WO2023117053A1 - Imprimante 3d avec structure en saillie pour générer un rideau de gaz - Google Patents

Imprimante 3d avec structure en saillie pour générer un rideau de gaz Download PDF

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Publication number
WO2023117053A1
WO2023117053A1 PCT/EP2021/086987 EP2021086987W WO2023117053A1 WO 2023117053 A1 WO2023117053 A1 WO 2023117053A1 EP 2021086987 W EP2021086987 W EP 2021086987W WO 2023117053 A1 WO2023117053 A1 WO 2023117053A1
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WO
WIPO (PCT)
Prior art keywords
gas
door
gas inflow
roof
floor
Prior art date
Application number
PCT/EP2021/086987
Other languages
English (en)
Inventor
Niko LEBEN
Original Assignee
S&S Scheftner Gmbh
Nppower D.O.O.
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 S&S Scheftner Gmbh, Nppower D.O.O. filed Critical S&S Scheftner Gmbh
Priority to PCT/EP2021/086987 priority Critical patent/WO2023117053A1/fr
Publication of WO2023117053A1 publication Critical patent/WO2023117053A1/fr

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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
    • 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
    • B22F12/70—Gas flow means
    • 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
    • B29C64/30—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
    • 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
    • B22F10/322—Process control of the atmosphere, e.g. composition or pressure in a building chamber of the gas flow, e.g. rate or direction
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B22—CASTING; POWDER METALLURGY
    • B22F—WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
    • B22F10/00—Additive manufacturing of workpieces or articles from metallic powder
    • B22F10/70—Recycling
    • B22F10/77—Recycling of gas
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
    • Y02P—CLIMATE CHANGE MITIGATION TECHNOLOGIES IN THE PRODUCTION OR PROCESSING OF GOODS
    • Y02P10/00—Technologies related to metal processing
    • Y02P10/25—Process efficiency

Definitions

  • the invention relates to devices for manufacturing three-dimensional objects from powder as print medium.
  • the powder can be metallic, organopolymer as well as oxides.
  • Such devices which are also known and often referred to as 3D-printers, can be used to manufacture three-dimensional objects and goods from different types of powders by locally sintering or locally melting the powder by means of a directed laser beam or by different means.
  • a device for manufacturing three-dimensional objects from powders is known from WO 2006/024373 A2.
  • the device comprises a building chamber which can be evacuated and filled with inert gas to prevent the powder from oxidization during melting or sintering.
  • a metal printer having a gas-protected laser printer head is disclosed in US 2016/0318128 A1 .
  • the laser printer head is physically moved over the surface of the printed object, while powder is added with help of another 3D-printer head.
  • WO 2021/154609 A1 discloses a 3D-printer having a gas exchange mechanism for removing contaminants during re-coating. For this purpose, a re-coater is moved over the printing surface.
  • EP 3 023 228 A1 discloses a device for manufacturing three-dimensional objects on a building platform in an object forming chamber.
  • the device has a gas flow system for providing a gas flow across the building platform section which blows a gas flow from a door to a back side of the object forming chamber.
  • the gas flow is used to control smoke distribution inside the object forming chamber and thus protect optical elements from smoke deposit formation.
  • the gas flow according to EP 3 023 228 A1 has the disadvantage that it might affect the top powder layer which is to be sintered or melted.
  • a gas flow disturbance may occur due to coater or spreading device crossing the path of the laminar flow, thus changing the direction of the gas flow.
  • the positioning of the gas flow openings in direct proximity to the build plate (elevation from build plate) and consequently the added powder layer, may be affected by powder erosion.
  • a disadvantage of systems according to the state of the art is thus that the gas flow is of limited effect due to the distribution of the smoke by the gas flow itself and that the powder particles of the powder, from which the three-dimensional object is manufactured, are moved and dislocated by the gas flow on the surface of the powder layer to be sintered or melted.
  • the surface of the powder can be affected by the gas flow. Particles can be moved and the evenness of the surface can be disrupted prior to sintering or melting, thereby negatively affecting the quality of the manufactured three-dimensional object.
  • the gas flow across the building platform is perpendicularly to the door structure as suggested in EP 3 023 228 A1 the gas flow can be disturbed on a regular basis by the spreading device that traverses the building platform orthogonally with respect to the gas flow to uniformly disperse virgin powder before a laser illumination cycle.
  • the spreading device that traverses the building platform orthogonally with respect to the gas flow to uniformly disperse virgin powder before a laser illumination cycle.
  • turbulence in the gas flow patterns is introduced by such disturbances that might disrupt the integrity of the powder bed. Deactivation of the gas flow while the distributing device is active in order to avoid said powder bed disruption might detrimentally affect both stable gas flow patterns in the chamber and atmospheric purity.
  • the object of the present invention is to overcome these and other disadvantages of presently known devices for manufacturing three-dimensional objects from powder and methods for using such devices.
  • the object of the present invention is thus to provide a device for additive manufacturing of three-dimensional objects from powdered material which protects windows or lenses in the building chamber from condensation of smoke and dust produced while melting or sintering the powder and at the same time preventing the surface of the powder from being affected by gas flow moving powder particles.
  • the invention solves the problem by a device according to claim 1 and by a method according to claim 24.
