WO2020232500A1 - An additive manufacturing installation - Google Patents

An additive manufacturing installation Download PDF

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Publication number
WO2020232500A1
WO2020232500A1 PCT/AU2020/050492 AU2020050492W WO2020232500A1 WO 2020232500 A1 WO2020232500 A1 WO 2020232500A1 AU 2020050492 W AU2020050492 W AU 2020050492W WO 2020232500 A1 WO2020232500 A1 WO 2020232500A1
Authority
WO
WIPO (PCT)
Prior art keywords
build
housing
sub
chamber
installation
Prior art date
Application number
PCT/AU2020/050492
Other languages
French (fr)
Inventor
Peter Farrer
Jack Martinich
Original Assignee
AmPro Innovations Pty Ltd
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Priority claimed from AU2019901698A external-priority patent/AU2019901698A0/en
Application filed by AmPro Innovations Pty Ltd filed Critical AmPro Innovations Pty Ltd
Publication of WO2020232500A1 publication Critical patent/WO2020232500A1/en

Links

Classifications

    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B22—CASTING; POWDER METALLURGY
    • B22F—WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
    • 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
    • B22F10/32—Process control of the atmosphere, e.g. composition or pressure in a building chamber
    • 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
    • B22F12/22—Driving means
    • 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
    • B22F12/38—Housings, e.g. machine housings
    • 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
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C64/00—Additive manufacturing, i.e. manufacturing of three-dimensional [3D] objects by additive deposition, additive agglomeration or additive layering, e.g. by 3D printing, stereolithography or selective laser sintering
    • B29C64/20—Apparatus for additive manufacturing; Details thereof or accessories therefor
    • B29C64/25—Housings, e.g. machine housings
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C64/00—Additive manufacturing, i.e. manufacturing of three-dimensional [3D] objects by additive deposition, additive agglomeration or additive layering, e.g. by 3D printing, stereolithography or selective laser sintering
    • B29C64/20—Apparatus for additive manufacturing; Details thereof or accessories therefor
    • B29C64/255—Enclosures for the building material, e.g. powder containers
    • B29C64/259—Interchangeable
    • 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
    • B29C64/364—Conditioning of environment
    • B29C64/371—Conditioning of environment using an environment other than air, e.g. inert gas
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B33—ADDITIVE MANUFACTURING TECHNOLOGY
    • B33Y—ADDITIVE MANUFACTURING, i.e. MANUFACTURING OF THREE-DIMENSIONAL [3-D] OBJECTS BY ADDITIVE DEPOSITION, ADDITIVE AGGLOMERATION OR ADDITIVE LAYERING, e.g. BY 3-D PRINTING, STEREOLITHOGRAPHY OR SELECTIVE LASER SINTERING
    • B33Y10/00—Processes of additive manufacturing
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B33—ADDITIVE MANUFACTURING TECHNOLOGY
    • B33Y—ADDITIVE MANUFACTURING, i.e. MANUFACTURING OF THREE-DIMENSIONAL [3-D] OBJECTS BY ADDITIVE DEPOSITION, ADDITIVE AGGLOMERATION OR ADDITIVE LAYERING, e.g. BY 3-D PRINTING, STEREOLITHOGRAPHY OR SELECTIVE LASER SINTERING
    • B33Y30/00—Apparatus for additive manufacturing; Details thereof or accessories therefor
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • 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
    • B33Y40/20—Post-treatment, e.g. curing, coating or polishing
    • 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
    • B22F2999/00—Aspects linked to processes or compositions used in powder metallurgy
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
    • Y02P—CLIMATE CHANGE MITIGATION TECHNOLOGIES IN THE PRODUCTION OR PROCESSING OF GOODS
    • Y02P10/00—Technologies related to metal processing
    • Y02P10/25—Process efficiency

Definitions

  • the present invention relates to an installation for use in additive manufacturing and to a method of additive manufacturing using the installation.
  • the installation and method are well suited to the production of at least one component in each build production cycle to form a build assembly of a build plate and an attached build of the at least one component.
  • the production cycle involves selective application of a directed beam energy source, such as a laser in a selective laser process involving melting (SLM) or sintering (SLS) or a similar additive manufacturing process employing an electron beam energy source.
  • SLM melting
  • SLS sintering
  • the production of at least component by an SLM process involves the spreading of successive thin layers of powder in a process chamber of an SLM installation, over a build plane above a build plate initially adjacent to the base of the process chamber.
  • Each layer of powder is scanned by a laser and thereby subjected to selective melting to form, at the build plane, a respective slice of at least one required component, before spreading of the next of successive layers of powder in an iterative operation.
  • the first slice bonds to the build plate or a support structure, while subsequent slices bond to a preceding slice, to progressively build up a complete component, or a plurality of complete components.
  • the build plate is lowered away from the process chamber into a build chamber of the SLM installation, to offset the increased height of material building up on the build plate and to maintain a constant build plane at which the laser scans and selectively melts the powder of each layer.
  • a resultant completed build creating the at least one component is contained within the build chamber, along with unfused powder of the successive layers that was not subjected to selective melting by the laser.
  • a build assembly comprising the build plate with the still attached build, with the residue of the unfused powder, is removed from the SLM installation via the process chamber and transferred to a glove box to enable recovery of the residue of unfused powder.
  • the build assembly is removed from the glove box, the build is separated from the build plate and the build plate then can be prepared and repositioned in the SLM installation for re-use.
  • the present invention is directed to providing an installation for use in additive manufacturing and to a method of additive manufacturing with the installation, with use of either a laser or an electron beam energy source, by a build production cycle forming a build assembly, of a build plate and an attached build of the at least one component, with improved recovery of unfused powder remaining after the build production cycle.
  • the present invention provides an additive manufacturing installation having: a main housing with an upper part containing a process chamber and a lower part containing a build housing defining an open topped build chamber and containing a build platform in the build chamber, the lower part of the housing having an access opening spaced laterally from the build chamber and an access panel secured over the access opening; a powder dispensing system for deposition of successive layers of a heat fusible powder over a build plane across the process chamber, adjacent to the build chamber; a directed beam energy source in the upper part of the main housing and operable in a build cycle to selectively scan and thereby selectively sinter or melt powder in a respective defined area of each of successive powder layers; an adjustment device in the build chamber operable during the build cycle to lower the build platform in the build chamber from an upper position in which an upper surface of the build platform is at or adjacent to the build plane; a holding device operable to release the build housing, with completion of the build cycle, from a position in which it is retained during the build cycle; and a drive
  • the directed beam energy source a laser
  • the installation including an associated pressurised source of protective or inert gas by which a protective or inert atmosphere is able to be provided throughout the main housing, including in both the process chamber and the build chamber and also exteriorly of the build housing in the lower part of the main housing.
  • the directed beam energy source is an electron beam source
  • the installation including an associated vacuum system by which a vacuum is able to be provided throughout the main housing, including in both the process chamber and the build chamber and also exteriorly of the build housing in the lower part of the main housing.
  • the installation most preferably includes an open-sided sub-housing that defines a sub-chamber accessible through the open side.
  • the sub-housing With the access panel of the main housing removed or open, the sub-housing can be securely engaged with the lower part of the main housing to provide communication between the main housing and the sub-housing, through the access opening and the open side of the sub-housing.
  • a substantially gas-tight seal may be provided between opposed surfaces of the main housing and the sub-housing, around the peripheries of the access opening and the open side of the sub-housing.
  • the present invention provides an installation for use in additive manufacturing, with use of either a laser, or an electron, directed beam energy source, wherein the installation includes a main housing having an upper part containing a process chamber and a lower part accommodating an open-topped build housing that defines a build chamber.
  • the installation further includes a powder dispensing system for the deposition of successive layers of powder material over a build plane defined across a junction between the process chamber and the build housing.
  • a build platform extends across the build chamber and is supported by an adjustment mechanism positioned in the build housing and operable to lower the build platform stepwise in the build chamber, from an upper position in which an upper surface of the build platform is at or adjacent to the build plane, to successive lower positions within the build chamber.
  • the installation has a scanning system that includes a directed energy source device for generating and emitting energy as a directed beam, a focusing and directing system operable to direct an energy beam downwardly through the process chamber to the build plane, and a computer control system including a CAD/CAM system for generating data specifying dimensions defining a component to be built by additive manufacturing.
