WO2020240128A1 - Method for additive manufacturing of a part comprising a step of manufacturing a mixed support - Google Patents

Method for additive manufacturing of a part comprising a step of manufacturing a mixed support Download PDF

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Publication number
WO2020240128A1
WO2020240128A1 PCT/FR2020/050871 FR2020050871W WO2020240128A1 WO 2020240128 A1 WO2020240128 A1 WO 2020240128A1 FR 2020050871 W FR2020050871 W FR 2020050871W WO 2020240128 A1 WO2020240128 A1 WO 2020240128A1
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WO
WIPO (PCT)
Prior art keywords
support
additive manufacturing
manufacturing
powder
needle
Prior art date
Application number
PCT/FR2020/050871
Other languages
French (fr)
Inventor
François MASSIE
Jean-Baptiste Mottin
Original Assignee
Addup
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
Application filed by Addup filed Critical Addup
Publication of WO2020240128A1 publication Critical patent/WO2020240128A1/en

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Classifications

    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C64/00—Additive manufacturing, i.e. manufacturing of three-dimensional [3D] objects by additive deposition, additive agglomeration or additive layering, e.g. by 3D printing, stereolithography or selective laser sintering
    • B29C64/40—Structures for supporting 3D objects during manufacture and intended to be sacrificed after completion thereof
    • 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
    • B22F10/40—Structures for supporting workpieces or articles during manufacture and removed afterwards
    • B22F10/47—Structures for supporting workpieces or articles during manufacture and removed afterwards characterised by structural features
    • 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
    • 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
    • B22—CASTING; POWDER METALLURGY
    • B22F—WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
    • B22F10/00—Additive manufacturing of workpieces or articles from metallic powder
    • B22F10/60—Treatment of workpieces or articles after build-up
    • 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

  • a method of additive manufacturing of a part comprising a step of manufacturing a mixed support
  • additive manufacturing by powder bed deposition consists in manufacturing a part by successive superposition of layers of powder which are locally melted.
  • additive manufacturing by depositing a bed of powder consists in producing three-dimensional objects by consolidating selected areas on successive layers of pulverulent material (metallic powder, ceramic powder, etc.).
  • the consolidated areas correspond to successive sections of the three-dimensional object. Consolidation is done, for example, layer by layer, by total or partial selective melting carried out with a consolidation source (high power laser beam, electron beam, etc.).
  • This manufacturing method makes it possible to produce structures that cannot be manufactured with traditional methods (machining, molding).
  • additive manufacturing allows the production of parts having undercuts and undercuts, that is to say parts with contrary convex geometric shapes, impossible to achieve by molding and very difficult to achieve in machining.
  • Additive manufacturing also makes it possible to produce lattice structures that cannot be manufactured otherwise.
  • this manufacturing method can be quick and relatively inexpensive, allowing it to be used in rapid prototyping, for example instead of high-speed machining which remains complex.
  • the part is produced by successively stacking layers.
  • a part having a return that is to say a large convexity, an offset
  • the present invention aims to provide an additive manufacturing process for manufacturing a part having feedback, supporting it.
  • the invention proposes an additive manufacturing method of a part comprising a manufacturing step, by melting a layer of powder, of a mixed support having at least one flat surface intended to support the powder. unmelted additive manufacturing and at least one needle having a support end for supporting a portion of the part.
  • the supporting end of said at least one needle is located at an altitude higher than the altitude of said at least one flat surface, so that the space between said at least one flat surface and the supporting end of said at least one needle can be filled with unmelted additive manufacturing powder to form a mat partially supporting the part.
  • the mixed support combines needles to support a portion of the part, with a flat surface intended to support unmelted powder.
  • This arrangement allows the mixed support to offer both a rigid support with point connections (i.e. the support ends of the needles) making it possible to guarantee the correct positioning of the part portion during its manufacture, with a or several layers of powder forming non-rigid support zones under the part portion.
  • This double support strategy allows for optimal synergy between: heat dissipation, surface condition, respect for the geometry of the part, mechanical strength, and maintenance in position.
  • the mixed support according to the invention therefore makes it possible to provide an additive manufacturing process making it possible to manufacture a part having a return, by supporting it.
  • the step of fabricating the mixed carrier may include fabricating at least one element having the planar surface and may include separately fabricating at least one needle.
  • the step of manufacturing the mixed support can comprise the manufacture of at least two elements spaced apart from one another by a gap, the planar surfaces of the two elements being able to be coplanar, and at least one needle being able to be manufactured in said. gap between the two elements.
  • a space can be maintained between the needle and said at least one element.
  • Said at least one needle may have a circular section, the diameter of which may be between 0.05 millimeter and 1.50 millimeter.
  • the difference in altitude between said at least one supporting end and at least one flat surface may be greater than a particle size of the additive manufacturing powder.
  • the difference in altitude between said at least one supporting end and the at least one flat surface may be between 0.1 and 0.8 millimeters.
  • the method may include steps of manufacturing, layer by layer, a part and a portion of that part on a mixed medium, the manufacture of the mixed medium being able to be started at the same time as the manufacture of the part.
  • the patch portion may have a layer fused with the supporting end of said at least one needle.
  • the method may include a step of separating the part, or the part of the part and the mixed support.
