cavity have / have a plurality of resilient wall sections, which are designed such that a first resilient wall section has a highest deformability and a second resilient wall section and further resilient wall sections have an ever lower deformability at a same stage of the pressurization , In particular, it may be provided that the resilient wall portions are designed such that a deformation of the first resilient wall portion in the first stage of pressurization, a deformation of the second resilient wall portion in the second stage of pressurization and a deformation of each other compliant wall portion in a corresponding Level of pressurization are the same or comparable.

Furthermore, the cavity may be part of a larger cavity, which is a part of the support structure and separately with pressure, preferably different stages, can be acted upon.

According to a further particular embodiment of the present invention, the structure has at least one cavity, which is partially bounded by at least one component, and at least one cavity, which is partially bounded by the construction platform, and the support elements of the at least one component and of the building platform separated by the at least one cavity, which is partially bounded by the at least one component, and the at least one cavity, which is partially bounded by the construction platform, at the same time or almost simultaneously or chronologically successively acted upon by a working medium with a predetermined positive or negative pressure become.

Expediently, during or after the production of the at least one component, a treatment of the entire component or of all components or of a respective part thereof is carried out by passing an active medium through the cavity or at least one of the cavities.

In particular, it may be provided that the treatment comprises a passage of pressurized air for removing loose powder located in the cavity and takes place before the pressurization of the cavity for separating the connection points between the component and the support structure or between the component and the building platform. Furthermore, the treatment may comprise a cooling, heating or maintaining a temperature (temperature control), and / or a pressure treatment.

Furthermore, it can be provided that after separation of the support elements from the at least one component by the pressure load a remaining, not separated wall of the cavity by means of another separation process, in particular by milling or laser cutting, is separated from the at least one component.

In addition, it can be provided that after separation of the support elements of the building platform by the pressure load a remaining, not separated wall of the cavity by means of another separation process, in particular by milling or wire EDM, is separated from the build platform.

In a particular embodiment, the powder bed-based additively manufactured component, the cavity or at least one of the cavities partially from at least one component, in particular its underside or a part thereof, a component of the support structure, in particular a wall, the building platform and the component connects, and the build platform are limited and in which there are support elements that connect the construction platform and the component at the support points.

In addition, it can be provided that the cavity or at least one of the cavities is bounded in part by the at least one component, in particular by its underside or a part thereof or by the construction platform or a part thereof and a component, in particular a wall, of the support structure Surface of the component of the support structure on the side of the cavity with the component or with the building platform directly and / or is connected by support elements.

Furthermore, it can be provided that the wall or the walls of the cavity or at least one of the cavities is part of a support element / which is the at least one component with the construction platform or the at least one component with a part of Support structure or the building platform with a part of the support structure or different parts of the support structure interconnects.

According to a further particular embodiment, the component (s) comprise / comprise at least one active medium inlet for selectively selectively exposing the at least one cavity to an active medium with an overpressure or underpressure.

Furthermore, it can be provided that the at least one connection point between the component or one of the components and the support structure and / or the at least one connection point between the construction platform and the support structure and / or the at least one connection point between different parts of the support structure has / have a predetermined breaking point ,

In the system for carrying out a method according to one of claims 1 to 20 and 27 it can be provided that this further comprises an active medium supply device, which for the controlled loading of the cavity or at least one of the cavities with at least one active medium with a Wirlanediumanschlusseinrichtung of the component or at least one the components and / or the support structure can be brought into connection.

Furthermore, the system may include a post-processing device integrated in the package housing or separate therefrom for separating a non-broken wall of the cavity remaining after pressurizing the cavity on the component or on a build platform by means of another separation method, in particular milling or laser cutting.

Preferably, the plant or the plant module for automatic separation of a support structure, a post-processing device for separating a remaining after the pressurization of the cavity on the component or on a building platform, not broken wall of the cavity by means of another separation process, in particular milling or laser cutting on. In the method for calculating geometry description data of one or more component / components having a support structure, at least one connection point between the component or one of the components and the support structure or the at least one connection point between the build platform and the support structure is specifically designed such that the connection surface of this connection point continuously increases in a predetermined direction, so that the separation of this connection point takes place in this direction.

In particular, it can be provided that the connecting surfaces of at least two connection points between the support structure and the component or one of the components or between the support structure and the construction platform are designed unequally unequal, so that at the same pressure load, the junction with a smaller connection surface breaks earlier than the Joint with a larger interface.