  • a scanning system that includes a directed energy source device for generating and emitting energy as a directed beam, a focusing and directing system operable to direct an energy beam downwardly through the process chamber to the build plane, and a computer control system including a CAD/CAM system for generating data specifying dimensions defining a component to be built by additive manufacturing.
  • the control system is operable in response to the data to cause the focusing and directing system to focus and direct an energy beam emitted by the source device for selectively scanning, and thereby selectively sintering or melting, powder in a defined area of a powder layer disposed over the build plane, such that the defined area of each of successive powder layers corresponds to a layer of the component and bonds to the area of any preceding layer of powder to thereby progressively build the component in the course of an additive manufacturing build cycle.
  • the process chamber and the build chamber are maintained under a protective or inert atmosphere or placed under a vacuum, depending respectively on whether a laser or electron beam directed beam energy source is employed.
  • the installation of the first form of the invention has an access panel provided over an access opening in a lower part of a sidewall of the main housing, with the access panel able to be removed or opened manually or by means of an access device.
  • the access opening is positioned and of a size to permit the build housing to be moved through the access opening, to an advanced position outside the main housing.
  • the installation also includes in the lower part of the main housing an adjustment system for controlling the position of the build housing.
  • the adjustment system includes a lifting or biasing device operable to hold the build housing in a raised position in which, during operation of the installation to conduct a build cycle, a substantially gas-tight seal is maintained around the open top of the build housing so a protective or inert atmosphere or vacuum is maintained in each of the process chamber and the build chamber.
  • the lifting or biasing device also is operable on completion of a build cycle to lower the build housing from the raised position to a lowered position, or to enable the build housing to lower under gravity to a lowered position, and thereby break the gas- tight seal around the open the build housing.
  • the adjustment system also includes a drive system that is operable, with the build housing in the lowered position enabled by the lifting or biasing device, to move the build housing laterally between the lowered position and an advanced position beyond the access opening.
  • the extent to which the build housing is moved or moves from the raised position to the lowered position is to be sufficient not only to break the seal, but also to position laterally in line with the access opening when the build housing in a lower position.
  • the installation includes an open-sided sub-housing that defines a sub- chamber accessible through the open side.
  • the sub-housing can be securely engaged with the lower part of the main housing to provide communication between the main housing and the sub-housing, through the access opening and the open side of the sub-housing, with a substantially gas-tight seal provided between opposed surfaces of the main housing and the sub-housing, around the peripheries of the access opening and the open side of the sub-housing.
  • the installation has an associated pressurised source of protective or inert gas, or an associated vacuum system, by which a protective or inert atmosphere or a vacuum, respectively, is able to be provided throughout the main housing, including in both the process chamber and the build chamber and also exteriorly of the build housing in the lower part of the main housing.
  • a substantially gas-tight seal is provided between respective opposed faces of the main housing and the access panel, around and between the peripheries of the access opening and the access panel. The atmosphere or vacuum in the main housing, exteriorly of the build housing, is lost when the access panel is removed or opened.
  • the pressurised gas source or the vacuum source is operable to re-establish the atmosphere or vacuum exteriorly of the build housing, within the main housing, and also to establish the atmosphere or vacuum in the sub-housing, via the access opening and the open side of the sub-housing.
  • the lifting or biasing device then is able to be operated to enable the build housing to be lowered, to break the gas-tight seal around the open top of the build housing.
  • the volume of the sub-chamber and the dimensions of the side opening are such that the drive system then is able to operate to advance the build housing to the advanced position, by moving the build housing laterally from the main housing, through the access opening and the open side of the sub-housing, and into the sub-chamber of the sub-housing.
  • the arrangement is such as to enable a build assembly in the build chamber, comprising the build platform, a build attached the build platform as a consequence of a production cycle and powder that remains unfused after the production cycle, to be to be moved from the build chamber by reverse operation of the adjustment mechanism of the build chamber.
  • This removal of the build assembly occurs prior to operation of the drive system to retract the build housing and its adjustment mechanism back into the main housing and is achieved by reversal of the operation of the adjustment mechanism by which the build platform previously was lowered stepwise into the build chamber.
  • the arrangement is such that, after removal of the build assembly from the build chamber, the sub-housing is able to be disengaged from the main housing and, following closing of the access opening by the access panel and insertion of a replacement build plate, such as via the process chamber, the installation is able to be readied for commencement of a next production cycle.
  • the sub-housing preferably has an open-topped body that defines the sub-chamber and the open side of the sub-housing, and a cover member that comprises a downwardly open glove box enclosure secured over the open top of the open-topped body.
  • the body of the sub-housing includes a lifting or biasing system operable to lift the build housing to, and hold the build housing at, an upper position in the sub-chamber in which a substantially gas-tight seal is maintained around and between the open top of the build housing and a periphery of the glove box enclosure, to maintain a protective or inert atmosphere, or a vacuum, in each of the build chamber and the glove box enclosure.
  • the adjustment mechanism within the build housing by which the build platform was lowered stepwise during a build cycle, can be operated to raise the build platform in the build chamber to the lower periphery of the glove box enclosure, and thereby move the build and unfused powder into the glove box enclosure.
  • the installation of the present invention may, and preferably does, operate with at least two sub-housings.
  • a build housing present in the main housing on completion of a build production cycle, can be moved out of the main housing to enable removal and recovery of the build assembly without the need to hold the build housing and the build assembly in the main housing until the build housing, and the contained build assembly, is sufficiently cooled to enable further processing for recovery of unfused powder and separation of the build.
  • the holding time can be up to several hours.
  • the present invention enables avoidance of this substantial down-time in which the installation will be out of productive use.
  • the lifting or biasing device operable to hold the build housing in a raised position during operation of the installation to conduct a build cycle can take a variety of forms.
  • the drive system operable to move the build housing laterally between the lowered position and an advanced position beyond the access opening, can take a variety of forms.
  • the weight of the build housing and the contained build assembly can be substantial, and each of the lifting or biasing device and the drive system need to be sufficiently robust to accommodate the loads.
  • the lifting or biasing device may comprise a short-acting scissor lift, such as an electrically, pneumatically or hydraulically driven scissor lift.
  • the device may comprise at least one short stroke flat hydraulic cylinder such as available under the trade mark ENERPAC.
  • the drive system may comprise a system of rollers mounted in relation to the build housing and engaged with horizontally extending rails mounted in relation to the main housing, with drive provided by an electric motor.
  • the main housing may be rectangular in plan view, with the build housing horizontally movable towards and retractable from the advanced position in a direction that is perpendicular to a first pair of sidewalls of the main housing, of which one sidewall defines the access opening, and intermediate of and substantially parallel to a second pair of sidewalls.
  • the build housing When retracted, the build housing may be nearer to the one sidewall, and spaced from the other sidewall, of the first pair, to leave a space between the build housing and the other sidewall in which a mounting arrangement for the build housing and a drive motor is able to be provided.
  • the space may be about half the distance between the sidewalls of the first pair.
  • the mounting arrangement may be provided by a respective rail that is secured on each sidewall of the second pair and that extends horizontally between each sidewall of the first pair, and by rollers mounted on extensions mounted on the build chamber that projecting towards the other sidewall of the first pair, to enable the drive motor to be mounted within the space.
  • the invention also provides a sub-housing suitable for use with the installation of the invention.
  • the sub-housing defines a sub-chamber accessible through an open side of the sub-housing, while the sub-housing is adapted to be securely engaged with the lower part of the main housing of the installation to provide communication between the main housing and the sub-housing, with the access panel of the main housing removed or open, through the access opening and the open side of the sub-housing.
  • a substantially gas-tight seal provided between opposed surfaces of the main housing and the sub-housing, around the peripheries of the access opening and the open side of the sub-housing.
  • the sub-housing when securely engaged with the main housing and containing the established atmosphere or vacuum, enables the holding device to be operated to enable the build housing to be lowered, to break the gas-tight seal around the open top of the build housing.
  • the sub-housing is such that, with the build housing in the advanced position within the sub-housing, a build assembly in the build chamber comprising the build platform, a build attached the build platform as a consequence of a production cycle and powder that remains unfused after the production cycle, can be moved from the build chamber by reverse operation of the adjustment mechanism of the build chamber.
  • the sub housing has an open-topped body that defines the sub-chamber and the open side of the sub-housing, and a cover member that comprises a downwardly open glove box enclosure secured over the open top of the open-topped body.