  • the manufacturing process can be an additive manufacturing process by depositing a bed of powder.
  • Figure 1 is a schematic representation of a part and a mixed support manufactured according to a method of the invention.
  • Figure 2 is a schematic perspective representation of several flat surfaces and support ends of a mixed support manufactured according to a method of the invention.
  • Figure 3 is a schematic side view of a mixed support manufactured according to a method of the invention.
  • the invention relates to an additive manufacturing process of a part 1.
  • additive manufacturing it is, for example, understood a manufacturing process by depositing a powder bed in which layers of powder are superimposed. Then, each layer of powder is locally melted according to the plan of part 1 to be manufactured (in a classical fusion can be carried out by an electron beam or a laser). Part 1 is thus manufactured by incrementation, that is to say a superposition, of different layers.
  • additive manufacturing by powder bed deposition consists in producing three-dimensional objects by consolidating selected areas on successive layers of pulverulent material (metallic powder, ceramic powder, etc.).
  • the consolidated areas correspond to successive sections of the three-dimensional object. Consolidation is done, for example, layer by layer, by total or partial selective melting carried out with a consolidation source (high power laser beam, electron beam, etc.).
  • the part 1 has a return 11, that is to say a significant convexity, making it difficult to manufacture according to known methods.
  • return 1 1 it is understood a portion of the part 1 not being located directly above the rest of the part 1 and being located in cantilever of the rest of the part, as by example a T-shape which thus presents two returns 1 1.
  • This type of geometry requires additional support to be manufactured without risk of defect.
  • the support is welded to the part and it is difficult not to damage the part during the separation.
  • the method comprises a manufacturing step, by melting a layer of powder, of a mixed support 2.
  • the manufacture of the mixed support 2 is a particularly advantageous arrangement of the invention.
  • the manufacture of the mixed support 2 is advantageously started at the same time as the manufacture of the part 1.
  • the mixed support 2 comprises at least one flat surface 21 intended to support unmelted additive manufacturing powder and at least one needle 22 having a support end 23 for supporting a return 11 of the part 1.
  • each needle 22 is located at an altitude A higher than the altitude B of the flat surfaces 21, so as to maintain a space C between the support ends 23 and the flat surfaces 21.
  • the space C between the planar surfaces 21 and the support ends 23 can be filled with unmelted powder of additive manufacturing.
  • additive manufacturing powder it is understood, a powder made of plastic, metallic, ceramic, or composite material, suitable for being melted to form a part 1.
  • the step of manufacturing a mixed support 2 comprises the manufacture of elements 25 each having a flat surface 21.
  • Each flat surface 21 is intended not to come into contact with the part 1.
  • the mixed support 2 is manufactured with a plurality of elements 25.
  • the elements 25 are spaced from each other by interstices D.
  • planar surfaces 21 of the different elements 25 are substantially coplanar. It is therefore understood that the planar surfaces 21 can be arranged according to a complex geometry but do not form a concave or convex structure in which the planar surfaces are inclined with respect to each other. This arrangement advantageously makes it possible to guarantee constant support while allowing simple manufacture.
  • the needles 22 are made in the interstices D.
  • the needles 22 have a rod 28 and a support end 23. Each support end 23 for supporting a portion of the return 1 1 of the part 1. Each support end 23 is in contact with part 1. Each support end 23 is integral with part 1 at the end of manufacture. Each support end 23 is easily detachable from the part 1 because of the small section of the needles 22.
  • the needles 22 are cylindrical and have a circular section with a diameter between 0.05 millimeter and 1.50 millimeter.
  • the needles have a circular section. According to other embodiments, the needles could have other sections of different shapes.
  • the space C corresponding to the difference in altitude between the flat surfaces 21 and the support ends 23 is for example a function of the particle size of the powder used and the number of layers of unmelted powder that it is desired to keep between the flat surfaces 21 and return 1 1.
  • the difference in altitude between the support ends 23 and the flat surfaces 21 is between 0.1 and 0.8 millimeter.
  • the mixed support 2 supports the return 1 1 at the same time with rigid point links (that is to say the support ends 23) making it possible to guarantee the correct positioning of the return 1 1 during its manufacture, and with one or more layers of powder forming non-rigid support zones under the return 11.
  • This double support strategy makes it possible to have an optimal synergy between: heat dissipation, surface condition, respect for the geometry of the part, mechanical resistance, and hold in position.
  • the return 11 is optimally maintained throughout the manufacturing.
  • part 1 During the manufacturing process of part 1, it is possible to simultaneously manufacture part 1 and the mixed support 2.
  • the powder necessary for the manufacture of the return 11 is spread over the flat surfaces 21. Depending on the dimensioning of the space C, several layers of powder can be superimposed.
  • the needles 22 are manufactured in the space C or continue to be manufactured in the space C. Then, the layer of powder flush with the support ends 23 of the needles 22 is melted according to the geometric specificities of the return 11.
  • the first layer of the return 11 is welded to the support ends 23 and the layers spread over the flat portions 21 form a flexible support mat, that is to say not rigid as could be a one-piece structure.
  • melted is meant that, under the effect of an input of energy, the powder changes from a granular state to an agglomerated state, this change of state being able to take place through melting and / or polymerization.