  • Preferred embodiments are described in claims 2 to 23, depending on claim 1 , and in claims 25 to 29, depending on claim 24.
  • the invention solves problems by a device for additive manufacturing of three-dimensional objects from powdered material, the device comprising: a building chamber in which the three-dimensional objects are manufactured by means of local sintering or local melting, said building chamber being delimited by a door on a front side of the building chamber and being delimited by walls, a roof and a floor, wherein the building chamber is accessible through said door when open, a building platform for manufacturing the three-dimensional objects thereon, said building platform being arranged inside said building chamber or bordering said building chamber, a laser source for sintering or melting particles of a powdered material for manufacturing said three-dimensional object on said building platform by means of a laser beam, a lens and/or window through which the laser beam from said laser source is guidable into said building chamber, a distributing device for applying and/or levelling a layer of said powdered material on the building platform, wherein said distributing device is arranged inside said building chamber and comprises a movable part which is movably arranged in a
  • gas outflow structure and the gas inflow structure can easily be connected to and disconnected from any one of said walls, door, floor and roof, without welding, soldering, gluing, bolting or other techniques which are typically used for final fixation.
  • gas outflow structure and the gas inflow structure are being detachably connected or being detachably connectable to any one of said walls, door, floor and roof means that they can be connected or connectable to any of said walls, door, floor and roof.
  • gas outflow structure and the gas inflow structure are being detachably connected each to only a single one of said walls, floor, door and roof.
  • the gas flow system for driving the gas flow inside the building chamber can be driven by a pressure pump, a blower, a circulation pump, a vacuum pump and/or a compressed gas reservoir like a pressurized gas cylinder containing an inert gas under pressure.
  • the gas outflow structure and the gas inflow structure are both physical devices for guiding a flow of a gas through the respective gas lines into or from the building chamber.
  • the gas outflow structure and the gas inflow structure need not be connected to the same of the at least one of said walls, said door, said floor and said roof. Therefore, for example the gas outflow structure can be connected to a wall, while the gas inflow structure is connected to said floor or the opposite wall or door. However, it is preferred that both the gas outflow structure and the gas inflow structure are connected to the same of the at least one of said wall, said door, said floor and said roof.
  • the building chamber is preferably closed to the outside apart from gas inflow lines and gas outflow lines when the door is closed.
  • the movable part can be a spreading device or can comprise a spreading device.
  • the building chamber is sealable gas tight and vacuum tight by closing the door.
  • Vacuum tight means that the pressure in the sealed building chamber does not increase with a rate of more than 10 kPa per minute.
  • a seal can be arranged on the door and/or on a door stop.
  • the at least one outlet opening can be a bore or bores reaching to the gas outflow line, but can also be realized by a single slit, by slits or by multiple pores of a porous structure like tissue, fabrics, foam, sponge or the like.
  • the at least one outlet opening can be a bore or bores reaching to the gas inflow line, but can also be realized by a single slit, by slits or by multiple pores of a porous structure like tissue, fabrics, foam, sponge or the like.
  • said gas outflow structure protrudes into the interior of said building chamber when connected to any one of said walls, door, floor and roof, such that said at least one outlet opening is arranged with a distance of at least 20 mm to any of said walls, door, floor and roof and/or that said gas inflow structure protrudes into the interior of said building chamber when connected to any one of said walls, door, floor and roof, such that said at least one inlet opening is arranged with a distance of at least 20 mm to any of said walls, door, floor and roof.
  • said gas outflow structure protrudes into the interior of said building chamber when connected to any one of said walls, door, floor and roof, such that said at least one outlet opening is arranged with a distance of at least 50 mm to any of said walls, door, floor and roof and/or that said gas inflow structure protrudes into the interior of said building chamber when connected to any one of said walls, door and roof, such that said at least one inlet opening is arranged with a distance of at least 50 mm to any of said walls, door and roof.
  • the further the at least one gas outlet opening and the at least one gas inlet opening is distanced from the walls, roof, door and floor the better. Even though, if a distance of more than 40 mm is achieved no further improvement can be expected. The exact limit might depend on the flow rate of the gas flow and also on the area of the gas flow.
  • more than one gas outlet opening is provided in the gas outflow structure. Particular preferably there are at least five outlet openings in the gas outflow structure. Likewise, it is preferred that more than one gas inlet opening is provided in the gas inflow structure. Particular preferably there are at least five inlet openings in the gas inflow structure.
  • That the gas outflow structure is rigid means that it has a rigid outer structure, which holds its shape under gravitation, even though parts of it like fabrics or tissue or lamellas at the at least one outlet opening might be soft.
  • the gas inflow structure which is rigid if it has a rigid outer structure, which holds its shape under gravitation, even though parts of it like fabrics or tissue or lamellas at the at least one inlet opening might be soft.
  • the building chamber can be cubic, rectangular, cylindric or shaped differently. Therefore, the walls and the door need not to be flat surfaces.
  • the powder can be an oxide powder, a plastic powder or a metal powder.
  • Plastic powder can be organopolymer powder according to a preferred embodiment.
  • Metal powders are preferred.