  • the body of the sub-housing includes a lifting or biasing system operable to lift the build housing to, and hold the build housing at, an upper position in the sub chamber in which a substantially gas-tight seal is maintained around and between the open top of the build housing and a periphery of the glove box enclosure, to maintain a protective or inert atmosphere, or a vacuum, in each of the build chamber and the glove box enclosure, whereby with the build housing held in the upper position, the adjustment mechanism within the build housing, by which the build platform was lowered stepwise during a build cycle, can be operated to raise the build platform in the build chamber to the lower periphery of the glove box enclosure, and thereby move the build and unfused powder into the glove box enclosure.
  • a lifting or biasing system operable to lift the build housing to, and hold the build housing at, an upper position in the sub chamber in which a substantially gas-tight seal is maintained around and between the open top of the build housing and a periphery of the glove box enclosure, to maintain a protective or
  • Figure 1 is an isometric view of an additive manufacturing installation according to the present invention.
  • Figure 2 corresponds to Figure 1 , but with external parts removed to illustrate internal detail;
  • Figure 3 corresponds to Figure 2, but after adjustment to enable performance of a build cycle
  • Figure 4 corresponds to Figure 2, but with the installation in a condition enabled after completion of a build cycle
  • Figure 5 corresponds to Figure 5, but with external parts removed to illustrate internal detail
  • Figure 6 shows the installation of Figure 2, but after securement of a further component
  • Figure 7 is a side elevation of the installation as shown in Figure 5;
  • Figure 8 corresponds to Figure 7, but with the installation in the condition shown in Figure 2;
  • Figure 9 corresponds to Figure 8, but with the installation in the condition shown in Figure 3;
  • Figure 10 is a side elevation if the installation in the condition shown in Figure 6;
  • Figure 11 corresponds to Figure 10, but with the in the condition shown in Figure 4. Detailed Description of the Drawings
  • FIGS 1 to 11 show an installation 10, for use in additive manufacturing.
  • the installation 10 is shown in combination with a sub housing 12 of the installation, described later herein.
  • the installation 10 includes a main housing 14 having an upper part 16 containing a process chamber 18 and a lower part 20 accommodating an open-topped build housing 22 that defines a build chamber 24 shown in Figures 4 and 5.
  • the front of the installation 10 is facing to the left in all of the Figures and, as can be appreciated from a consideration of Figures 1 to 3, the front wall of lower part 20 comprises an access panel 26 that is removable to expose an access opening 28.
  • a side panel of lower part 20 has been omitted to reveal internal detail within part 20.
  • the installation 10 includes a powder dispensing system for the deposition of successive layers of powder material over a build plane defined across a junction between the process chamber and the build housing 22.
  • a build platform (not visible) extends across the build chamber 24 and is supported by an adjustment mechanism (also not visible) positioned in the build housing 22 and operable to lower the build platform stepwise in the build chamber, from an upper position in which an upper surface of the build platform is at or adjacent to the build plane, to successive lower positions within the build chamber 24.
  • the installation 10 has a scanning system (not visible) that includes a directed energy source device for generating and emitting energy as a directed beam, a focusing and directing system operable to direct an energy beam downwardly through the process chamber to the build plane, and a computer control system including a CAD/CAM system for generating data specifying dimensions defining a component to be built by additive manufacturing.
  • a scanning system (not visible) that includes a directed energy source device for generating and emitting energy as a directed beam, a focusing and directing system operable to direct an energy beam downwardly through the process chamber to the build plane, and a computer control system including a CAD/CAM system for generating data specifying dimensions defining a component to be built by additive manufacturing.
  • a directed beam energy source such as a laser in a selective laser process involving melting (SLM) or sintering (SLS) or a similar additive manufacturing process employing an electron beam energy source.
  • control system is operable in response to the generated data to cause the focusing and directing system to focus and direct an energy beam emitted by the source device for selectively scanning, and thereby selectively sintering or melting, powder in a defined area of a powder layer disposed over the build plane, such that the defined area of each of successive powder layers corresponds to a layer of the component and bonds to the area of any preceding layer of powder to thereby progressively build the component in the course of an additive manufacturing build cycle.
  • the process chamber 18 and the build chamber 24 are maintained under a protective or inert atmosphere or placed under a vacuum, depending respectively on whether a laser or electron beam directed beam energy source is employed.
  • the installation also includes in the lower part of the main housing an adjustment system 30 for controlling the position of the build housing 22.
  • the adjustment system 30 includes a lifting or biasing device 32 operable to hold the build housing 22 in a raised position shown in Figures 3 and 9, in which, during operation of the installation 10 to conduct a build cycle, a substantially gas-tight seal is maintained around the open top of the build housing so a protective or inert atmosphere or vacuum is maintained in each of the process chamber 18 and the build chamber 24.
  • the lifting or biasing device 32 also is operable on completion of a build cycle to lower the build housing 22 from the raised position, or to enable the build housing 22 to lower under gravity, to a lowered position shown in Figures 2, 6 and 10, and thereby break the gas-tight seal around the open top of the build housing 22.
  • the adjustment system 30 also includes a drive system 34 that is operable, with the build housing 22 in the lowered position enabled by the lifting or biasing device 32, to move the build housing 22 laterally between the lowered position shown in Figures 2, 6 and 10 and an advanced position beyond the access opening 28, as shown in 4, 5 and 7.
  • the lifting or biasing device 32 comprises a short acting scissor lift 36 that is raised and lowered by a hydraulic actuator 38, although other drives can be used.
  • the drive system 34 comprise a system of rollers 40 mounted in relation to the build housing 22 and engaged between upper and lower runs 42a of a horizontally extending rails 42 mounted in relation to each of opposite sidewalls 14a of main housing 14, with drive provided by an electric motor 44.
  • the arrangement is such that the build housing 22 is horizontally movable to and from the advanced position in a direction perpendicular to front and rear walls 14b and 14c of the main housing 14, and intermediate of and substantially parallel to sidewalls 14a of housing 14.
  • the build housing 22 When retracted into main housing 14, the build housing 22 is nearer to the front sidewall 14b than to the rear sidewall 14, and occupies about half of the spacing between wall 14b and 14c, to leave a space between the build housing 22 and the rear wall 14c in which a mounting arrangement 46 for the build housing 22 is able to be provided.
  • the mounting arrangement 46 includes a respective one of rails 42 secured on each sidewall 14a that extends horizontally between front wall 14b and rear wall 14c, the rollers 40, triangular extensions plates 48 mounted on the build chamber 22 and projecting towards the rear wall 14c, and the drive motor 47.
  • Each extension 48 is mounted on a respective side of the build housing 22 and projects towards rear wall14c, adjacent to and substantially parallel with a respective sidewall 14a.
  • a horizontally spaced pair of the rollers 40 is mounted on each extension plate 48 and run on a respective rail 42, between the upper and lower runs 42a, 42b of the rail 42.
  • the motor 47 is mounted in one of the rails 42 and has an output gear 47a that meshes with gear teeth (not discernible) along the underside of run 42b of the rail 42 so as to drive housing 22 between the advanced and retracted positions.
  • a limit switch 49 is mounted on one of the extensions 48 so as to be movable as housing 22 is advanced and retracted, with switch limiting the range of movement by contacting stops 49a spaced along the rail 42 to regulate operation of motor 47.
  • the sub-housing 12 of the installation 10 is mounted on wheels 49 for ease of mobility, and comprises a body 50 and a cover member 52.
  • the body 50 is open-topped and defines a sub-chamber 54 that, as shown in Figure 6, is accessible through an open side 56 of the body 50.
  • the cover member 52 comprises a downwardly open glove box enclosure secured over the open top of the body 50.
  • the body 50 a lifting or biasing system 58 that is similar to device 32 and is operable to lift the build housing 22 to, and hold the build housing 22 at, an upper position in the sub chamber 24 in which a substantially gas-tight seal is maintained around and between the open top of the build housing 22 and a periphery of the glove box enclosure cover member 52, to maintain a protective or inert atmosphere, or a vacuum, in each of the build chamber 22 and the glove box cover member 52.
  • a lifting or biasing system 58 that is similar to device 32 and is operable to lift the build housing 22 to, and hold the build housing 22 at, an upper position in the sub chamber 24 in which a substantially gas-tight seal is maintained around and between the open top of the build housing 22 and a periphery of the glove box enclosure cover member 52, to maintain a protective or inert atmosphere, or a vacuum, in each of the build chamber 22 and the glove box cover member 52.