According to another particular embodiment of the present invention, the geometric orientation of a portion of the walls of a cavity on the side of the support structure is calculated in accordance with a surface caused by a parallel displacement of at least a portion of the cavity-limiting component surface in a normal direction to that surface he follows.

For example, a calculation module for the interpretation of the geometry description data of one or more component / components may be present with a support structure. Alternatively or additionally, an interface for exporting the calculated geometry description data may be present. Again alternatively or additionally, there may be an interface for importing data about the position and geometry of the active medium connections in the build platform.

Alternatively or additionally, the support structure may be designed on the building platform side as well as on the component side. The separation of the support structure from a construction platform can be carried out analogously to and / or simultaneously with the separation of the support structure of the component components. The present invention is based on the surprising finding that the separation of the supports or at least part of the supports from the component can occur as a result of deformation of the support structure caused by pressurization with an active medium. A pressurization can be realized by providing the cavities through which the active medium can be passed. By providing the cavities for passing the active media, the support structure acquires additional functionality of "self-separation." A very large part of the supports can be separated from the component, and the walls of the cavity should be held during the pressure loading or separation of the supports. They can be separated from the component in a next step with other separation methods, such as milling or laser cutting, automatically.

In the conventional separation methods, the supports can only be positioned in places that are easily accessible, so that the subsequent removal of the supports would be possible. In the new method, the supports can also be arranged on the outside not or difficult to reach places.

Any permanent walls of the cavity associated with the component may, at least in one particular embodiment, preferably be positioned at locations readily accessible from the outside so that in a subsequent step they may be treated by methods such as e.g. Milling or laser cutting, in a, preferably automated, mode can be easily separated.

The pressurization with an active medium has the advantage of a uniform load (hydrostatic pressure) of the component and the support structure, at least in one particular embodiment. An even load during the separation of the columns "spares" the component from a strong deformation.

Further features and advantages of the invention will become apparent from the appended claims and the following description of several embodiments with reference to the schematic drawings. Showing: Figure 1 is a sectional view of a powder bed-based additively manufactured component with a support structure according to a particular embodiment of the present invention;

Figure 2 is a sectional view taken along the line II - II in Figure 1;

Figure 3 is a sectional view of a powder bed-based additively manufactured component with a support structure according to another particular embodiment of the present invention;

Figure 4 is a sectional view taken along the line IV - IV in Figure 3;

Figure 5 shows various stages of a method for automatically separating at least part of a support structure from the component according to Figures 1 and 2 or 3 and 4 according to a particular embodiment of the present invention;

6 shows a sectional view along the line VI-VI in FIG. 7 of a powder bed-based additively manufactured component with a support structure according to a further particular embodiment of the present invention;

Figure 7 is a sectional view taken along the line VII - VII in Figure 6;

Figure 8 is a sectional view taken along the line VIII - VIII in Figure 7;

FIG. 9 shows a sectional view along the line IX - IX in FIG. 10 of a powder bed-based additively manufactured component with a support structure according to a further particular embodiment of the present invention;

Figure 10 is a sectional view taken along the line X - X in Figure 9; Figure 1 1 is a sectional view taken along the line XI - XI in Figure 10;

Figure 12 shows various stages of a method for automatically separating at least a part of a support structure from the component according to Figures 6 to 8 or 9 to 1 1 according to a particular embodiment of the present invention;

FIG. 13 shows a sectional view of a powder bed-based additively manufactured component with a support structure according to a further particular embodiment of the present invention;

Figure 14 is a sectional view taken along the line XIV - XIV in Figure 13;

FIG. 15 shows various stages of a method for automatically separating at least part of a support structure from the component according to FIGS. 13 and 14 according to a particular embodiment of the present invention;

FIG. 16 is a sectional view of a powder bed-based additive-fabricated component having a support structure according to another particular embodiment of the present invention;

FIG. 17 is a sectional view of a powder bed-based additive-fabricated component having a support structure according to another particular embodiment of the present invention;

FIG. 18 is a sectional view of a powder bed-based additive-fabricated component having a support structure according to another particular embodiment of the present invention; Fig. 19 is a sectional view taken along the line XIX-XIX in Fig. 18;

Figure 20 is a sectional view of a powder bed-based additively manufactured component with a support structure according to another particular embodiment of the present invention;

Fig. 21 is a sectional view taken along the line XXI-XXI in Fig. 20;

FIG. 22 shows a detail of FIG. 20;

Figure 23 is a sectional view taken along the line XXIII - XXIII in Figure 22;

FIG. 24 shows a variant of the embodiment shown in FIG. 22;

Fig. 25 is a sectional view taken along the line XXV-XXV in Fig. 24; and

Figures 26 to 36 are views of a powder bed based additive manufactured component with a support structure according to another particular embodiment of the invention.