  • That the distributing device is designed for applying and/or levelling a layer of said powdered material on the building platform, means that the layer of said powder material can be applied and/or leveled directly onto said building platform or directly onto another layer of said powdered material, wherein said another layer of said powdered material may comprise sintered or solidified parts previously manufactured by said laser beam during manufacturing of the three-dimensional object to be manufactured. Therefore, a new powder layer can be applied and/or levelled on top of another powder layer of any already created portion of the partly manufactured three- dimensional object.
  • the gas outflow structure and the gas inflow structure being detachably connected or being detachably connectable to any one of said walls, said floor or said roof, preferably the gas outflow structure and the gas inflow structure being detachably connected or being detachably connectable to any one of said walls or said roof, particular preferably the gas outflow structure and the gas inflow structure being detachably connected or being detachably connectable to a back side wall of the building chamber opposite the door.
  • any feedthroughs for connecting the gas outflow structure and the gas inflow structure can be arranged inside the main structure comprising the walls, the floor and the roof delimiting said building chamber.
  • the back side wall of the building chamber is especially easily accessible and thus preferred.
  • the gas outflow structure is connected to the gas flow system when connected to any one of said walls, said door, said floor and said roof such that the gas outflow line is fluid-permeably connected to a pressure pump or a pressurized gas source of the gas flow system, and/or the gas inflow structure is connected to the gas flow system when connected to any one of said walls, said door, said floor and said roof such that the gas inflow line is fluid-permeably connected to a vacuum pump, a vacuum source or a low-pressure source of the gas flow system.
  • the gas flow is a laminar gas flow at least in areas between the gas outflow structure and the gas inflow structure, preferably the gas flow is a laminar gas flow in a whole area between the gas outflow structure and the gas inflow structure.
  • the device comprising a gas inlet connection and a gas outlet connection at least one of said walls, said door, said floor and said roof, the gas inlet connection and the gas outlet connection both comprising gas lines leading from the building chamber to outside the building chamber and the gas inflow structure is detachably connected or detachably connectable to the gas inlet connection and the gas outflow structure is detachably connected or detachably connectable to the gas outlet connection.
  • the gas inflow structure and the gas outflow structure can easily be connected to the corresponding connections at defined locations in the building chamber.
  • mounting of the gas inflow structure and the gas outflow structure is made easier to handle.
  • the at least one outlet opening of the gas outflow structure and the at least one inlet opening of the gas inflow structure are located on identical locations on the gas outflow structure and the gas inflow structure or are located mirror- inverted to one another, preferably the gas inflow structure and the gas outflow structure are formed completely identically or mirror-inverted to one another.
  • the at least one outlet opening of the gas outflow structure and the at least one inlet opening of the gas inflow structure are located mirror-inverted to one another each with respect to a vertical plane perpendicular to the site of the building chamber to which the gas outflow structure and the gas inflow structure are connected or the complete gas inflow structure and the complete gas outflow structure are formed mirror-inverted to one another each with respect to a vertical plane perpendicular to the site of the building chamber to which the gas outflow structure and the gas inflow structure are connected to.
  • the number of the at least one outlet opening of the gas outflow structure and the number the at least one inlet opening of the gas inflow structure are equal or do not deviate of more than 50 % from one another. This also helps to avoid unwanted turbulences in the gas flow.
  • gas outflow structure and the gas inflow structure are magnetically connected or are magnetically connectable to at least one of said walls, said door, said floor and said roof.
  • the gas outflow structure and the gas inflow structure comprise a magnetic connector or a magnetizable connector and at least one of said walls, said door, said floor and said roof, to which the gas outflow structure and the gas inflow structure is to be connected, comprises a magnetic connector for connecting the magnetizable connector of the gas outflow structure and the magnetizable connector of the gas inflow structure to the at least one of said walls, said door, said floor and said roof or the gas outflow structure and the gas inflow structure each comprise a permanent magnet and at least one of said walls, said door, said floor and said roof, to which the gas outflow structure and the gas inflow structure is to be connected, comprises a magnetic or magnetizable material for connecting the permanent magnet of the gas outflow structure and the permanent magnet of the gas inflow structure to the at least one of said walls, said door, said floor and said roof.
  • the magnetic connector can be permanent magnets or electromagnets. Electromagnets are preferred, because they can easily be switched on and off. This allows an especially user-friendly mounting of the gas outflow structure and the gas inflow structure inside the building chamber.
  • the at least one outlet opening of the gas outflow structure are outlet holes having diameters between 0.1 mm and 30 mm, wherein preferably the diameters of the outlet holes increase in the direction away from a proximal end of the gas outflow structure connected or to be connected to at least one of said walls, said door, said floor and said roof.
  • a distal end of the gas outflow structure which is on the opposite side of the proximal end of the gas outflow structure, projects or protrudes into the interior of the building chamber when the gas outflow structure is connected to the at least one of said walls, said door, said floor and said roof.
  • the at least one outlet opening will not be blocked easily by powder particles and the volume flow rate of the gas flowing from the outlet openings can be evened, because a pressure drop on every opening can be balanced.
  • the at least one inlet opening of the gas inflow structure are inlet holes having diameters between 0.1 mm and 30 mm, wherein preferably the diameters of the inlet holes increase in the direction away from a proximal end of the gas inflow structure connected or to be connected to at least one of said walls, said door, said floor and said roof.
  • a distal end of the gas inflow structure which is on the opposite side of the proximal end of the gas inflow structure, projects or protrudes into the interior of the building chamber when the gas inflow structure is connected to the at least one of said walls, said door, said floor and said roof.