  • the adjustment mechanism within the build housing by which the build platform was lowered stepwise during a build cycle, can be operated to raise the build platform in the build chamber to the lower periphery of the glove box enclosure, and thereby move the build and unfused powder into the glove box cover member 52.
  • the arrangement of sub-housing 12 is such that, with the access panel 26 of the main housing 14 removed from access opening 28 of main housing 14, the sub-housing 12 can be securely engaged with the lower part of the main housing 14 to provide communication between the main housing 14 and the sub-housing 12, through the access opening 28 and the open side 56 of body 50 of sub- housing 12, as shown in Figures 6, 10 and 11.
  • a substantially gas-tight seal is provided between opposed surfaces of the main housing 14 and the sub-housing 12, around the peripheries of the access opening 28 and the open side 56 of the sub-housing 12.
  • the engagement of sub-housing 12 with the main housing 14, and the establishment and maintenance of the seal between those opposed surfaces is secured by clamps 58 operable between sub-housing 12 and housing 14.
  • the installation has an associated pressurised source of protective or inert gas, or an associated vacuum system, by which a protective or inert atmosphere or a vacuum, respectively, is able to be provided throughout the main housing.
  • the arrangement is such that the atmosphere or vacuum prevails in both the process chamber 18 and the build chamber 24, as well as exteriorly of the build housing 22 in the lower part of the main housing 14.
  • a substantially gas-tight seal is provided between respective opposed faces of the main housing 14 and the access panel 26, around and between the peripheries of the access opening 28 and the access panel 26.
  • the atmosphere or vacuum in the main housing 14, exteriorly of the build housing 22, is lost when the access panel 26 is removed or opened.
  • the pressurised gas source or the vacuum source is operable to re-establish the atmosphere or vacuum exteriorly of the build housing 22, within the main housing 14, and also to establish the atmosphere or vacuum in the sub-housing 12, via the access opening 28 and the open side 56 of the body 50 sub-housing 12.
  • the lifting or biasing device 32 With the sub housing 12 securely engaged with the main housing 14 and containing the established atmosphere or vacuum, the lifting or biasing device 32 then is able to be operated to enable the build housing 22 to be lowered, to break the gas-tight seal around the open top of the build housing 22.
  • the volume of the sub-chamber 54 of the body 50 and the dimensions of the side opening 56 are such that the drive system 34 then is able to operate to advance the build housing 22 to the advanced position, by moving the build housing 22 laterally from the main housing 14, through the access opening 28 and the open side 56 of the sub-housing 12, and into the sub-chamber 54 of the sub-housing 12.
  • a build assembly in the build chamber comprising the build platform, a build attached the build platform as a consequence of a production cycle and powder that remains unfused after the production cycle, can be moved from the build chamber 24 by reverse operation of the adjustment mechanism of the build chamber 24.
  • This removal of the build assembly occurs prior to operation of the drive system 34 to retract the build housing 22 and its adjustment mechanism back into the main housing 14. The removal achieved by reversal of the operation of the adjustment mechanism by which the build platform previously was lowered stepwise into the build chamber 24.
  • the sub-housing 12 After removal of the build assembly from the build chamber 24, the sub-housing 12 is able to be disengaged from the main housing 14 and, following closing of the access opening 28 by the access panel 26 and insertion of a replacement build plate, such as via the process chamber 18, the installation 10 is able to be readied for commencement of a next production cycle.
  • the installation 10 of the present invention preferably is operated with at least two sub-housings 12.
  • a build housing 22 present in the main housing 14 on completion of a build production cycle, can be moved out of the main housing 14 to enable removal and recovery of the build assembly without the need to hold the build housing 22 and the build assembly in the main housing 14 they are sufficiently cooled to enable further processing for recovery of unfused powder and separation of the build.
  • the holding time can be up to several hours.
  • the present invention enables avoidance of this substantial down time in which the installation will be out of productive use.

Abstract

An additive manufacturing installation has a main housing with an upper part containing a process chamber and a lower part containing a build housing defining an open topped build chamber and containing a build platform in the build chamber, the lower part of the housing having an access opening spaced laterally from the build chamber and an access panel secured over the access opening. A powder dispensing system enables deposition of successive layers of a heat fusible powder over a build plane across the process chamber, adjacent to the build chamber. A directed beam energy source in the upper part of the main housing is operable in a build cycle to selectively scan and thereby selectively sinter or melt powder in a respective defined area of each of successive powder layers. An adjustment device in the build chamber is operable during the build cycle to lower the build platform in the build chamber from an upper position in which an upper surface of the build platform is at or adjacent to the build plane. A holding device is operable to release the build housing, with completion of the build cycle, from a position in which it is retained during the build cycle. With the build chamber released by the holding device and with the access panel moved to open the access opening, a drive system is operable to move the build chamber laterally through the access opening to a position outside the main housing, beyond the access opening.

Description

An Additive Manufacturing Installation Field of the Invention
[001] The present invention relates to an installation for use in additive manufacturing and to a method of additive manufacturing using the installation. The installation and method are well suited to the production of at least one component in each build production cycle to form a build assembly of a build plate and an attached build of the at least one component. The production cycle involves selective application of a directed beam energy source, such as a laser in a selective laser process involving melting (SLM) or sintering (SLS) or a similar additive manufacturing process employing an electron beam energy source. While the invention is to be understood as extending to the use of both laser and electron beam directed beam energy sources, the description largely is disclosed herein in relation to operation with at least one laser source, specifically in an SLM production cycle. Background to the Invention
[002] The production of at least component by an SLM process involves the spreading of successive thin layers of powder in a process chamber of an SLM installation, over a build plane above a build plate initially adjacent to the base of the process chamber. Each layer of powder is scanned by a laser and thereby subjected to selective melting to form, at the build plane, a respective slice of at least one required component, before spreading of the next of successive layers of powder in an iterative operation. The first slice bonds to the build plate or a support structure, while subsequent slices bond to a preceding slice, to progressively build up a complete component, or a plurality of complete components. After each slice is formed, the build plate is lowered away from the process chamber into a build chamber of the SLM installation, to offset the increased height of material building up on the build plate and to maintain a constant build plane at which the laser scans and selectively melts the powder of each layer. Thus, a resultant completed build creating the at least one component is contained within the build chamber, along with unfused powder of the successive layers that was not subjected to selective melting by the laser. [003] The SLM process is conducted under an inert or protective atmosphere maintained in both the process and build chambers. The considerable temperatures generated in the course of each SLM production cycle for the production of components necessitates maintenance of the protective atmosphere after completion of the build, until the contents of the build chamber cool sufficiently, such as to a temperature below 40 °C. In current arrangements cooling is conducted within the SLM installation, after which the build plate is raised back to or towards the level of the build plane to thereby lift both the build and the unfused powder. The process chamber then is accessed to enable recovery of at least a major part of the unfused powder, usually by means of brushes or a suction line. Subsequently a build assembly comprising the build plate with the still attached build, with the residue of the unfused powder, is removed from the SLM installation via the process chamber and transferred to a glove box to enable recovery of the residue of unfused powder. After the build assembly is removed from the glove box, the build is separated from the build plate and the build plate then can be prepared and repositioned in the SLM installation for re-use.
[004] Many current SLM installations having a build chamber of up to about 250 x 250 x 250 mm although, in larger installations becoming available, the build chambers are increasing in size up to 1000 x 800 x 500 mm, and higher. Even with build chambers of the lesser sizes, the time required for cooling in the installation results in a very considerable down-time in which the installation is not available for ongoing production of components, while still further time is lost in raising the build plate, accessing the process chamber and recovering a major part of the unfused powder from the build before the build assembly is removed from the process chamber of the installation. This part of powder recovery within the confines of the process chamber can be difficult, while it complicates readying the installation for a next build production cycle, particularly if there is to be a change in powder to be used in the next production cycle. Also, the recovery will be further complicated with the development of SLM installations of increased sizes, while the volume and weight of larger build chambers are limiting factors for manoeuvring a build assembly to a location suitable for recovery of residual powder recovery and, if required, for adjusting the orientation of the build assembly during recovery of residual powder.