Figures 1 and 2 show a powder bed-based additively manufactured component 10 with a support structure 12 according to a particular embodiment of the present invention in a sectional view and along the line II-II in Figure 1 (Figure 2). The support structure 12 is located between a lower construction platform 14 and the upper component 10 and supports the component 10 at support points 16. The support points 16 are located on the underside 18 of the component. The support structure 12 includes an outer wall 28, which in this example is arranged in a rectangle and which directly connects the build platform 14 and the component 10 in this example, as well as inner support elements 30 that support the build platform 14 and the component 18 at the support points 16 will be discussed in more detail below. The outer wall 28 is connected to right and left sides 20 and 22 and front and rear sides 24 and 26 of the component 10. The structure 32 of the component 10, the support structure 12 and the building platform 14 has a cavity 34 which extends from the underside 18 and the sides 20 to 26 of the component 10 and from the wall 28 of the support structure 12 and from a part of the top 36 the construction platform 14 is limited and in which the support elements 30 are located.

The wall 28 in this example has a circumferential resilient wall section 38 which, upon pressure of the cavity 34, has a greater deformation without fracture than the remaining wall of the cavity 34 (see FIG. 5).

So that the cavity 34 can be acted upon with an active medium, such as compressed air, in this example, the construction platform 14 has an opening (passage opening) 40 arranged centrally in this example as the active medium inlet and if necessary. also - outlet on.

As is apparent from Figures 1 and 2, the support members 30 are designed needle-shaped in this example. The support members 30 taper continuously from the side of the build platform 14 to the side of the component 10 in this example. In this example, there are twelve support members 30 within the cavity 34.

The embodiment shown in FIGS. 3 and 4 differs from the embodiment shown in FIGS. 1 and 2 only in that the support elements 30 are not needle-shaped but plate-shaped. In addition, only four instead of twelve inner support members 30 are present in this example.

The embodiments shown in FIGS. 1 and 2 as well as 3 and 4 can be produced, for example, by a process for powder bed-based additive manufacturing, in which powder (not shown) from which the component 10 is to be produced is laid in layers is applied as a powder bed (not shown) on a building platform 14, the component 10 is made by local melting of the powder in layers and is produced together with the component 10, the support structure 12, the the component 10 is supported on the support points 16, wherein the structure 32 is made of the component 10, the support structure 12 and the build platform 14 with the cavity 34, from the bottom 18 and the sides 20 to 26 of the component 10, the wall 28th , which connects the build platform 14 and the component 10, and the upper side 36 of the build platform 14 is limited and in which the support elements 30 are that connect the build platform 14 and the component 10 at the support points 16.

FIG. 5 shows by way of example how, for example, in the two embodiments shown in FIGS. 1 to 4 a separation of the component 10 from the upper ends of the support elements 30 at the connection points 42, which in this case coincide with the support points 16, under pressure by means of an active medium, pressurized through the opening 40 in the build platform 14 in this example from below into the cavity 34. Since the wall 28 has a resilient wall portion 38, it withstands the pressure P (see Figures 5 (a) and (b)) and also does not detach at its upper end from the component 10, while the aforementioned joints 42 between the Bottom 18 of the component 10 and the upper ends of the support members 30 are broken or separated (see Figure 5 (b)). The outer elements of the support structure 12, in this example the wall 28, can then be separated, for example by preferably automatic milling on the component 10 thereafter.

FIGS. 6 to 8 show a further exemplary embodiment of a powder-bed-based additive-fabricated component 100 having a support structure 112 which supports the component 100 at three support points or lines or surfaces 116 on the underside 118 of the component 100 in this example an outer wall 128, which is rectangular in this example, and in this example has an inner support member 130 disposed between a lower build platform 114 and the upper component 100. More specifically, Fig. 6 is a sectional view taken along the line VI-VI of Fig. 7, Fig. 7 is a sectional view taken along the line VII-VII in Fig. 6, and Fig. 8 is a sectional view taken along the line VIII-VIII in Fig. 7. The structure 132 of the component 100, the support structure 1 12 and the build platform 114 has a cavity 134 which from the bottom 1 18 of the component 100, of the wall 128 of the support structure 112 and of a portion of the top 136 of the building platform. 1 14 is limited. The supporting element 130, which is centrally arranged in this example on the lower side 1 18 of the component 100 and supports the component 100 at the support point 16, is not directly connected to the upper side 136 of the building platform 114, but is connected to the inner surface via a resilient part 138 139 of the wall 128 connected. In sectional view (see Figures 6 and 8), the resilient member 138 has the shape of a symmetrical in this example pointed roof. The two parts 138 form in this example an angle of about 90 °.