  • the at least one inlet opening will not be blocked easily by powder particles and the volume flow rate of the gas flowing into the inlet openings can be evened, because an increasing pressure on every opening closer to the vacuum source can be balanced.
  • the at least one inlet opening of the gas inflow structure and/or the at least one outlet opening of the gas outflow structure are bordered or are covered by a tissue, by a gas permeable filter or foam material and/or the device comprises a particle filter for filtering particles from the inert gas for creating the gas flow, wherein preferably the particle filter is arranged in a gas feed line leading to the gas inflow structure.
  • the sum of the free cross sections of the at least one inlet opening of the gas inflow structure are same or larger than the cross section of the gas inflow line and/or the sum of the free cross sections of the at least one outlet opening of the gas outflow structure are same or larger than the cross section of the gas outflow line.
  • the free cross sections of the at least one inlet opening and of the at least one outlet opening are the unblocked areas of the openings which participate in gas flow through the respective opening.
  • the at least one outlet opening of the gas outflow structure is oriented in the direction of the gas inflow structure and the at least one inlet opening of the gas inflow structure is oriented in the direction of the gas outflow structure.
  • a beam area inside the building chamber is defined to be a partial area of a gas flow area inside the building chamber, said gas flow area being bordered by the gas outflow structure and the gas inflow structure and the beam area being an area through which the laser beam is to be radiated during melting or sintering of the powder when the laser beam is maximally deflected towards borders of the building platform, wherein the beam area lies fully within the gas flow area, wherein preferably inner limits of the gas outflow structure and the gas inflow structure are distanced to the borders beam area between 0.1 mm and 50 mm, especially preferably between 0.5 mm and 10 mm.
  • the beam area is defined by the maximal deflection of the laser beam which can occur during operation of the device.
  • the maximal deflection thereby limits the area on the building platform which can be reached by the laser beam.
  • the gas outflow structure and the gas inflow structure are distanced and are formed such that the inner limits of the gas outflow structure and the gas inflow structure defining the gas flow area are distanced to the borders of the beam area within a limit of 20 mm, preferably within a limit of 5 mm.
  • the gas flow area can be small and thus a smaller volume flow of the gas flow is needed and laminar flow is easier to achieve.
  • the gas inflow structure and the gas outflow structure can be used to shield from smoke and dust created from the powder. The smoke and dust can be absorbed by the gas being sucked into the gas inflow structure and pushed by the gas blowing from the gas outflow structure.
  • the gas outflow structure and the gas inflow structure are distanced and are formed such that the inner limits of the gas outflow structure and the gas inflow structure are distanced to the borders of the beam area at least 0.1 mm, preferably at least 0.5 mm.
  • said at least one gas outlet opening and said at least one gas inlet opening are arranged closer to said level of said movable part of said distributing device than to said lens and/or window.
  • said at least one gas outlet opening and said at least one gas inlet opening are arranged closer to said building platform than to said lens and/or window or closer to said floor of said building chamber than to said lens and/or window.
  • said movable part of said distributing device for applying and/or levelling a layer of said powdered material on the building platform is a spreading device or comprises a spreading device and/or said movable part of said distributing device comprises a powder supply and/or a powder collector.
  • the spreading device is used for levelling the powder and is thus very useful. To avoid turbulences it is essential, that the gas flow does not directly hit any parts of the distributing device, such as the spreading device.
  • said gas outflow structure and said gas inflow structure are designed to provide a gas flow starting from said gas outflow structure to said gas inflow structure, such that the gas flow being arranged closer to said level of said movable part of said distributing device than to said lens and/or window.
  • said gas inflow structure and said gas outflow structure are adjustable in height such that vertical adjustment of the operating height of the gas flow above the building platform is possible, wherein it is preferred that said gas inflow structure and said gas outflow structure are manually adjustable in height or motor driven adjustable in height.
  • the height is the distance from the floor of said building chamber.
  • the height of the gas flow can be adjusted depending on the height of the three-dimensional object as well as on the height of the movable part of said distributing device.
  • said at least one gas outlet opening is delimited by a pipe, which pipe protrudes inside the hollow gas outflow structure and/or said at least one gas inlet opening is delimited by a pipe, which pipe protrudes inside the hollow gas inflow structure.
  • At least one of the at least one gas outlet opening is delimited by a pipe, which pipe protrudes inside the hollow gas outflow structure, preferably all gas outlet openings are delimited by a pipe.
  • at least one of the at least one gas inlet opening is delimited by a pipe, which pipe protrudes inside the hollow gas inflow structure, preferably all gas inlet openings are delimited by a pipe.
  • the pipe or the pipes have a cylindric bore.
  • the pipe or the pipes are at least twice as long as the diameter of the gas line in the pipe or the pipes, particular preferably at least 5 times as long as the diameter of the gas line in the pipe or the pipes.
  • said gas outflow structure and said gas inflow structure are solidly connected to one another or are a single part.
  • said gas outflow structure and said gas inflow structure are detachably connected or are detachably connectable to any one of said walls, door, floor and roof, such that they are manually disconnectable without any tearing or breaking any material of said gas outflow structure or said gas inflow structure or any one of said walls, door, floor and roof.