[005] The present invention is directed to providing an installation for use in additive manufacturing and to a method of additive manufacturing with the installation, with use of either a laser or an electron beam energy source, by a build production cycle forming a build assembly, of a build plate and an attached build of the at least one component, with improved recovery of unfused powder remaining after the build production cycle.
Broad Summary of the Invention
[006] The present invention provides an additive manufacturing installation having: a main housing with an upper part containing a process chamber and a lower part containing a build housing defining an open topped build chamber and containing a build platform in the build chamber, the lower part of the housing having an access opening spaced laterally from the build chamber and an access panel secured over the access opening; a powder dispensing system for deposition of successive layers of a heat fusible powder over a build plane across the process chamber, adjacent to the build chamber; a directed beam energy source in the upper part of the main housing and operable in a build cycle to selectively scan and thereby selectively sinter or melt powder in a respective defined area of each of successive powder layers; an adjustment device in the build chamber operable during the build cycle to lower the build platform in the build chamber from an upper position in which an upper surface of the build platform is at or adjacent to the build plane; a holding device operable to release the build housing, with completion of the build cycle, from a position in which it is retained during the build cycle; and a drive system that, with the build chamber released by the holding device and with the access panel moved to open the access opening, is operable to move the build chamber laterally through the access opening to a position outside the main housing, beyond the access opening.
[007] In one form, wherein the directed beam energy source a laser, with the installation including an associated pressurised source of protective or inert gas by which a protective or inert atmosphere is able to be provided throughout the main housing, including in both the process chamber and the build chamber and also exteriorly of the build housing in the lower part of the main housing. However, in an alternative form, the directed beam energy source is an electron beam source, with the installation including an associated vacuum system by which a vacuum is able to be provided throughout the main housing, including in both the process chamber and the build chamber and also exteriorly of the build housing in the lower part of the main housing.
[008] The installation most preferably includes an open-sided sub-housing that defines a sub-chamber accessible through the open side. With the access panel of the main housing removed or open, the sub-housing can be securely engaged with the lower part of the main housing to provide communication between the main housing and the sub-housing, through the access opening and the open side of the sub-housing. A substantially gas-tight seal may be provided between opposed surfaces of the main housing and the sub-housing, around the peripheries of the access opening and the open side of the sub-housing.
[009] According to a first form, the present invention provides an installation for use in additive manufacturing, with use of either a laser, or an electron, directed beam energy source, wherein the installation includes a main housing having an upper part containing a process chamber and a lower part accommodating an open-topped build housing that defines a build chamber. The installation further includes a powder dispensing system for the deposition of successive layers of powder material over a build plane defined across a junction between the process chamber and the build housing. A build platform extends across the build chamber and is supported by an adjustment mechanism positioned in the build housing and operable to lower the build platform stepwise in the build chamber, from an upper position in which an upper surface of the build platform is at or adjacent to the build plane, to successive lower positions within the build chamber. The installation has a scanning system that includes a directed energy source device for generating and emitting energy as a directed beam, a focusing and directing system operable to direct an energy beam downwardly through the process chamber to the build plane, and a computer control system including a CAD/CAM system for generating data specifying dimensions defining a component to be built by additive manufacturing. The control system is operable in response to the data to cause the focusing and directing system to focus and direct an energy beam emitted by the source device for selectively scanning, and thereby selectively sintering or melting, powder in a defined area of a powder layer disposed over the build plane, such that the defined area of each of successive powder layers corresponds to a layer of the component and bonds to the area of any preceding layer of powder to thereby progressively build the component in the course of an additive manufacturing build cycle. Throughout the build cycle the process chamber and the build chamber are maintained under a protective or inert atmosphere or placed under a vacuum, depending respectively on whether a laser or electron beam directed beam energy source is employed.
[010] The installation of the first form of the invention has an access panel provided over an access opening in a lower part of a sidewall of the main housing, with the access panel able to be removed or opened manually or by means of an access device. The access opening is positioned and of a size to permit the build housing to be moved through the access opening, to an advanced position outside the main housing. The installation also includes in the lower part of the main housing an adjustment system for controlling the position of the build housing. The adjustment system includes a lifting or biasing device operable to hold the build housing in a raised position in which, during operation of the installation to conduct a build cycle, a substantially gas-tight seal is maintained around the open top of the build housing so a protective or inert atmosphere or vacuum is maintained in each of the process chamber and the build chamber. The lifting or biasing device also is operable on completion of a build cycle to lower the build housing from the raised position to a lowered position, or to enable the build housing to lower under gravity to a lowered position, and thereby break the gas- tight seal around the open the build housing. The adjustment system also includes a drive system that is operable, with the build housing in the lowered position enabled by the lifting or biasing device, to move the build housing laterally between the lowered position and an advanced position beyond the access opening. The extent to which the build housing is moved or moves from the raised position to the lowered position is to be sufficient not only to break the seal, but also to position laterally in line with the access opening when the build housing in a lower position.
[011] The installation includes an open-sided sub-housing that defines a sub- chamber accessible through the open side. With the access panel of the main housing removed or open, the sub-housing can be securely engaged with the lower part of the main housing to provide communication between the main housing and the sub-housing, through the access opening and the open side of the sub-housing, with a substantially gas-tight seal provided between opposed surfaces of the main housing and the sub-housing, around the peripheries of the access opening and the open side of the sub-housing.
[012] The installation has an associated pressurised source of protective or inert gas, or an associated vacuum system, by which a protective or inert atmosphere or a vacuum, respectively, is able to be provided throughout the main housing, including in both the process chamber and the build chamber and also exteriorly of the build housing in the lower part of the main housing. To maintain the atmosphere or vacuum in the lower part of the main housing, exteriorly of the build housing, a substantially gas-tight seal is provided between respective opposed faces of the main housing and the access panel, around and between the peripheries of the access opening and the access panel. The atmosphere or vacuum in the main housing, exteriorly of the build housing, is lost when the access panel is removed or opened. However, with the sub-housing securely engaged with the main housing, the pressurised gas source or the vacuum source is operable to re-establish the atmosphere or vacuum exteriorly of the build housing, within the main housing, and also to establish the atmosphere or vacuum in the sub-housing, via the access opening and the open side of the sub-housing. With the sub-housing securely engaged with the main housing and containing the established atmosphere or vacuum, the lifting or biasing device then is able to be operated to enable the build housing to be lowered, to break the gas-tight seal around the open top of the build housing. The volume of the sub-chamber and the dimensions of the side opening are such that the drive system then is able to operate to advance the build housing to the advanced position, by moving the build housing laterally from the main housing, through the access opening and the open side of the sub-housing, and into the sub-chamber of the sub-housing.
[013] With the build housing in the advanced position within the sub-housing, the arrangement is such as to enable a build assembly in the build chamber, comprising the build platform, a build attached the build platform as a consequence of a production cycle and powder that remains unfused after the production cycle, to be to be moved from the build chamber by reverse operation of the adjustment mechanism of the build chamber. This removal of the build assembly occurs prior to operation of the drive system to retract the build housing and its adjustment mechanism back into the main housing and is achieved by reversal of the operation of the adjustment mechanism by which the build platform previously was lowered stepwise into the build chamber. The arrangement is such that, after removal of the build assembly from the build chamber, the sub-housing is able to be disengaged from the main housing and, following closing of the access opening by the access panel and insertion of a replacement build plate, such as via the process chamber, the installation is able to be readied for commencement of a next production cycle.
[014] To enable the contents of the build housing to be moved from the build chamber, the sub-housing preferably has an open-topped body that defines the sub-chamber and the open side of the sub-housing, and a cover member that comprises a downwardly open glove box enclosure secured over the open top of the open-topped body. Also, the body of the sub-housing includes a lifting or biasing system operable to lift the build housing to, and hold the build housing at, an upper position in the sub-chamber in which a substantially gas-tight seal is maintained around and between the open top of the build housing and a periphery of the glove box enclosure, to maintain a protective or inert atmosphere, or a vacuum, in each of the build chamber and the glove box enclosure. With the build housing held in the upper position, the adjustment mechanism within the build housing, by which the build platform was lowered stepwise during a build cycle, can be operated to raise the build platform in the build chamber to the lower periphery of the glove box enclosure, and thereby move the build and unfused powder into the glove box enclosure.