In contrast to the embodiments shown in FIGS. 1 to 4, the delivery of an active medium does not take place via an opening in the build platform, but via openings 140 and 141 as the active medium inlet and / or outlet.

The embodiment shown in FIGS. 9 to 11 essentially differs from the embodiment shown in FIGS. 6 to 8 in that the support element 130 is not needle-shaped, tapering from bottom to top, but instead has a top or wall shape , spaced through passage openings 129 and interposed predetermined breaking points 131 is formed. Furthermore, the resilient part 138 in the sectional view shown in Figure 1 1 is not pointed roof-shaped, but formed with a blunt top.

FIG. 12 now shows a method for preferably automatically separating at least a part of the support structure 112 of the embodiments shown in FIGS. 6 to 11 by applying pressure P through at least one of the openings 140 and 141 141 may be closed to build up a pressure in the cavity 134. Since the portion 138 is compliant while the support member 130 is at least stiffer than the compliant portion 138, the upper end of the support member 130 at the junction 142 corresponding to the support point 16 in the center of the bottom surface 118 of the component 100 is severed ( see Figure 12 (b)). The outer ones Elements of the support structure 112, in this example the wall 128, can then be separated from the component 100, for example by preferably automatic milling.

Figures 13 and 14 show another embodiment of a powdered-based additive-fabricated component 200 according to a particular embodiment of the present invention having a support structure 212 disposed between a lower build platform 214 and the upper component 200 and the component 200 in place therein Example a total of eleven support points 216 supports. More specifically, Fig. 13 is a sectional view taken along the line XIII-XIII in Fig. 14, and Fig. 14 is a sectional view taken along the line XIV in Fig. 13. The formation 232 of the component 200, the support structure 212 and the build platform 214 has a cavity 234, wherein the wall 228 of the cavity 234 is part of a support member 230 which connects the component 200 with the build platform 214. The wall 228 of the cavity 234 has a resilient wall portion 238 which, upon pressurization of the cavity 234, experiences a greater deformation without fracture than the remainder of the wall of the cavity. The support element 230 is connected to the component 200 at a support point 216 which is arranged centrally on the underside 218 of the component 200 in this example. At the four corners of the build platform 214, the component 200 is connected to the build platform 214 via four bar or columnar support members 230 in this example, or is supported over the build platform 214 thereabove. The central in this example four support members 230 are above the respective cavity 234 to the side of the component 200 in the form of a needle, tapering from bottom to top, designed. Below the respective cavity 234, the respective support member 230 is substantially rod-or. designed columnar and has an opening or a channel 240 for insertion and / or omission of an active medium (not shown).

FIG. 15 shows how the respective cavity 234, when acted upon by pressure P by means of an active medium, passes through the channel 240 from a substantially oval shape with a vertical longitudinal axis (see FIG. 15 (a)) into a substantially round shape (see FIG FIG. 15 (b)) and the support elements 230 at the connection point 242, which corresponds to the respective support point 216, is separated from the underside 218 of the component 200. 16 shows, in principle, a component 300 having a support structure 312 according to a particular embodiment of the present invention, wherein the support structure 312 is in principle a plurality of the support elements 130, shown for example in FIGS. 6 to 8 and 9 to 11, here identified as support elements 330 , includes. The resilient parts 338 are supported on an outer wall 328 of the cavity 334 and on the lower sockets 339.

The further embodiment of a component 400 with a support structure 412 shown in FIG. 17 differs from the embodiment shown in FIG. 16 in that the resilient parts 438 are not arranged symmetrically but asymmetrically. In this example, each two parts 438 in sectional view form an asymmetrical pointed roof with an angle which is smaller than 90 °.