  • Return 11 is then manufactured by stacking molten layers.
  • the needles 22 act as a prop supporting the return 11 during its manufacture.
  • the return 11 and the mixed support 2 are separated. Typically this separation can be achieved by breaking the connections between the support ends 23 and the return 11.
  • the support by needles of small section makes it possible to combine reliable mechanical support while facilitating the breaking of the connection, the small section of the needles making it possible to withstand axial compressive loads while being fragile to a shear force.

Abstract

The present invention concerns a method for additive manufacturing of a part (1) comprising a step of manufacturing, by melting a layer of powder, a mixed support having at least one planar surface (21) intended to support the unmelted additive manufacturing powder and at least one needle (22) having a supporting end (23) for supporting a portion of the part (1). The supporting end (23) of the at least one needle (22) is situated at an altitude (A) higher than the altitude (B) of the at least one planar surface (21), such that the space (C) between the at least one planar surface (21) and the supporting end (23) of the at least one needle (22) can be filled by unmelted additive manufacturing powder so as to form a mat partially supporting the part (1).

Description

Procédé de fabrication additive d’une pièce comprenant une étape de fabrication d’un support mixte A method of additive manufacturing of a part comprising a step of manufacturing a mixed support
DOMAINE DE L'INVENTION FIELD OF THE INVENTION
La présente invention concerne le domaine de la fabrication additive et plus particulièrement de la fabrication additive de pièces présentant un retour The present invention relates to the field of additive manufacturing and more particularly to the additive manufacturing of parts having a return
ETAT DE LA TECHNIQUE STATE OF THE ART
D’une manière connue, la fabrication additive par dépôt de lit de poudre consiste à fabriquer une pièce par superposition successive de couches de poudre qui sont fondues localement. In a known manner, additive manufacturing by powder bed deposition consists in manufacturing a part by successive superposition of layers of powder which are locally melted.
Plus précisément, la fabrication additive par dépôt de lit de poudre consiste à réaliser des objets tridimensionnels par consolidation de zones sélectionnées sur des strates successives de matériau pulvérulent (poudre métallique, poudre de céramique, etc...). Les zones consolidées correspondent à des sections successives de l'objet tridimensionnel. La consolidation se fait par exemple couche par couche, par une fusion sélective totale ou partielle réalisée avec une source de consolidation (faisceau laser de forte puissance, faisceau d’électrons, etc.). More precisely, additive manufacturing by depositing a bed of powder consists in producing three-dimensional objects by consolidating selected areas on successive layers of pulverulent material (metallic powder, ceramic powder, etc.). The consolidated areas correspond to successive sections of the three-dimensional object. Consolidation is done, for example, layer by layer, by total or partial selective melting carried out with a consolidation source (high power laser beam, electron beam, etc.).
Cette méthode de fabrication permet de réaliser des structures impossibles à fabriquer avec les méthodes traditionnelles (usinage, moulage). This manufacturing method makes it possible to produce structures that cannot be manufactured with traditional methods (machining, molding).
Notamment, la fabrication additive permet la réalisation de pièces présentant des dépouilles et contre-dépouilles, c’est-à-dire des pièces présentant des formes géométriques convexes contraires, impossibles à réaliser par moulage et très difficiles à réaliser en usinage. In particular, additive manufacturing allows the production of parts having undercuts and undercuts, that is to say parts with contrary convex geometric shapes, impossible to achieve by molding and very difficult to achieve in machining.
La fabrication additive permet aussi de réaliser des structures en treillis qui ne peuvent être fabriquées autrement. Additive manufacturing also makes it possible to produce lattice structures that cannot be manufactured otherwise.
En sus, cette méthode de fabrication peut s’avérer rapide et relativement peu onéreuse, ce qui permet de l’utiliser dans le cadre d’un prototypage rapide, à la place par exemple de l’usinage à grande vitesse qui demeure complexe. In addition, this manufacturing method can be quick and relatively inexpensive, allowing it to be used in rapid prototyping, for example instead of high-speed machining which remains complex.
En fabrication additive par dépôt de lit de poudre, la pièce est réalisée en empilant successivement des couches. Or, dans le cas d’une pièce présentant un retour (c’est-à-dire une importante convexité, un déport), il peut être nécessaire de soutenir temporairement la portion de la pièce formant un retour durant sa fabrication. In additive manufacturing by powder bed deposition, the part is produced by successively stacking layers. However, in the case of a part having a return (that is to say a large convexity, an offset), it may be necessary to temporarily support the portion of the part forming a return during its manufacture.