[015] The installation of the present invention may, and preferably does, operate with at least two sub-housings. As a result, a build housing present in the main housing, on completion of a build production cycle, can be moved out of the main housing to enable removal and recovery of the build assembly without the need to hold the build housing and the build assembly in the main housing until the build housing, and the contained build assembly, is sufficiently cooled to enable further processing for recovery of unfused powder and separation of the build. Depending on the size of the build housing and, hence, the volume of the build and unfused powder contained in the build chamber on completion of the build cycle, the holding time can be up to several hours. However the present invention enables avoidance of this substantial down-time in which the installation will be out of productive use.
[016] The lifting or biasing device operable to hold the build housing in a raised position during operation of the installation to conduct a build cycle, can take a variety of forms. Also, the drive system, operable to move the build housing laterally between the lowered position and an advanced position beyond the access opening, can take a variety of forms. However, particularly with build housings for larger build chambers, the weight of the build housing and the contained build assembly can be substantial, and each of the lifting or biasing device and the drive system need to be sufficiently robust to accommodate the loads. Also, with the lateral movement provided by the drive system, it can be necessary, at least with very large build housings, to incorporate a system of counter-weights that moves oppositely to the build housing and at least partially offsets the weight of the build housing and the contained build assembly.
[017] The lifting or biasing device may comprise a short-acting scissor lift, such as an electrically, pneumatically or hydraulically driven scissor lift. Alternatively, the device may comprise at least one short stroke flat hydraulic cylinder such as available under the trade mark ENERPAC. The drive system may comprise a system of rollers mounted in relation to the build housing and engaged with horizontally extending rails mounted in relation to the main housing, with drive provided by an electric motor. [018] The main housing may be rectangular in plan view, with the build housing horizontally movable towards and retractable from the advanced position in a direction that is perpendicular to a first pair of sidewalls of the main housing, of which one sidewall defines the access opening, and intermediate of and substantially parallel to a second pair of sidewalls. When retracted, the build housing may be nearer to the one sidewall, and spaced from the other sidewall, of the first pair, to leave a space between the build housing and the other sidewall in which a mounting arrangement for the build housing and a drive motor is able to be provided. The space may be about half the distance between the sidewalls of the first pair. The mounting arrangement may be provided by a respective rail that is secured on each sidewall of the second pair and that extends horizontally between each sidewall of the first pair, and by rollers mounted on extensions mounted on the build chamber that projecting towards the other sidewall of the first pair, to enable the drive motor to be mounted within the space.
[019] The invention also provides a sub-housing suitable for use with the installation of the invention. The sub-housing defines a sub-chamber accessible through an open side of the sub-housing, while the sub-housing is adapted to be securely engaged with the lower part of the main housing of the installation to provide communication between the main housing and the sub-housing, with the access panel of the main housing removed or open, through the access opening and the open side of the sub-housing. A substantially gas-tight seal provided between opposed surfaces of the main housing and the sub-housing, around the peripheries of the access opening and the open side of the sub-housing.
[020] Secure engagement of the sub-housing with the main housing enables the pressurised gas source or the vacuum source to be operable to re-establish the atmosphere or vacuum exteriorly of the build housing, within the main housing, and also to establish the atmosphere or vacuum in the sub-housing, via the access opening and the open side of the sub-housing.
[021] The sub-housing when securely engaged with the main housing and containing the established atmosphere or vacuum, enables the holding device to be operated to enable the build housing to be lowered, to break the gas-tight seal around the open top of the build housing.
[022] The sub-housing is such that, with the build housing in the advanced position within the sub-housing, a build assembly in the build chamber comprising the build platform, a build attached the build platform as a consequence of a production cycle and powder that remains unfused after the production cycle, can be moved from the build chamber by reverse operation of the adjustment mechanism of the build chamber.
[023] To enable the build assembly to be moved from the build chamber, the sub housing has an open-topped body that defines the sub-chamber and the open side of the sub-housing, and a cover member that comprises a downwardly open glove box enclosure secured over the open top of the open-topped body.
[024] The body of the sub-housing includes a lifting or biasing system operable to lift the build housing to, and hold the build housing at, an upper position in the sub chamber in which a substantially gas-tight seal is maintained around and between the open top of the build housing and a periphery of the glove box enclosure, to maintain a protective or inert atmosphere, or a vacuum, in each of the build chamber and the glove box enclosure, whereby with the build housing held in the upper position, the adjustment mechanism within the build housing, by which the build platform was lowered stepwise during a build cycle, can be operated to raise the build platform in the build chamber to the lower periphery of the glove box enclosure, and thereby move the build and unfused powder into the glove box enclosure.
General Description of the Drawings
[025] Figure 1 is an isometric view of an additive manufacturing installation according to the present invention;
[026] Figure 2 corresponds to Figure 1 , but with external parts removed to illustrate internal detail;
[027] Figure 3 corresponds to Figure 2, but after adjustment to enable performance of a build cycle; [028] Figure 4 corresponds to Figure 2, but with the installation in a condition enabled after completion of a build cycle;
[029] Figure 5 corresponds to Figure 5, but with external parts removed to illustrate internal detail;
[030] Figure 6 shows the installation of Figure 2, but after securement of a further component;
[031] Figure 7 is a side elevation of the installation as shown in Figure 5;
[032] Figure 8 corresponds to Figure 7, but with the installation in the condition shown in Figure 2;
[033] Figure 9 corresponds to Figure 8, but with the installation in the condition shown in Figure 3;
[034] Figure 10 is a side elevation if the installation in the condition shown in Figure 6; and
[035] Figure 11 corresponds to Figure 10, but with the in the condition shown in Figure 4. Detailed Description of the Drawings
[036] Figures 1 to 11 show an installation 10, for use in additive manufacturing. In Figures 6, 10 and 11 the installation 10 is shown in combination with a sub housing 12 of the installation, described later herein. The installation 10 includes a main housing 14 having an upper part 16 containing a process chamber 18 and a lower part 20 accommodating an open-topped build housing 22 that defines a build chamber 24 shown in Figures 4 and 5. The front of the installation 10 is facing to the left in all of the Figures and, as can be appreciated from a consideration of Figures 1 to 3, the front wall of lower part 20 comprises an access panel 26 that is removable to expose an access opening 28. In Figures 2, 3 and 5 to 11 , a side panel of lower part 20 has been omitted to reveal internal detail within part 20. While not visible within process chamber 18, the installation 10 includes a powder dispensing system for the deposition of successive layers of powder material over a build plane defined across a junction between the process chamber and the build housing 22. A build platform (not visible) extends across the build chamber 24 and is supported by an adjustment mechanism (also not visible) positioned in the build housing 22 and operable to lower the build platform stepwise in the build chamber, from an upper position in which an upper surface of the build platform is at or adjacent to the build plane, to successive lower positions within the build chamber 24. The installation 10 has a scanning system (not visible) that includes a directed energy source device for generating and emitting energy as a directed beam, a focusing and directing system operable to direct an energy beam downwardly through the process chamber to the build plane, and a computer control system including a CAD/CAM system for generating data specifying dimensions defining a component to be built by additive manufacturing.