  • said gas outflow structure and said gas inflow structure are detachably connected or are detachably connectable to any one of said walls, door, floor and roof, such that they are manually disconnectable without needing any tools.
  • Both measures serve to allow the user to easily assemble and disassemble the gas outflow and gas inflow structures in the building chamber.
  • said gas outflow structure and said gas inflow structure are detachably connected or are detachably connectable to any one of said walls, door, floor and roof, by means of a magnetic connection, a plug connection, a ratchet connection or by a screw connection, wherein the magnetic connection and the plug connection are particularly preferred.
  • These types of connections are especially easy to connect and disconnect and allow quick but also precise positioning.
  • the problem underlying the present invention are also solved by a method for operating such a device, the method comprising the chronological steps of
  • steps C) and D) the gas flow is provided by pressing a gas through the gas outflow line and out of the at least one outlet opening of the gas outflow structure into the building chamber and by evacuating the gas from the building chamber into the at least one inlet opening and through the inflow line of the gas inflow structure by means of a negative pressure compared to the pressure in the building chamber.
  • the gas is preferably an inert gas, such that an inert gas flow is provided.
  • step B2) is performed:
  • the closed building chamber is evacuated at least once via the gas inflow structure and thereafter an inert gas is filled into the closed building chamber via the gas outflow structure.
  • the manufacturing of the three-dimensional object can be performed under inert gas without need of an additional system and additional connections for creating an inert gas atmosphere inside the building chamber.
  • the gas outflow structure and the gas inflow structure are simply used for evacuating gas and filling inert gas into the building chamber.
  • the gas flow is provided from an inert gas flowing from the gas outlet openings.
  • the gas flow in step C) is provided with filtered gas, wherein particles are removed from the gas prior to creating the gas flow.
  • step D) at least once a new layer of the powder is applied on top of a previous layer of the powder and the new layer of powder is leveled, in particular by means of the distributing device, wherein preferably the gas flow is upheld and the laser beam is not radiated through said lens and/or window into said building chamber.
  • step D) smoke and/or dust created by the laser beam melting or sintering the particles of the powder is at least partly absorbed by the gas flow and preferably also by the gas inflow structure and the gas outflow structure.
  • the invention is based on the surprising recognition that, by providing a gas inflow structure and a gas outflow structure which protrude into the building chamber a gas flow is obtained above a movable part of the distributing device, which movable part is movable in a level above the building platform in the building chamber, such that the movable part of the distributing device does not interfere with the gas flow and the gas flow is kept in relatively small dimensions compared to the building chamber thereby reducing the development of turbulences.
  • the gas flow is not disrupted by the movable part of the distributing device i. e. the coating system and/or the spreading device.
  • the distance between inflow and outflow is reduced or even minimal, so that the gas flow can be kept maximally constant and at the same time can be kept close to the surface of the fresh powder to maximize the amount of absorbed or blown of smoke and particles which occur during sintering or melting of the powder by means of the laser beam.
  • a steady inert gas flow across the building platform can be achieved without facing disruption of flow patterns by the movement of the spreading device that is necessary for the device to function. Furthermore, fumes created by the action of the laser beam are by the nature of their creation hot and thus rise up due to buoyant uplift. Placement of the gas discharge or inert gas discharge in close proximity to and above the build platform ensures a more reliable fume reduction and dust reduction than is possible with current state-of-the-art devices.
  • Fig. 1 shows a schematic perspective view of a cross sectioned (vertical cutting plane) device according to the present invention
  • Fig. 2 shows a schematic detailed view on a gas outflow structure and gas inflow structure for a device according to the present invention
  • Fig. 3 shows a schematic detailed view of a horizontal cross-section of the gas outflow structure and the gas inflow structure of figure 2 from below;
  • Fig. 4 shows a schematic view from in top view on a horizontal cross-section (horizontal cutting plane) of a device according to the present invention.
  • Figures 1 to 4 show an exemplary device for additive manufacturing of three- dimensional objects from powdered material, which are often referred to as 3D- printers.
  • the device comprises a building chamber 1 in which the three-dimensional object is manufactured.
  • the building chamber 1 can be delimited by a backside wall 2, by side walls 3, a roof 4 and a floor 5, a front side wall 46 and a door 11 .
  • the front side wall 46 can comprise a door frame delimiting a door opening 52 which can be closed by the door 11.
  • the building chamber 1 can be of rectangular shape.
  • a building platform 6 can be movably arranged in the floor 5. The building platform 6 can be lowered into a hole in the floor 5 while the three-dimensional object (not shown) is manufactured layer by layer on the building platform 6.
  • the device can comprise a laser source 7 which can radiate a laser beam (not shown) through a lens and/or a window 8 into the building chamber 1.
  • the three-dimensional object can be manufactured from powder by locally melting or sintering the powder by means of the laser beam.
  • the powder can be applicated and levelled on the building platform 6 by means of a distributing device 9.
  • the distributing device 9 can comprise a movable part 10 which can be moved in the building chamber 1 across the building platform 6 for applying and/or levelling fresh powder onto the building platform 6.
  • the movable part 10 can be a spreading device 48 or can comprise a spreading device 48.
  • the device can further comprise a gas flow system 12 for driving a gas flow 62 inside the building chamber 1 .