En conséquence, la présente invention a pour objectif de fournir un procédé de fabrication additive permettant de fabriquer une pièce présentant un retour, en la soutenant. EXPOSE DE L'INVENTION Accordingly, the present invention aims to provide an additive manufacturing process for manufacturing a part having feedback, supporting it. DISCLOSURE OF THE INVENTION
Selon un premier aspect, l’invention propose un procédé de fabrication additive d’une pièce comprenant une étape de fabrication, par fusion d’une couche de poudre, d’un support mixte présentant au moins une surface plane destinée à supporter de la poudre de fabrication additive non fondue et au moins une aiguille présentant une extrémité de soutien permettant de soutenir une portion de la pièce. L’extrémité de soutien de ladite au moins une aiguille se situe à une altitude supérieure à l’altitude de ladite au moins une surface plane, de sorte que l’espace entre ladite au moins une surface plane et l’extrémité de soutien de ladite au moins une aiguille puisse être comblé par de la poudre non fondue de fabrication additive pour former un tapis supportant partiellement la pièce. According to a first aspect, the invention proposes an additive manufacturing method of a part comprising a manufacturing step, by melting a layer of powder, of a mixed support having at least one flat surface intended to support the powder. unmelted additive manufacturing and at least one needle having a support end for supporting a portion of the part. The supporting end of said at least one needle is located at an altitude higher than the altitude of said at least one flat surface, so that the space between said at least one flat surface and the supporting end of said at least one needle can be filled with unmelted additive manufacturing powder to form a mat partially supporting the part.
Ainsi, le support mixte combine des aiguilles permettant un soutient d’une portion de la pièce, avec une surface plane destinée à supporter de la poudre non fondue. Cette disposition permet au support mixte d’offrir à la fois un soutient rigide avec des liaisons ponctuelles (c’est à dire les extrémités de soutien des aiguilles) permettant de garantir le juste positionnement de la portion de pièce lors de sa fabrication, avec une ou plusieurs couches de poudre formant des zones d’appui non rigides sous la portion de pièce. Cette double stratégie de supportage permet d’avoir une synergie optimale entre : la dissipation thermique, l’état de surface, le respect de la géométrie de la pièce, la tenue mécanique, et le maintien en position. Ainsi, la portion de pièce est maintenue de manière optimale durant toute la fabrication. Le support mixte selon l’invention permet donc de fournir un procédé de fabrication additive permettant de fabriquer une pièce présentant un retour, en la soutenant. Thus, the mixed support combines needles to support a portion of the part, with a flat surface intended to support unmelted powder. This arrangement allows the mixed support to offer both a rigid support with point connections (i.e. the support ends of the needles) making it possible to guarantee the correct positioning of the part portion during its manufacture, with a or several layers of powder forming non-rigid support zones under the part portion. This double support strategy allows for optimal synergy between: heat dissipation, surface condition, respect for the geometry of the part, mechanical strength, and maintenance in position. Thus, the part portion is optimally maintained throughout the manufacturing. The mixed support according to the invention therefore makes it possible to provide an additive manufacturing process making it possible to manufacture a part having a return, by supporting it.
L’étape de fabrication du support mixte peut comprendre la fabrication d’au moins un élément présentant la surface plane et peut comprendre la fabrication distincte d’au moins une aiguille. The step of fabricating the mixed carrier may include fabricating at least one element having the planar surface and may include separately fabricating at least one needle.
L’étape de fabrication du support mixte peut comprendre la fabrication d’au moins deux éléments espacés l’un de l’autre par un interstice, les surfaces planes des deux éléments pouvant être coplanaires, et au moins une aiguille pouvant être fabriquée dans ledit interstice entre les deux éléments. The step of manufacturing the mixed support can comprise the manufacture of at least two elements spaced apart from one another by a gap, the planar surfaces of the two elements being able to be coplanar, and at least one needle being able to be manufactured in said. gap between the two elements.
Un espace peut être maintenu entre l’aiguille et ledit au moins un élément. A space can be maintained between the needle and said at least one element.
Ladite au moins une aiguille peut présenter une section circulaire dont le diamètre peut être compris entre 0,05 millimètre et 1 ,50 millimètre. La différence d’altitude entre ladite au moins une extrémité de soutien et l’au moins une surface plane peut-être supérieure à une granulométrie de la poudre de fabrication additive. Said at least one needle may have a circular section, the diameter of which may be between 0.05 millimeter and 1.50 millimeter. The difference in altitude between said at least one supporting end and at least one flat surface may be greater than a particle size of the additive manufacturing powder.
La différence d’altitude entre ladite au moins une extrémité de soutien et l’au moins une surface plane peut-être comprise entre 0,1 et 0,8 millimètre. The difference in altitude between said at least one supporting end and the at least one flat surface may be between 0.1 and 0.8 millimeters.
Le procédé peut comprendre des étapes de fabrication, couche par couche, d’une pièce et d’une portion de cette pièce sur un support mixte, la fabrication du support mixte pouvant être entamée en même temps que la fabrication de la pièce. The method may include steps of manufacturing, layer by layer, a part and a portion of that part on a mixed medium, the manufacture of the mixed medium being able to be started at the same time as the manufacture of the part.
La portion de pièce peut présenter une couche fusionnée avec l’extrémité de soutien de ladite au moins une aiguille. The patch portion may have a layer fused with the supporting end of said at least one needle.
Le procédé peut comprendre une étape de séparation de la pièce, ou de la portion de pièce et du support mixte. The method may include a step of separating the part, or the part of the part and the mixed support.
Le procédé de fabrication peut être un procédé de fabrication additive par dépôt d’un lit de poudre. The manufacturing process can be an additive manufacturing process by depositing a bed of powder.