[037] The features that are not shown or are not visible are well understood in the technology of additive manufacturing by selective application of a directed beam energy source, such as a laser in a selective laser process involving melting (SLM) or sintering (SLS) or a similar additive manufacturing process employing an electron beam energy source. As will be appreciated in that technology, the control system is operable in response to the generated data to cause the focusing and directing system to focus and direct an energy beam emitted by the source device for selectively scanning, and thereby selectively sintering or melting, powder in a defined area of a powder layer disposed over the build plane, such that the defined area of each of successive powder layers corresponds to a layer of the component and bonds to the area of any preceding layer of powder to thereby progressively build the component in the course of an additive manufacturing build cycle. Throughout the build cycle the process chamber 18 and the build chamber 24 are maintained under a protective or inert atmosphere or placed under a vacuum, depending respectively on whether a laser or electron beam directed beam energy source is employed. [038] With the access panel 26 removed from access opening 28, the build housing 22 can be moved through the access opening 28, to an advanced position outside the main housing 14. The installation also includes in the lower part of the main housing an adjustment system 30 for controlling the position of the build housing 22. The adjustment system 30 includes a lifting or biasing device 32 operable to hold the build housing 22 in a raised position shown in Figures 3 and 9, in which, during operation of the installation 10 to conduct a build cycle, a substantially gas-tight seal is maintained around the open top of the build housing so a protective or inert atmosphere or vacuum is maintained in each of the process chamber 18 and the build chamber 24. The lifting or biasing device 32 also is operable on completion of a build cycle to lower the build housing 22 from the raised position, or to enable the build housing 22 to lower under gravity, to a lowered position shown in Figures 2, 6 and 10, and thereby break the gas-tight seal around the open top of the build housing 22. The adjustment system 30 also includes a drive system 34 that is operable, with the build housing 22 in the lowered position enabled by the lifting or biasing device 32, to move the build housing 22 laterally between the lowered position shown in Figures 2, 6 and 10 and an advanced position beyond the access opening 28, as shown in 4, 5 and 7. As is evident from the drawings, the extent to which the build housing 22 is moved or moves from the raised position of Figures 3 and 9 to the lowered position of Figures 2, 6 and 10 is to be sufficient not only to break the seal, but also to position the housing 22 laterally in line with the access opening 28 when the build housing 2 is in the lower position. [039] In the arrangement shown, the lifting or biasing device 32 comprises a short acting scissor lift 36 that is raised and lowered by a hydraulic actuator 38, although other drives can be used. The drive system 34 comprise a system of rollers 40 mounted in relation to the build housing 22 and engaged between upper and lower runs 42a of a horizontally extending rails 42 mounted in relation to each of opposite sidewalls 14a of main housing 14, with drive provided by an electric motor 44. The arrangement is such that the build housing 22 is horizontally movable to and from the advanced position in a direction perpendicular to front and rear walls 14b and 14c of the main housing 14, and intermediate of and substantially parallel to sidewalls 14a of housing 14.
[040] When retracted into main housing 14, the build housing 22 is nearer to the front sidewall 14b than to the rear sidewall 14, and occupies about half of the spacing between wall 14b and 14c, to leave a space between the build housing 22 and the rear wall 14c in which a mounting arrangement 46 for the build housing 22 is able to be provided. The mounting arrangement 46 includes a respective one of rails 42 secured on each sidewall 14a that extends horizontally between front wall 14b and rear wall 14c, the rollers 40, triangular extensions plates 48 mounted on the build chamber 22 and projecting towards the rear wall 14c, and the drive motor 47. Each extension 48 is mounted on a respective side of the build housing 22 and projects towards rear wall14c, adjacent to and substantially parallel with a respective sidewall 14a. A horizontally spaced pair of the rollers 40 is mounted on each extension plate 48 and run on a respective rail 42, between the upper and lower runs 42a, 42b of the rail 42. The motor 47 is mounted in one of the rails 42 and has an output gear 47a that meshes with gear teeth (not discernible) along the underside of run 42b of the rail 42 so as to drive housing 22 between the advanced and retracted positions. A limit switch 49 is mounted on one of the extensions 48 so as to be movable as housing 22 is advanced and retracted, with switch limiting the range of movement by contacting stops 49a spaced along the rail 42 to regulate operation of motor 47. [041] The sub-housing 12 of the installation 10 is mounted on wheels 49 for ease of mobility, and comprises a body 50 and a cover member 52. The body 50 is open-topped and defines a sub-chamber 54 that, as shown in Figure 6, is accessible through an open side 56 of the body 50. The cover member 52 comprises a downwardly open glove box enclosure secured over the open top of the body 50. Also, at the bottom of the sub-chamber 54, the body 50 a lifting or biasing system 58 that is similar to device 32 and is operable to lift the build housing 22 to, and hold the build housing 22 at, an upper position in the sub chamber 24 in which a substantially gas-tight seal is maintained around and between the open top of the build housing 22 and a periphery of the glove box enclosure cover member 52, to maintain a protective or inert atmosphere, or a vacuum, in each of the build chamber 22 and the glove box cover member 52. With the build housing 22 held in the upper position, the adjustment mechanism within the build housing, by which the build platform was lowered stepwise during a build cycle, can be operated to raise the build platform in the build chamber to the lower periphery of the glove box enclosure, and thereby move the build and unfused powder into the glove box cover member 52. [042] The arrangement of sub-housing 12 is such that, with the access panel 26 of the main housing 14 removed from access opening 28 of main housing 14, the sub-housing 12 can be securely engaged with the lower part of the main housing 14 to provide communication between the main housing 14 and the sub-housing 12, through the access opening 28 and the open side 56 of body 50 of sub- housing 12, as shown in Figures 6, 10 and 11. While not visible, a substantially gas-tight seal is provided between opposed surfaces of the main housing 14 and the sub-housing 12, around the peripheries of the access opening 28 and the open side 56 of the sub-housing 12. The engagement of sub-housing 12 with the main housing 14, and the establishment and maintenance of the seal between those opposed surfaces is secured by clamps 58 operable between sub-housing 12 and housing 14.
[043] While not shown, the installation has an associated pressurised source of protective or inert gas, or an associated vacuum system, by which a protective or inert atmosphere or a vacuum, respectively, is able to be provided throughout the main housing. The arrangement is such that the atmosphere or vacuum prevails in both the process chamber 18 and the build chamber 24, as well as exteriorly of the build housing 22 in the lower part of the main housing 14. To maintain the atmosphere or vacuum in the lower part 20 of the main housing 14, exteriorly of the build housing 22, a substantially gas-tight seal is provided between respective opposed faces of the main housing 14 and the access panel 26, around and between the peripheries of the access opening 28 and the access panel 26. The atmosphere or vacuum in the main housing 14, exteriorly of the build housing 22, is lost when the access panel 26 is removed or opened. However, with the sub housing 12 securely engaged with the main housing 14, the pressurised gas source or the vacuum source is operable to re-establish the atmosphere or vacuum exteriorly of the build housing 22, within the main housing 14, and also to establish the atmosphere or vacuum in the sub-housing 12, via the access opening 28 and the open side 56 of the body 50 sub-housing 12. With the sub housing 12 securely engaged with the main housing 14 and containing the established atmosphere or vacuum, the lifting or biasing device 32 then is able to be operated to enable the build housing 22 to be lowered, to break the gas-tight seal around the open top of the build housing 22. The volume of the sub-chamber 54 of the body 50 and the dimensions of the side opening 56 are such that the drive system 34 then is able to operate to advance the build housing 22 to the advanced position, by moving the build housing 22 laterally from the main housing 14, through the access opening 28 and the open side 56 of the sub-housing 12, and into the sub-chamber 54 of the sub-housing 12.
[044] With the build housing 22 in the advanced position within the sub-housing 12, a build assembly in the build chamber, comprising the build platform, a build attached the build platform as a consequence of a production cycle and powder that remains unfused after the production cycle, can be moved from the build chamber 24 by reverse operation of the adjustment mechanism of the build chamber 24. This removal of the build assembly occurs prior to operation of the drive system 34 to retract the build housing 22 and its adjustment mechanism back into the main housing 14. The removal achieved by reversal of the operation of the adjustment mechanism by which the build platform previously was lowered stepwise into the build chamber 24. After removal of the build assembly from the build chamber 24, the sub-housing 12 is able to be disengaged from the main housing 14 and, following closing of the access opening 28 by the access panel 26 and insertion of a replacement build plate, such as via the process chamber 18, the installation 10 is able to be readied for commencement of a next production cycle.
[045] The installation 10 of the present invention preferably is operated with at least two sub-housings 12. As a result, a build housing 22 present in the main housing 14, on completion of a build production cycle, can be moved out of the main housing 14 to enable removal and recovery of the build assembly without the need to hold the build housing 22 and the build assembly in the main housing 14 they are sufficiently cooled to enable further processing for recovery of unfused powder and separation of the build. Depending on the size of the build housing 22 and, hence, the volume of the build and unfused powder contained in the build chamber on completion of the build cycle, the holding time can be up to several hours. However the present invention enables avoidance of this substantial down time in which the installation will be out of productive use.

Claims

Claims
1. An additive manufacturing installation having: a main housing with an upper part containing a process chamber and a lower part containing a build housing defining an open topped build chamber and containing a build platform in the build chamber, the lower part of the housing having an access opening spaced laterally from the build chamber and an access panel secured over the access opening; a powder dispensing system for deposition of successive layers of a heat fusible powder over a build plane across the process chamber, adjacent to the build chamber; a directed beam energy source in the upper part of the main housing and operable in a build cycle to selectively scan and thereby selectively sinter or melt powder in a respective defined area of each of successive powder layers; an adjustment device in the build chamber operable during the build cycle to lower the build platform in the build chamber from an upper position in which an upper surface of the build platform is at or adjacent to the build plane; a holding device operable to release the build housing, with completion of the build cycle, from a position in which it is retained during the build cycle; and a drive system that, with the build chamber released by the holding device and with the access panel moved to open the access opening, is operable to move the build chamber laterally through the access opening to a position outside the main housing, beyond the access opening.