  • the gas flow system 12 can comprise at least one pump or a pressurized gas source such as a pressurized inert gas such as argon or nitrogen.
  • the gas flow system 12 can further comprise at least one filter for filtering the gas stream before entering the building chamber 1 and/or after being evacuated from the building chamber 1 .
  • the device comprises a gas outflow structure 14, which can be connected to the gas flow system 12.
  • the gas outflow structure 14 can be releasably connected to the back side wall 2 of the building chamber 1 and protrudes into the building chamber 1.
  • the gas outflow structure 14 can be closed on a distal end of the gas outflow structure 14 by a closed end 15 and can comprise a multitude of gas outlet openings 16 which can be directed in a plane parallel to the building platform 6.
  • the gas outflow structure 14 is arranged such in the building chamber 1 that it does not interfere with the movement of the movable part 10 of the distributing device 9 and that it is arranged in a level between the level in which the movable part 10 moves and the lens and/or the window 8.
  • the gas outflow structure 14 can be or can form a hollow body, wherein the hollow body of the gas outflow structure 14 serves as a gas outflow line 17. Other forms and shapes of gas outflow lines are of course possible.
  • the gas outlet openings 16 are connected to the gas outflow line 17 such as the hollow body of the gas outflow structure 14.
  • the device comprises a gas inflow structure 24, which can be connected to the gas flow system 12.
  • the gas inflow structure 24 can be releasably connected to the back side wall 2 of the building chamber 1 and protrudes into the building chamber 1.
  • the gas inflow structure 24 can be closed on a distal end of the gas inflow structure 24 by a closed end 25 and can comprise a multitude of gas inlet openings 26 which can be directed in a plane parallel to the building platform 6.
  • the gas inflow structure 24 can be or can form a hollow body, wherein the hollow body of the gas inflow structure 24 serves as a gas inflow line 27. Other forms and shapes of gas inflow lines are of course possible.
  • the gas inlet openings 26 are connected to the gas inflow line 27 such as the hollow body of the gas inflow structure 24.
  • the gas inflow structure 24 and the gas outflow structure 14 can be shaped and can be arranged mirror symmetrically in a plane perpendicular to the building platform 6 and to the back side wall 2.
  • the gas inflow structure 24 is arranged such in the building chamber 1 that it does not interfere with the movement of the movable part 10 of the distributing device 9 and that it is arranged in the same level between the level in which the movable part 10 moves and the lens and/or window 8 as the gas outflow structure 14.
  • the gas outlet openings 16 and the gas inlet openings 26 can be arranged and provided for producing a laminar gas flow 62 (see figure 3) in a plane which covers all direct linear connections between the lens and/or window 8 and the building platform 6.
  • a laminar gas flow 62 see figure 3
  • all possible laser beams produced by the laser source 7 which can reach the building platform 6 from the lens and/or the window 8 need to pass the gas flow 62 (gas curtain).
  • the lens/window 8 cannot be directly hit by particles and smoke resulting from melting or sintering the powder by the laser beam. All such particles and smoke will be deviated or absorbed by the laminar gas flow 62.
  • the more laminar the laminar gas flow 62 flows the less powder particles will be moved in a fresh powder level on the building platform 6. Therefore, it is clear that not only a perfect laminar gas flow 62 is sufficient to realize the present invention.
  • the gas outflow structure 14 and the gas inflow structure 24 can be a single part which has a holding plate 18 common for both the gas outflow structure 14 and the gas inflow structure 24, the holding plate 18 comprising a reinforcement 20 and a magnetizable connector 22.
  • the reinforcement 20 maybe made of steel and the magnetizable connector 22 may be made of iron or another magnetizable metal while the gas outflow structure 14 and the gas inflow structure 24 may preferably be printed from plastic or metal.
  • the gas outflow structure 14 and the gas inflow structure 24 can be connected by a magnetic connector 34 in the back side wall 2 of the building chamber 1 to the back side wall 2 in the building chamber 2.
  • the magnetizable connector 22 may also serve as a shielding for shielding the building chamber 1 from magnetic fields of the magnetic connector 34 from entering the building chamber 1.
  • the magnetizable connector 22 can be larger than the magnetic connector 34 in the contact area to the magnetic connector 34.
  • the magnetic connector 34 is preferably realized by an electro magnet which can be switched on and off to connect or disconnect the holding plate 18 carrying the gas outflow structure 14 and the gas inflow structure 24 to the building chamber 1 .
  • this type of connection can be transferred to connections to the side walls 3, the roof 4, the floor 5 and the door 11 and can also be used if the gas outflow structure 14 and the gas inflow structure 24 are not made as a common single part.
  • the gas outflow structure 14 can be connected via a gas feed line 36 to the gas flow system 12 and the gas inflow structure 24 can be connected via an evacuation line 66 to a pump 64 of the gas flow system 12.
  • Lead throughs 68, 70 can be arranged in the holding plate 18 for allowing gas to be conducted to the gas outflow line 17 of the gas outflow structure 14 and from the gas inflow line 27 of the gas inflow structure 24.
  • Lead through 68 can connect the gas outflow line 17 in the gas outflow structure 14 with the gas feed line 36.
  • Lead through 70 can connect the gas inflow line 27 in the gas inflow structure 24 with the evacuation line 66.