DESCRIPTION DES FIGURES DESCRIPTION OF FIGURES
D’autres caractéristiques, buts et avantages de l’invention ressortiront de la description qui suit, qui est purement illustrative et non limitative, et qui doit être lue en regard des dessins annexés sur lesquels : Other characteristics, aims and advantages of the invention will emerge from the following description, which is purely illustrative and not limiting, and which should be read with reference to the accompanying drawings in which:
La figure 1 est une représentation schématique d’une pièce et un support mixte fabriquées selon un procédé objet de l’invention. Figure 1 is a schematic representation of a part and a mixed support manufactured according to a method of the invention.
La figure 2 est une représentation schématique en perspectives de plusieurs surfaces planes et extrémités de soutien d’un support mixte fabriqué selon un procédé objet de l’invention. Figure 2 is a schematic perspective representation of several flat surfaces and support ends of a mixed support manufactured according to a method of the invention.
La figure 3 est une représentation schématique de côté d’un support mixte fabriqué selon un procédé objet de l’invention. Figure 3 is a schematic side view of a mixed support manufactured according to a method of the invention.
Sur l’ensemble des figures, les éléments similaires portent des références identiques. In all of the figures, similar elements bear identical references.
DESCRIPTION DETAILLEE DE L'INVENTION DETAILED DESCRIPTION OF THE INVENTION
En référence à la figure 1 , selon un premier aspect, l’invention concerne un procédé de fabrication additive d’une pièce 1. Referring to Figure 1, according to a first aspect, the invention relates to an additive manufacturing process of a part 1.
Par fabrication additive, il est, par exemple, entendu un procédé de fabrication par dépôt de lit de poudre dans lequel on superpose des couches de poudre. Puis, chaque couche de poudre est fondue localement en fonction du plan de la pièce 1 à fabriquer (d’une manière classique la fusion peut être opérée par un faisceau d’électrons ou un laser). La pièce 1 est ainsi fabriquée par incrémentation, c’est-à-dire une superposition, de différentes couches. By additive manufacturing, it is, for example, understood a manufacturing process by depositing a powder bed in which layers of powder are superimposed. Then, each layer of powder is locally melted according to the plan of part 1 to be manufactured (in a classical fusion can be carried out by an electron beam or a laser). Part 1 is thus manufactured by incrementation, that is to say a superposition, of different layers.
Selon une définition admise, la fabrication additive par dépôt de lit de poudre consiste à réaliser des objets tridimensionnels par consolidation de zones sélectionnées sur des strates successives de matériau pulvérulent (poudre métallique, poudre de céramique, etc. ). Les zones consolidées correspondent à des sections successives de l'objet tridimensionnel. La consolidation se fait par exemple couche par couche, par une fusion sélective totale ou partielle réalisée avec une source de consolidation (faisceau laser de forte puissance, faisceau d’électrons, etc. ). According to one accepted definition, additive manufacturing by powder bed deposition consists in producing three-dimensional objects by consolidating selected areas on successive layers of pulverulent material (metallic powder, ceramic powder, etc.). The consolidated areas correspond to successive sections of the three-dimensional object. Consolidation is done, for example, layer by layer, by total or partial selective melting carried out with a consolidation source (high power laser beam, electron beam, etc.).
Selon une disposition particulière, la pièce 1 présente un retour 1 1 , c’est-à-dire une convexité importante, rendant délicate la fabrication selon les méthodes connues. En d’autres termes, par retour 1 1 il est entendu une portion de la pièce 1 ne se situant pas à l’aplomb du reste de la pièce 1 et se situant en porte-à-faux du reste de la pièce, comme par exemple une forme en T qui présente ainsi deux retours 1 1 . Ce type de géométrie nécessite un supportage complémentaire pour être fabriqué sans risque de défaut. Or selon les méthodes connues, le support est soudé à la pièce et il est difficile de ne pas endommager la pièce lors de la séparation. According to a particular arrangement, the part 1 has a return 11, that is to say a significant convexity, making it difficult to manufacture according to known methods. In other words, by return 1 1 it is understood a portion of the part 1 not being located directly above the rest of the part 1 and being located in cantilever of the rest of the part, as by example a T-shape which thus presents two returns 1 1. This type of geometry requires additional support to be manufactured without risk of defect. However, according to known methods, the support is welded to the part and it is difficult not to damage the part during the separation.
Fabrication d’un support mixte Manufacture of mixed media
Le procédé comprend une étape de fabrication, par fusion d’une couche de poudre, d’un support mixte 2. Tel que cela sera développé ci-après la fabrication du support mixte 2 est une disposition particulièrement avantageuse de l’invention. La fabrication du support mixte 2 est avantageusement entamée en même temps que la fabrication de la pièce 1 . The method comprises a manufacturing step, by melting a layer of powder, of a mixed support 2. As will be developed below, the manufacture of the mixed support 2 is a particularly advantageous arrangement of the invention. The manufacture of the mixed support 2 is advantageously started at the same time as the manufacture of the part 1.
Le support mixte 2 comprend au moins une surface plane 21 destinée à supporter de la poudre de fabrication additive non fondue et au moins une aiguille 22 présentant une extrémité de soutien 23 permettant de soutenir un retour 1 1 de la pièce 1 . 11 s’agit là d’une disposition technique particulièrement avantageuse dont les effets seront détaillés ultérieurement. The mixed support 2 comprises at least one flat surface 21 intended to support unmelted additive manufacturing powder and at least one needle 22 having a support end 23 for supporting a return 11 of the part 1. This is a particularly advantageous technical provision, the effects of which will be detailed later.