The embodiment of a component 500 with a support structure 512 shown in FIG. 18 essentially differs from the embodiment shown in FIG. 16 in that the support structure does not comprise any needle-shaped support elements but only the resilient parts 538, the pedestals 539 and the outer wall 528 (see Figure 18 (a)). As can be seen from the sectional view along the line ΧΓΧ - XIX in FIG. 18 (see FIG. 19), passage openings 544 are present along the connecting line 542 for passing through an active medium (not shown). Furthermore, FIG. 19 shows a thickness d of the linear connection point 516 and predetermined breaking points 546 between the passage openings 544.

Figure 20 is a sectional view taken along the line XX - XX in Figure 21 (top) and Figure 21 (bottom) is a sectional view taken along the line XXI - XXI in Figure 20 of another component 600 having a support structure 612 between a lower building platform The build platform 614 has two lateral, vertically extending openings 602 and 603 in this example, which are for the inlet and / or outlet of an active medium (not shown) having a respective active medium inlet opening 604, 605 and / or outlet in the support structure 612 and further openings 606 and 607 in an inner wall 629 of the support structure 612 is in active medium connection, such that an active medium can be given under pressure from a active medium supply device via the active-medium connection device 608 or 609 (shown only in FIG. 20) into a cavity 634.

Fig. 22 is a sectional view taken along a line XXII - XXII in Fig. 23 and Fig. 23 is a sectional view taken along the line XXIII - XXIII in Fig. 22. It shows the arrangement and connection of a support member 730 below the bottom 718 of another component 700 according to another particular embodiment of the present invention. As can be seen in combination with Figure 23, the joint 742, which in principle corresponds to the support point 716, is a connection surface or strip, the width of which in a direction FD ("Fracture Direction") continuously increases in this example achieve a targeted directed breakage of the support member 730.

The embodiment of a component 800 shown in FIGS. 24 and 25 essentially differs from the embodiment shown in FIGS. 22 and 23 in that the support element 830 in the upper region is not plate-shaped but has a needle-shaped design and a plurality of support elements are present.

Figures 26 to 35 show a further embodiment of a powder bed-based additively manufactured component 900 according to a particular embodiment of a present invention. The component 900 (FIGS. 26-28) has three interior spaces 936, 937 and 938 with ellipsoidal inner surfaces 916, 917 and 918, respectively. The inner surfaces 916, 917 and 918 must be supported in the region of overhangs. FIG. 29 shows that a surface 919 to be supported can not be reworked after the build-up process due to an inability to access a tool 950 (eg a milling cutter). For this reason, support members attached to the upper surface area 919 can not be removed by mechanical post-processing. FIGS. 30-32 illustrate a support structure 912 that enables the solution to the separation and removal task of the inaccessible surface 919. The support structure 912 is arranged in the interiors 936, 937 and 938 of the component 900 and supports the component 900 in this example a total of ten support points 916 (five in the upper area and another five in the lower area). The formation 932 of the component 900 and the support structure 912 has two cavities 934 and 935. A wall 928 of the cavity 934 has a resilient wall section 938 which, upon pressurization of the cavity 934, has a greater deformation without fracture than the remaining wall of the cavity learns. The cavity 935 is completely part of the support structure 912. The powder is removed from the cavity 935 through openings 942 and 943 prior to pressurization of the other cavity 934 so that the compliant wall sections 938 could deform without resistance during pressurization , Support members 930 are connected to the component 900 at a plurality of support points 916. The pressurization of the cavity 34 is carried out by the active medium (not shown), which is in and out through the openings 941 and 942. FIG. 33 shows the deformation of the resilient wall sections 938 after the pressurization of the cavity 934. This deformation leads to the separation of the support elements 930 from the component 900 at joints 942. FIGS. 34 and 35 show the subsequent mechanical finishing. Movement of the tool 950 (RM, "vertical movement", HM "horizontal movement") removes a large portion of the support structure 912 from the interior spaces 937 and 938. In the interior 936, the support elements are also removed 930 are separated from the support structure at locations 920. The remaining remnants of the support members 930 separated from the support structure 912 are readily removable via the interior spaces 937 and 938 vacated by the support structure 912.

The features of the invention disclosed in the foregoing description, in the drawings and in the claims may be essential both individually and in any desired combinations for the realization of the invention in its various embodiments.