  • a further gas line 50 can connect different parts of the gas flow system 12, such as a pump 64 and a pressurized gas source, with one another.
  • a Galvano scanner 38 can be provided for being able to precisely direct the laser beam.
  • a powder feeding system 40 can be arranged in the floor 5 of the building chamber 1 .
  • the powder feeding system 40 can be used for providing new powder layers on the building platform 6 by means of a movable part of the distributing device 9.
  • the building platform 6 can be held by means of a rod 42 which holds the building platform 6.
  • a motor (not shown) can be used to set and adapt the level of the building platform 6 in the building chamber 1.
  • the distributing device 9 can comprise a spreading device 48 for levelling the powder on the building platform 6.
  • the spreading device 48 can be moved over the building platform 6 thereby wiping off excess powder and levelling the powder on the building platform 6.
  • the wiped off powder can be collected by a powder collector 72.
  • the gas outflow structure 14 can comprise small pipes 54 which open into the gas outlet openings 16.
  • the gas inflow structure 24 can comprise small pipes 56 which open into the gas inlet openings 26.
  • the pipes 54, 56 can protrude in the otherwise hollow gas outflow structure 14 and the otherwise hollow gas inflow structure 24.
  • the pipes 54, 56 and especially the pipes 54 in the gas outflow structure 14 help to produce and uphold the laminar gas flow 62 between the gas outlet openings 16 of the gas outflow structure 14 and the gas inlet openings 26 of the gas inflow structure 24 to be more laminar.
  • the gas flow system 12 presses a gas flow 58 into the gas outflow structure 14 and sucks a gas flow 60 from the gas inflow structure 24.
  • the door 11 of the device is opened (see figure 1 ).
  • the gas outflow structure 14 and the gas inflow structure 24 can be connected to the back side wall 2 by means of the magnetizable connector 22 of the holding plate 18 and the magnet connector 34 in the back side wall 2, such that the lead troughs 68, 70 flush with the open gas feed line 36 and the evacuation line 66.
  • the door 11 is then closed (see figure 4) and thereby the building chamber 1 can be closed gas tight.
  • the building chamber 1 can be evacuated through the gas inflow structure 24 by means of the pump 64 of the gas flow system 12 and an inert gas can be filled in the building chamber 1 through the gas outflow structure 14 by means of the gas flow system 12.
  • a powder, from which the three-dimensional object is to be produced, can be taken from the powder feeding source 40 and can be applied to and can be levelled on the building platform 6 by means of the distributing device 9.
  • a laminar gas flow 62 can be generated by means of the gas flow system 12 starting from the gas outflow structure 14 and ending at the gas inflow structure 24.
  • the laminar gas flow 62 separates the building platform 6 from the lens/window 8 of the laser source 7.
  • the three-dimensional object is manufactured layer wise by the laser beam on fresh powder arranged on the building platform 6 by sintering or melting the powder with the laser beam, while fresh powder layers are regularly applied to the building platform 6 with the distributing device 9. Throughout this process the laminar gas flow 62 is upheld. Smoke and particles from the powder surface are deviated or removed from their way to the lens/window 8 thereby reducing the amount of deposit on the lens/window 8 which could scatter the light of the laser beam.
  • the laminar gas flow 62 flows in a level above the level in which the movable part 10 of the distributing device 9 moves, the laminar gas flow 62 will not be interfered by the movable part 10 and thus the laminar gas flow 62 will not be redirected to the surface of the fresh powder. This prevents powder particles in the levelled powder to be unwillingly moved and thus quality of the levelled powder surface remains high and so will the quality of the manufactured three-dimensional object.
  • the laminar gas flow 62 can be stopped and the door 11 can be opened to remove the manufactured three- dimensional object from the building chamber 1.

Abstract

L'invention concerne un dispositif de fabrication additive d'objets tridimensionnels à partir d'un matériau en poudre, comprenant une chambre de construction (1) qui est délimitée par une porte (11), des parois (2, 3), un toit (4) et un plancher (5), une plate-forme de construction (6) étant disposé à l'intérieur de ladite chambre de construction (1), une source de laser (7), une lentille et/ou une fenêtre (8) à travers laquelle un faisceau laser provenant de ladite source de laser (7) peut être guidé dans ladite chambre de construction (1), un dispositif de distribution (9) destiné à appliquer et/ou à mettre à niveau une couche dudit matériau en poudre sur la plate-forme de construction (6), comprenant une partie mobile (10) qui est disposée de manière mobile dans un niveau entre ladite plate-forme de construction (6) et ladite lentille et/ou fenêtre (8), un système d'écoulement de gaz (12), une structure de sortie de gaz (14) qui est reliée de manière amovible à l'un quelconque des éléments parmi lesdites parois (2, 3), la porte (11), le plancher (5) et le toit (4), comprenant au moins une ouverture de sortie (16), qui fait saillie à l'intérieur de ladite chambre de construction (1) lorsqu'elle est raccordée et au moins une ouverture de sortie de gaz (16) ayant au moins 10 mm, une structure d'entrée de gaz (24) étant reliée de manière amovible ou pouvant être reliée de manière amovible à l'un quelconque des éléments parmi lesdites parois (2, 3), la porte (11), le sol (5) et le toit (4), comprenant au moins une ouverture d'entrée (26), qui fait saillie à l'intérieur de ladite chambre de construction (1) lorsqu'elle est raccordée et au moins une ouverture d'entrée de gaz (26) ayant une distance d'au moins 10 mm par rapport à la chambre de construction (1 ), ladite structure de sortie de gaz (14) et ladite structure d'entrée de gaz (24) étant conçues pour fournir un flux de gaz (62), de sorte que le flux de gaz est disposé entre ledit niveau de ladite partie mobile (10) dudit dispositif de distribution (9) et ladite lentille et/ou fenêtre (8).