Il est notable que l’extrémité de soutien 23 de chaque aiguille 22 se situe à une altitude A supérieure à l’altitude B des surfaces planes 21 , de sorte à conserver un espace C entre les extrémités de soutien 23 et les surfaces planes 21 . It is notable that the support end 23 of each needle 22 is located at an altitude A higher than the altitude B of the flat surfaces 21, so as to maintain a space C between the support ends 23 and the flat surfaces 21.
Ainsi, tel que cela sera développé ci-après, l’espace C entre les surfaces planes 21 et les extrémités de soutien 23 peut être comblé par de la poudre non fondue de fabrication additive. Il est précisé que par poudre de fabrication additive, il est entendu, une poudre en matériau plastique, métallique, céramique, ou composite, adaptée pour être fondue pour former une pièce 1 . Thus, as will be developed below, the space C between the planar surfaces 21 and the support ends 23 can be filled with unmelted powder of additive manufacturing. It is specified that by additive manufacturing powder, it is understood, a powder made of plastic, metallic, ceramic, or composite material, suitable for being melted to form a part 1.
Selon une disposition particulière, l’étape de fabrication d’un support mixte 2 comprend la fabrication d’éléments 25 présentant chacun une surface plane 21. Chaque surface plane 21 est destinée à ne pas venir au contact de la pièce 1 . According to a particular arrangement, the step of manufacturing a mixed support 2 comprises the manufacture of elements 25 each having a flat surface 21. Each flat surface 21 is intended not to come into contact with the part 1.
Selon l’exemple ici présenté, le support mixte 2 est fabriqué avec une pluralité d’éléments 25. Les éléments 25 sont espacés les uns des autres par des interstices D. According to the example presented here, the mixed support 2 is manufactured with a plurality of elements 25. The elements 25 are spaced from each other by interstices D.
En outre, il est notable que les surfaces planes 21 des différents éléments 25 sont sensiblement coplanaires. On comprend donc que les surfaces planes 21 peuvent être agencées selon une géométrie complexe mais ne forment pas une structure concave ou convexe dans laquelle des surfaces planes seraient inclinées les unes par rapport aux autres. Cette disposition permet avantageusement de garantir un appui constant tout en permettant une fabrication simple. In addition, it is notable that the planar surfaces 21 of the different elements 25 are substantially coplanar. It is therefore understood that the planar surfaces 21 can be arranged according to a complex geometry but do not form a concave or convex structure in which the planar surfaces are inclined with respect to each other. This arrangement advantageously makes it possible to guarantee constant support while allowing simple manufacture.
En référence aux figures 1 à 3, les aiguilles 22 sont fabriquées dans les interstices D. Referring to Figures 1 to 3, the needles 22 are made in the interstices D.
Les aiguilles 22 présentent une tige 28 et une extrémité de soutien 23. Chaque extrémité de soutien 23 permettant de soutenir une portion du retour 1 1 de la pièce 1 . Chaque extrémité de soutien 23 est au contact de la pièce 1 . Chaque extrémité de soutien 23 est solidaire de la pièce 1 en fin de fabrication. Chaque extrémité de soutien 23 est facilement détachable de la pièce 1 en raison de la faible section des aiguilles 22. The needles 22 have a rod 28 and a support end 23. Each support end 23 for supporting a portion of the return 1 1 of the part 1. Each support end 23 is in contact with part 1. Each support end 23 is integral with part 1 at the end of manufacture. Each support end 23 is easily detachable from the part 1 because of the small section of the needles 22.
D’une manière préférentielle, les aiguilles 22 sont cylindriques et présentent une section circulaire dont le diamètre est compris entre 0,05 millimètre et 1 ,50 millimètre. Preferably, the needles 22 are cylindrical and have a circular section with a diameter between 0.05 millimeter and 1.50 millimeter.
Il est précisé que selon le mode de réalisation ici présenté, les aiguilles présentent une section circulaire. Selon d’autres modes de réalisation, les aiguilles pourraient présenter d’autres sections de formes différentes. It is specified that according to the embodiment presented here, the needles have a circular section. According to other embodiments, the needles could have other sections of different shapes.
L’espace C correspondant à la différence d’altitude entre les surfaces planes 21 et les extrémités de soutien 23 est par exemple fonction de la granulométrie de la poudre utilisée et du nombre de couche de poudre non fondue que l’on souhaite conserver entre les surfaces planes 21 et le retour 1 1 . Selon un mode de réalisation, la différence d’altitude entre les extrémités de soutien 23 et les surfaces planes 21 est comprise entre 0,1 et 0,8 millimètre. Ainsi, le support mixte 2 soutient le retour 1 1 à la fois avec des liaisons ponctuelles rigides (c’est-à-dire les extrémités de soutien 23) permettant de garantir le juste positionnement du retour 1 1 lors de sa fabrication, et avec une ou plusieurs couches de poudre formant des zones d’appui non rigides sous le retour 11. Cette double stratégie de supportage permet d’avoir une synergie optimale entre : la dissipation thermique, l’état de surface, le respect de la géométrie de la pièce, la tenue mécanique, et le maintien en position. Ainsi, le retour 11 est maintenu de manière optimale durant toute la fabrication. The space C corresponding to the difference in altitude between the flat surfaces 21 and the support ends 23 is for example a function of the particle size of the powder used and the number of layers of unmelted powder that it is desired to keep between the flat surfaces 21 and return 1 1. According to one embodiment, the difference in altitude between the support ends 23 and the flat surfaces 21 is between 0.1 and 0.8 millimeter. Thus, the mixed support 2 supports the return 1 1 at the same time with rigid point links (that is to say the support ends 23) making it possible to guarantee the correct positioning of the return 1 1 during its manufacture, and with one or more layers of powder forming non-rigid support zones under the return 11. This double support strategy makes it possible to have an optimal synergy between: heat dissipation, surface condition, respect for the geometry of the part, mechanical resistance, and hold in position. Thus, the return 11 is optimally maintained throughout the manufacturing.