LIST OF REFERENCE NUMBERS

component

support structure

building platform

reference points

bottom

, 22, 24, 26 pages

wall

support elements

shape

cavity

top

wall section

opening

joints

0 component

2 support structure

4 construction platform

6 interpolation points

8 bottom

8 wall

9 passage opening

0 support element

1 predetermined breaking points W

- 25 -

132 entities

134 cavity

136 top

138 part

139 surface

140, 141 openings

200 component

212 supporting structure

214 construction platform

216 interpolation points

218 bottom

228 wall

230 support elements

232 entities

234 cavity

238 wall section

240 channel

242 connection points

300 component

312 support structure

314 construction platform

316 interpolation points

328 wall

330 support elements

332 entities 334 cavity

338 parts

339 socket

340, 341 openings

400 component

412 support structure

414 construction platform

416 interpolation points

428 wall

430 support elements

432 entities

434 cavity

438 parts

439 socket

440, 441 openings

500 component

512 support structure

514 construction platform

516 interpolation points

528 wall

532 structures

534 cavity

538 parts

539 socket

540, 541 openings 542 connecting line

544 passage openings

546 predetermined breaking points

600 component

602, 603 openings

604, 605 openings

606, 607 openings

608, 609 Wirkmediumanschlusseinrichtung

612 support structure

614 construction platform

616 support point (s)

628 wall

629 wall

630 support element

632 structures

634 cavity

638 parts

700 component

716 support point

718 bottom

730 support element

738 parts

742 junction

800 component

816 support point 830 support elements

838 parts

842 junction

900 component

912 support structure

916 interpolation points

916, 917, 91! inner surfaces

919 area

920 digits

928 wall

930 support elements

931 support element

934, 935 cavities

936, 937, 938 interiors

938 wall section

940, 942 openings

942 connection points

942, 943 openings

942, junction

950 tool b width

d thickness

P pressure

FD direction

Claims

claims

1. A process for powder bed-based additive manufacturing of at least one component, in which

Powder, from which at least one component (10, 100, 200, 300, 400, 500, 600, 700, 800, 900) is to be produced, laid up in layers as a powder bed on a building platform (14, 114, 214, 314, 414; 514; 614) is applied,

- The at least one component by local melting of the powder is produced in layers and

a support structure (12; 112; 212; 312; 412; 512; 612; 912) is produced together with the at least one component, said support structure (16,116; ; 716; 816; 916), wherein a structure (32; 132; 232; 332; 432; 532; 632) is formed from the at least one component (10; 100; 200; 300; 400; 500; 600; 700; 800) 900), the support structure (12; 112; 212; 312; 412; 512; 612; 912), and the build platform (14; 114; 214; 314; 414; 514; 614) having at least one cavity (34; 134; 234; 334; 434; 534; 634; 934; 935), which is designed such that when the cavity is exposed to a reaction medium with a predeterminable pressure, this cavity withstands the pressure load without breakage until at least one connection point (42 142, 242, 842, 942) between the component or one of the components and the support structure or at least one connection point between the construction platform and the support structure or at least one connection between different parts of the support structure is broken by the pressure load.

2. The method of claim 1, wherein the cavity or at least one of the cavities partially of at least one component, in particular of its underside or a part thereof, a part of the support structure, in particular a wall, which connects the building platform and the component, and the construction platform is limited and in which there are support elements which connect the construction platform and the component at the support points.

3. The method of claim 1, wherein the cavity or at least one of the cavities is partially bounded by the at least one component, in particular its underside or a part thereof or by the build platform or a part thereof and a component, in particular a wall, the support structure, wherein the surface of the component part of the support structure on the side of the cavity is connected directly to the component or to the construction platform and / or by support elements.

4. The method of claim 1, wherein the wall or the walls of the cavity or at least one of the cavities is completely a part of a support structure, in particular a support member which connects the construction platform and the component at the support points is / are.

5. A method according to any one of the preceding claims, wherein the wall (s) of the cavity or at least one of the cavities has / have at least one resilient wall portion which, upon pressure of the cavity, exhibits a greater deformation without fracture than the remainder of the cavity wall.

6. The method of claim 5, wherein the at least one compliant wall portion in sectional view has a symmetrical or asymmetrical zigzag line or a symmetrical or asymmetrical curved line course.

7. The method according to any one of the preceding claims, wherein the at least one connection point between the component or one of the components and the support structure and / or the at least one connection point between the building platform and the support structure and / or the at least one connection point has / have a predetermined breaking point between different parts of the support structure.