PCT/EP2021/086987 2021-12-21 2021-12-21 Imprimante 3d avec structure en saillie pour générer un rideau de gaz WO2023117053A1 (fr)

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WO2006024373A2 (fr) 2004-08-27 2006-03-09 Hek Gmbh Dispositif pour realiser des corps moules
DE102006014835A1 (de) 2006-03-30 2007-10-04 Fockele, Matthias, Dr. Vorrichtung zur Herstellung von Gegenständen durch schichtweises Aufbauen aus pulverförmigem Werkstoff
WO2010007394A1 (fr) 2008-07-18 2010-01-21 Mtt Technologies Limited Appareil et procédé de fabrication
DE102010052206A1 (de) 2010-11-10 2012-05-10 Cl Schutzrechtsverwaltungs Gmbh Vorrichtung zum Herstellen von dreidimensionalen Objekten
EP2492084A1 (fr) 2009-10-21 2012-08-29 Panasonic Corporation Procédé de fabrication d'un objet de forme tridimensionnelle et son dispositif de fabrication
US20160121398A1 (en) * 2014-10-30 2016-05-05 MTU Aero Engines AG Device and method for the manufacture or repair of a three-dimensional object
EP3023228A1 (fr) 2014-11-24 2016-05-25 Trumpf Sisma S.r.l. Écoulement de gaz à l'intérieur d'un dispositif de fabrication par addition de couches
US20160318128A1 (en) 2015-04-28 2016-11-03 Brigante Aviation Limited Metal Printer
EP3689502A1 (fr) * 2019-01-30 2020-08-05 General Electric Company Ensemble d'outillage pour alignement magnétique de composants dans une machine de fabrication additive
WO2020178220A1 (fr) * 2019-03-04 2020-09-10 SLM Solutions Group AG Dispositif et procédé de production d'une pièce tridimensionnelle
WO2021154609A1 (fr) 2020-01-28 2021-08-05 Divergent Technologies, Inc. Imprimante 3d à mécanisme d'échange gazeux pour éliminer des contaminants pendant une réenduction
DE102020115420A1 (de) * 2020-06-10 2021-12-16 Trumpf Laser- Und Systemtechnik Gmbh Absaugkanal bei der generativen Fertigung

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* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
DE102004031881A1 (de) * 2004-06-30 2006-01-26 Concept Laser Gmbh Vorrichtung zum Absaugen von Gasen, Dämpfen und/oder Partikeln aus dem Arbeitsbereich einer Laserbearbeitungsmaschine
WO2006024373A2 (fr) 2004-08-27 2006-03-09 Hek Gmbh Dispositif pour realiser des corps moules
DE102006014835A1 (de) 2006-03-30 2007-10-04 Fockele, Matthias, Dr. Vorrichtung zur Herstellung von Gegenständen durch schichtweises Aufbauen aus pulverförmigem Werkstoff
WO2010007394A1 (fr) 2008-07-18 2010-01-21 Mtt Technologies Limited Appareil et procédé de fabrication
EP2323787A1 (fr) * 2008-07-18 2011-05-25 MTT Technologies Limited Appareil et procédé de fabrication
EP2492084A1 (fr) 2009-10-21 2012-08-29 Panasonic Corporation Procédé de fabrication d'un objet de forme tridimensionnelle et son dispositif de fabrication
DE102010052206A1 (de) 2010-11-10 2012-05-10 Cl Schutzrechtsverwaltungs Gmbh Vorrichtung zum Herstellen von dreidimensionalen Objekten
US20160121398A1 (en) * 2014-10-30 2016-05-05 MTU Aero Engines AG Device and method for the manufacture or repair of a three-dimensional object
EP3023228A1 (fr) 2014-11-24 2016-05-25 Trumpf Sisma S.r.l. Écoulement de gaz à l'intérieur d'un dispositif de fabrication par addition de couches
US20160318128A1 (en) 2015-04-28 2016-11-03 Brigante Aviation Limited Metal Printer
EP3689502A1 (fr) * 2019-01-30 2020-08-05 General Electric Company Ensemble d'outillage pour alignement magnétique de composants dans une machine de fabrication additive
WO2020178220A1 (fr) * 2019-03-04 2020-09-10 SLM Solutions Group AG Dispositif et procédé de production d'une pièce tridimensionnelle
WO2021154609A1 (fr) 2020-01-28 2021-08-05 Divergent Technologies, Inc. Imprimante 3d à mécanisme d'échange gazeux pour éliminer des contaminants pendant une réenduction
DE102020115420A1 (de) * 2020-06-10 2021-12-16 Trumpf Laser- Und Systemtechnik Gmbh Absaugkanal bei der generativen Fertigung

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