Durant le procédé de fabrication de la pièce 1 , il est possible de fabriquer simultanément la pièce 1 et le support mixte 2. During the manufacturing process of part 1, it is possible to simultaneously manufacture part 1 and the mixed support 2.
Fabrication du retour Return manufacturing
Lors de la fabrication du retour 11 , la poudre nécessaire à la fabrication du retour 11 est étalée sur les surfaces planes 21. En fonction du dimensionnement de l’espace C, plusieurs couches de poudre peuvent être superposées. Les aiguilles 22 sont fabriquées dans l’espace C ou continuent d’être fabriquées dans l’espace C. Puis, la couche de poudre affleurant les extrémités de soutien 23 des aiguilles 22 est fondue selon les spécificités géométriques du retour 11. Ainsi, la première couche du retour 11 est soudée aux extrémités de soutien 23 et les couches étalées sur les portions planes 21 forment un tapis de soutien souple, c’est- à-dire non rigide comme pourrait l’être une structure monobloc. During the manufacture of the return 11, the powder necessary for the manufacture of the return 11 is spread over the flat surfaces 21. Depending on the dimensioning of the space C, several layers of powder can be superimposed. The needles 22 are manufactured in the space C or continue to be manufactured in the space C. Then, the layer of powder flush with the support ends 23 of the needles 22 is melted according to the geometric specificities of the return 11. Thus, the first layer of the return 11 is welded to the support ends 23 and the layers spread over the flat portions 21 form a flexible support mat, that is to say not rigid as could be a one-piece structure.
Il est précisé que par fondu, on entend que, sous l’effet d’un apport d’énergie la poudre passe d’une état granulaire à état aggloméré, ce changement d’état pouvant passer par une fusion et/ou une polymérisation. It is specified that by melted is meant that, under the effect of an input of energy, the powder changes from a granular state to an agglomerated state, this change of state being able to take place through melting and / or polymerization.
Le retour 11 est ensuite fabriqué par empilement de couches fondues. Durant la fabrication du retour 11 , d’une manière particulièrement avantageuse, les aiguilles 22 ont un rôle d’étai supportant le retour 11 durant sa fabrication. Return 11 is then manufactured by stacking molten layers. During the manufacture of the return 11, in a particularly advantageous manner, the needles 22 act as a prop supporting the return 11 during its manufacture.
A l’issue de la fabrication de la pièce 1 , le retour 11 et le support mixte 2 sont séparés. Typiquement cette séparation peut être réalisée en brisant les liaisons entre les extrémités de soutien 23 et le retour 11. D’une manière particulièrement avantageuse, le soutien par des aiguilles de faible section permet de combiner un soutien mécanique fiable tout en facilitant la rupture de la liaison, la faible section des aiguilles permettant de supporter des charges de compression axiale tout en étant fragile à un effort de cisaillement. At the end of the manufacture of part 1, the return 11 and the mixed support 2 are separated. Typically this separation can be achieved by breaking the connections between the support ends 23 and the return 11. In a particularly advantageous manner, the support by needles of small section makes it possible to combine reliable mechanical support while facilitating the breaking of the connection, the small section of the needles making it possible to withstand axial compressive loads while being fragile to a shear force.
Ainsi, il est aisé de séparer la pièce 1 du support mixte 2 après la fabrication. Thus, it is easy to separate the part 1 from the mixed support 2 after manufacture.