8. The method according to any one of the preceding claims, wherein the connecting surface of the at least one connection point between the support structure and the component or at least one of the components and / or between the support structure and the building platform in a sectional view parallel to the surface of the at least one component or the building platform one direction, preferably continuously, increases to control the sequence of the separation.

9. The method according to any one of the preceding claims, wherein the connecting surfaces of at least two connection points between the support structure and the component or at least one of the components and / or between the support structure and the building platform in sectional view parallel to the surface of the component or the building platform targeted unequal size are such that at the same pressure load, the joint with a smaller joint surface breaks earlier than the joint with a larger joint surface.

10. The method according to any one of the preceding claims, wherein the pressurization takes place in stages, wherein in a first stage, a first pressure is used and in a second stage and all other stages, an ever higher pressure is used.

11. The method of claim 10, wherein in the first stage of the pressurization only a first part of the joints between the support structure and the component or one of the components and / or between the support structure and the building platform is broken and in the second and the further stages of Be pressurized a second part and other parts of the joints to be broken.

12. The method of claim 10 or 11, wherein the wall or the walls of the cavity has / have a plurality of resilient wall sections, which designed so in that a first compliant wall portion has a highest deformability and a second compliant wall portion and further compliant wall portions have an ever lower deformability at a same stage of the pressurization.

13. The method of claim 12, wherein the resilient wall portions are configured such that deformation of the first compliant wall portion in the first stage of pressurization, deformation of the second compliant wall portion in the second stage of pressurization, and deformation of each further compliant wall portion in one corresponding level of pressurization are equal or comparable.

14. The method of claim 11, wherein the cavity is part of a larger cavity, which is a part of the support structure and separately with pressure, preferably different stages acted upon.

15. The method according to any one of claims 2 to 14, wherein the structure comprises at least one cavity which is partially bounded by at least one component, and at least one cavity which is partially bounded by the building platform, and wherein the support elements of the at least one component and be separated from the building platform by the at least one cavity, which is partially bounded by the at least one component, and the at least one cavity, which is bounded in part by the building platform, at the same time or almost simultaneously or sequentially with an active medium with a predeterminable Über- or negative pressure can be applied specifically.

16. The method according to any one of the preceding claims, wherein during or after the manufacture of the at least one component, a treatment of the entire component or all components or a respective part thereof by passing an active medium through the cavity or at least one of the cavities is performed.

The method of claim 16, wherein the treatment comprises passing compressed air to remove loose powder in the cavity and before pressurizing the cavity to sever the joints between the component and the support structure or between the component and the build platform.

The method of claim 16, wherein the treatment comprises cooling or heating or maintaining a temperature and / or pressure treatment.

Method according to one of the preceding claims, wherein after separation of the support elements from the at least one component by the pressure load a remaining, not separated wall of the cavity by means of another separation method, in particular by milling or laser cutting, is separated from the at least one component.

Method according to one of the preceding claims, wherein after separation of the support elements from the building platform by the pressure load a remaining, not separated wall of the cavity by means of another separation process, in particular by milling or wire EDM, is separated from the build platform.

Powder bed based additive fabricated component (s) (10; 100; 200; 300; 400; 500; 600; 700; 800; 900) having a support structure (12; 112; 212; 312; 412; 512; 612 912) supporting the at least one component at support points (16; 16; 216; 316; 416; 516; 616; 716; 816; 916), wherein a formation (32; 132; 232; 332; 432; 532 632) of at least one component (10; 100; 200; 300; 400; 500; 600; 700; 800; 900), a support structure (12; 112; 212; 312; 412; 512; 612; 912) and a Construction platform (14 114; 214; 314; 414; 514; 614) has at least one cavity (34; 134; 234; 334; 434; 534; 634; 934; 935) which is designed such that upon application of the cavity with an impact medium with a predeterminable pressure of the cavity, the pressure load so long without breakage endures at least one connection point (42, 142, 242, 842; 942) between the component or one of the components and the support structure or at least one connection point between the construction platform and the support structure or at least one connection point between different parts of the support structure is broken by this pressure load.

22. Component (s) according to claim 21, wherein the cavity or at least one of the cavities is partially connected by the at least one component, in particular by its underside or a part thereof, a component of the support structure, in particular a wall connecting the construction platform and the component. and the building platform is limited and in which there are support elements which connect the construction platform and the component at the support points.

23. The component (s) according to claim 21, wherein the cavity or at least one of the cavities is partially formed by the at least one component, in particular its underside or a part thereof or by the construction platform or a part thereof and a component, in particular a wall, of the support structure is limited, wherein the surface of the component of the support structure on the side of the cavity with the component or with the construction platform is connected directly and / or by supporting elements.