2. The installation of claim 1 , wherein the directed beam energy source a laser.
3. The installation of claim 1 , wherein the directed beam energy source is an electron beam source.
4. The installation of any one of claims 1 to 3, wherein the holding device is a lifting or biasing device operable to hold the build housing in a raised position in which, during operation of the installation to conduct a build cycle, a substantially gas-tight seal is maintained around the open top of the build housing so a protective or inert atmosphere or vacuum is maintained in each of the process chamber and the build chamber and, on completion of a build cycle, operable to lower the build housing from the raised position to a lowered position, or to enable the build housing to lower under gravity to a lowered position, and thereby break the gas-tight seal around the open the build housing.
5. The installation of claim 4, wherein the drive system is operable, with the build housing in the lowered position, to move the build housing laterally between the lowered position and an advanced position beyond the access opening.
6. The installation of any one of claims 1 to 5, including an associated pressurised source of protective or inert gas, or an associated vacuum system, by which a protective or inert atmosphere or a vacuum, respectively, is able to be provided throughout the main housing, including in both the process chamber and the build chamber and also exteriorly of the build housing in the lower part of the main housing.
7. The installation of claim 6, wherein to maintain the atmosphere or vacuum in the lower part of the main housing, exteriorly of the build housing, a substantially gas-tight seal is provided between respective opposed faces of the main housing and the access panel, around and between the peripheries of the access opening and the access panel.
8. The installation of an one of claims 1 to 7, further including an open-sided sub housing that defines a sub-chamber accessible through the open side, and wherein with the access panel of the main housing removed or open, the sub housing can be securely engaged with the lower part of the main housing to provide communication between the main housing and the sub-housing, through the access opening and the open side of the sub-housing, with a substantially gas-tight seal provided between opposed surfaces of the main housing and the sub-housing, around the peripheries of the access opening and the open side of the sub-housing.
9. The installation of claim 8 as appended to claim 6 or claim 7, wherein with the sub-housing securely engaged with the main housing, the pressurised gas source or the vacuum source is operable to re-establish the atmosphere or vacuum exteriorly of the build housing, within the main housing, and also to establish the atmosphere or vacuum in the sub-housing, via the access opening and the open side of the sub-housing.
10. The installation of claim 8 or claim 9, wherein with the sub-housing securely engaged with the main housing and containing the established atmosphere or vacuum, the holding device then is able to be operated to enable the build housing to be lowered, to break the gas-tight seal around the open top of the build housing.
11. The installation of any one of claims 8 to 10, wherein with the build housing in the advanced position within the sub-housing, a build assembly in the build chamber comprising the build platform, a build attached the build platform as a consequence of a production cycle and powder that remains unfused after the production cycle, can be moved from the build chamber by reverse operation of the adjustment mechanism of the build chamber.
12. The installation of claim 11 , wherein to enable the build assembly to be moved from the build chamber, the sub-housing has an open-topped body that defines the sub-chamber and the open side of the sub-housing, and a cover member that comprises a downwardly open glove box enclosure secured over the open top of the open-topped body.
13. The installation of claim 12, wherein the body of the sub-housing includes a lifting or biasing system operable to lift the build housing to, and hold the build housing at, an upper position in the sub-chamber in which a substantially gas- tight seal is maintained around and between the open top of the build housing and a periphery of the glove box enclosure, to maintain a protective or inert atmosphere, or a vacuum, in each of the build chamber and the glove box enclosure, whereby with the build housing held in the upper position, the adjustment mechanism within the build housing, by which the build platform was lowered stepwise during a build cycle, can be operated to raise the build platform in the build chamber to the lower periphery of the glove box enclosure, and thereby move the build and unfused powder into the glove box enclosure.
14. The installation of any one of claims 1 to 13, wherein the holding device comprises a short-acting scissor lift, such as an electrically, pneumatically or hydraulically driven scissor lift.
15. The installation of any one of claims 1 to 14, wherein the drive system comprises a system of rollers mounted in relation to the build housing and engaged with horizontally extending rails mounted in relation to the main housing, with drive provided by an electric motor.
16. The installation of claim 15, wherein the build housing is horizontally movable towards and retractable from the advanced position in a direction that is perpendicular to a first opposed pair of sidewalls of the main housing, of which one sidewall defines the access opening, and when retracted, the build housing is nearer to the one sidewall, and spaced from the other sidewall, of the first pair, to leave a space between the build housing and the other sidewall in which a mounting arrangement for the build housing and a drive motor is provided, with the mounting arrangement provided by a respective rail that is secured on each sidewall of a second pair and that extends horizontally between each sidewall of the first pair, and by rollers mounted on extensions mounted on the build chamber that projecting towards the other sidewall of the first pair, to enable the drive motor to be mounted within the space.
17. The installation of any one of claims 1 to 6, wherein the directed beam energy source is included in a scanning system including a focusing and directing system operable to direct an energy beam from the source downwardly through the process chamber to the build plane, and a computer control system including a CAD/CAM system for generating data specifying dimensions defining a component to be built by additive manufacturing; wherein the control system is operable in response to the data to cause the focusing and directing system to focus and direct an energy beam emitted by the source device for selectively scanning, and thereby selectively sintering or melting, powder in a defined area of a powder layer disposed over the build plane, such that the defined area of each of successive powder layers corresponds to a layer of the component and bonds to the area of any preceding layer of powder to thereby progressively build the component in the course of an additive manufacturing build cycle conducted under a protective or inert atmosphere or under a vacuum in the process chamber and the build chamber, depending respectively on whether a laser or electron beam directed beam energy source.
18. A sub-housing suitable for use with the installation of an one of claims 1 to 7, wherein the sub-housing defines a sub-chamber accessible through an open side, the sub-housing is adapted to be securely engaged with the lower part of the main housing of the installation to provide communication between the main housing and the sub-housing, with the access panel of the main housing removed or open, through the access opening and the open side of the sub housing, with a substantially gas-tight seal provided between opposed surfaces of the main housing and the sub-housing, around the peripheries of the access opening and the open side of the sub-housing.
19. The sub-housing of claim 18 for use with the installation of claim 6 or claim 7, wherein secure engagement of the sub-housing with the main housing enables the pressurised gas source or the vacuum source to be operable to re-establish the atmosphere or vacuum exteriorly of the build housing, within the main housing, and also to establish the atmosphere or vacuum in the sub- housing, via the access opening and the open side of the sub-housing.
20. The sub-housing of claim 18 or claim 19, wherein the sub-housing when securely engaged with the main housing and containing the established atmosphere or vacuum, enables the holding device to be operated to enable the build housing to be lowered, to break the gas-tight seal around the open top of the build housing.
21. The sub-housing of any one of claims 18 to 20, wherein with the build housing in the advanced position within the sub-housing, a build assembly in the build chamber comprising the build platform, a build attached the build platform as a consequence of a production cycle and powder that remains unfused after the production cycle, can be moved from the build chamber by reverse operation of the adjustment mechanism of the build chamber.
22. The sub-housing of claim 21 , wherein to enable the build assembly to be moved from the build chamber, the sub-housing has an open-topped body that defines the sub-chamber and the open side of the sub-housing, and a cover member that comprises a downwardly open glove box enclosure secured over the open top of the open-topped body.
23. The installation of claim 22, wherein the body of the sub-housing includes a lifting or biasing system operable to lift the build housing to, and hold the build housing at, an upper position in the sub-chamber in which a substantially gas- tight seal is maintained around and between the open top of the build housing and a periphery of the glove box enclosure, to maintain a protective or inert atmosphere, or a vacuum, in each of the build chamber and the glove box enclosure, whereby with the build housing held in the upper position, the adjustment mechanism within the build housing, by which the build platform was lowered stepwise during a build cycle, can be operated to raise the build platform in the build chamber to the lower periphery of the glove box enclosure, and thereby move the build and unfused powder into the glove box enclosure.
PCT/AU2020/050492 2019-05-20 2020-05-19 An additive manufacturing installation WO2020232500A1 (en)

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