Claims

REVENDICATIONS
1. Procédé de fabrication additive d’une pièce (1 ) comprenant une étape de fabrication, par fusion d’une couche de poudre, d’un support mixte présentant au moins une surface plane (21 ) destinée à supporter de la poudre de fabrication additive non fondue et au moins une aiguille (22) présentant une extrémité de soutien (23) permettant de soutenir une portion de la pièce (1 ), l’extrémité de soutien (23) de ladite au moins une aiguille (22) se situant à une altitude (A) supérieure à l’altitude (B) de ladite au moins une surface plane (21 ), caractérisé en ce que l’étape de fabrication du support mixte (2) comprend la fabrication d’au moins deux éléments (25) présentant la surface plane (21 ) espacés l’un de l’autre par un interstice (D), et la fabrication distincte d’au moins une aiguille (22) dans ledit interstice (D) entre les deux éléments (25), de sorte que l’espace (C) entre ladite au moins une surface plane (21 ) et l’extrémité de soutien (23) de ladite au moins une aiguille (22) puisse être comblé par de la poudre non fondue de fabrication additive pour former un tapis supportant partiellement la pièce (1 ). 1. Method of additive manufacturing of a part (1) comprising a manufacturing step, by melting a layer of powder, of a mixed support having at least one flat surface (21) intended to support manufacturing powder. unmelted additive and at least one needle (22) having a supporting end (23) for supporting a portion of the workpiece (1), the supporting end (23) of said at least one needle (22) lying at an altitude (A) greater than the altitude (B) of said at least one flat surface (21), characterized in that the step of manufacturing the mixed support (2) comprises manufacturing at least two elements ( 25) having the flat surface (21) spaced from each other by a gap (D), and the separate manufacture of at least one needle (22) in said gap (D) between the two elements (25) , so that the space (C) between said at least one flat surface (21) and the supporting end (23) of said at least one needle (22) can be filled with unmelted powder of additive manufacturing to form a mat partially supporting the part (1).
2. Procédé de fabrication additive selon la revendication 1 , dans lequel un espace est maintenu entre l’aiguille (22) et chaque élément (25). 2. The additive manufacturing method according to claim 1, wherein a space is maintained between the needle (22) and each element (25).
3. Procédé de fabrication additive selon l’une des revendications 1 et 2, dans lequel ladite au moins une aiguille (22) présente une section circulaire dont le diamètre est compris entre 0,05 millimètre et 1 ,50 millimètre. 3. Additive manufacturing method according to one of claims 1 and 2, wherein said at least one needle (22) has a circular section whose diameter is between 0.05 millimeter and 1.50 millimeter.
4. Procédé de fabrication additive selon l’une quelconque des revendications 1 à 3, dans lequel la différence d’altitude entre ladite au moins une extrémité de soutien (23) et l’au moins une surface plane (21 ) est supérieure à une granulométrie de la poudre de fabrication additive. 4. The additive manufacturing method according to any one of claims 1 to 3, wherein the altitude difference between said at least one supporting end (23) and the at least one flat surface (21) is greater than one. particle size of the additive manufacturing powder.
5. Procédé de fabrication additive selon l’une quelconque des revendications 1 à 4, dans lequel la différence d’altitude entre ladite au moins une extrémité de soutien (23) et l’au moins une surface plane (21 ) est comprise entre 0,1 et 0,8 millimètre. 5. The additive manufacturing method according to any one of claims 1 to 4, wherein the altitude difference between said at least one support end (23) and the at least one flat surface (21) is between 0 , 1 and 0.8 millimeters.
6. Procédé de fabrication additive selon l’une des revendications 1 à 5, comprenant des étapes de fabrication, couche par couche, d’une pièce (1 ) et d’une portion (11 ) de cette pièce (1 ) sur un support mixte (2), la fabrication du support mixte (2) étant entamée en même temps que la fabrication de la pièce (1 ). 6. Additive manufacturing method according to one of claims 1 to 5, comprising steps of manufacturing, layer by layer, a part (1) and a portion (11) of this part (1) on a support. combination (2), the manufacture of the mixed support (2) being started at the same time as the manufacture of the part (1).
7. Procédé de fabrication additive selon la revendication 6, dans lequel la portion de pièce (11 ) présente une couche fusionnée avec l’extrémité de soutien (23) de ladite au moins une aiguille (22). 7. The additive manufacturing method according to claim 6, wherein the part portion (11) has a layer fused with the support end (23) of said at least one needle (22).
8. Procédé de fabrication additive selon l’une quelconque des revendications 6 ou 7 comprenant une étape de séparation de la pièce, ou de la portion de pièce et du support mixte (2). 8. Additive manufacturing method according to any one of claims 6 or 7 comprising a step of separating the part, or the part of the part and the mixed support (2).
9. Procédé de fabrication additive selon l’une des revendications précédentes, dans lequel le procédé de fabrication est un procédé de fabrication additive par dépôt d’un lit de poudre. 9. The additive manufacturing process according to one of the preceding claims, wherein the manufacturing process is an additive manufacturing process by depositing a bed of powder.
PCT/FR2020/050871 2019-05-24 2020-05-25 Method for additive manufacturing of a part comprising a step of manufacturing a mixed support WO2020240128A1 (en)

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Citations (3)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US20170066083A1 (en) * 2015-09-09 2017-03-09 Toyota Jidosha Kabushiki Kaisha Manufacturing method of metal member
US20180154441A1 (en) * 2016-12-07 2018-06-07 General Electric Company Methods and table supports for additive manufacturing
EP3351321A1 (en) * 2017-01-24 2018-07-25 Siemens Aktiengesellschaft Device and method for additive manufacturing of at least one shaped body

Patent Citations (3)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US20170066083A1 (en) * 2015-09-09 2017-03-09 Toyota Jidosha Kabushiki Kaisha Manufacturing method of metal member
US20180154441A1 (en) * 2016-12-07 2018-06-07 General Electric Company Methods and table supports for additive manufacturing
EP3351321A1 (en) * 2017-01-24 2018-07-25 Siemens Aktiengesellschaft Device and method for additive manufacturing of at least one shaped body

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