24. Component (s) according to claim 21, wherein the wall or the walls of the cavity or at least one of the cavities is part of a support element / which is the at least one component with the construction platform or the at least one component with a part of the support structure or the Construction platform with a part of the support structure or different parts of the support structure interconnects.

25. component (s) according to any one of claims 21 to 24, further comprising at least one Wirkmediumeinlass for selectively selectively acting on the at least one cavity with an active medium with an overpressure or underpressure.

26. Component (s) according to one of claims 21 to 25, wherein the at least one connection point between the component or one of the components and the support structure and / or the at least one connection point between the construction platform and the support structure and / or the at least one connection point between different parts of the support structure has a predetermined breaking point / have.

27. A method for automatically separating a support structure of one or more powder bed-based additively manufactured component (s), in particular according to one of claims 21 to 26, and / or a build platform, wherein the support structure with the component or the components or the build platform is connected and a structure of the at least one component, a support structure which supports the at least one component at support points, and a building platform comprises at least one cavity, comprising

28. Plant for carrying out a method according to one of claims 1 to 20 and 27, comprising

a construction space housing with a construction platform for supporting one or more powder bed-based additive components / components to be manufactured,

a layer preparation device for preparing respective powder layers on the building platform, an irradiation device for irradiating the respectively last-prepared powder layer on the construction platform in accordance with geometry description data of the component or components to be manufactured and the associated support structure and

a control device for controlling the irradiation device in accordance with the geometry description data.

29. Plant according to claim 28, further comprising an active medium supply device, which can be brought into fluid communication with the controlled actuation of the cavity or at least one of the cavities with at least one active medium with a Wirkmediumanschlusseinrichtung of the component or at least one of the components and / or the support structure.

30. Plant according to claim 28 or 29, further comprising a built-in space or separate post-processing device for separating a, after the pressurization of the cavity on the component or on a building platform remaining, not broken wall of the cavity by means of another separation method, in particular milling or laser cutting.

31. Plant or system module for automatically separating a support structure of one or more powder bed-based additively manufactured component (s), in particular according to one of claims 21 to 26, and / or a construction platform, wherein the support structure with the component or the components or Building platform is connected and a structure of the at least one component, a support structure which supports the at least one component at support points, and a building platform at least one cavity, comprising a Wirkmediumversorgungseinrichtung, for controlling the cavity or at least one of the cavities with at least one Active medium with a Wirl mediumanschlusseinrichtung the component or at least one of the components and / or the support structure can be brought into fluid communication.

32. The system of claim 31, further comprising a post-processing device for separating a, after the pressurization of the cavity on the component or on a building platform remaining, not broken wall of the cavity by means of another separation method, in particular milling or laser cutting.

33. Construction platform for carrying out a method according to one of claims 1 to 20, comprising at least one Wirkmediumanschlusseinrichtung for a Wirkmediumversorgung.

34. Method for calculating geometry description data of one or more components / components with a support structure according to one of claims 21 to 26, wherein for a predefinable pressure the geometry of the support structure is designed such that the expansion of each point of the wall of the cavity or one of the cavities is under compressive load lower than the value of the elongation at break of a material from which the component is to be built, and at at least one connection point between the component or one of the components and the support structure or at least one connection point between the construction platform and the support structure, an elongation is achieved which is equal to or higher than the value of the breaking elongation of the material from which the component is to be built.

35. The method of claim 34, wherein at least one connection point between the component or one of the components and the support structure or the at least one connection point between the construction platform and the support structure is specifically designed so that the connection surface of this connection point increases continuously in a predetermined direction, so that the separation of this junction takes place in this direction.

36. The method of claim 34, wherein the connecting surfaces of at least two connection points between the support structure and the component or one of the components or between the support structure and the building platform are designed specifically unequal, so that at the same pressure load, the junction with a smaller connection surface breaks earlier than the junction with a larger interface.

37. The method of claim 34, wherein the geometric orientation of a part of the walls of a cavity on the side of the support structure is calculated based on a surface which is displaced by a parallel displacement of at least a part of the cavity-limiting component surface into a normal Direction to this surface is done.

A computeogram product containing computer readable instructions which, when executed on a suitable system, execute a method according to any one of the preceding claims 1 to 20 and 33 to 37.