Additive production method

Patent metadata

Field	Value
Publication number	US-11110516-B2
Application number	US-201715719605-A
Country	US
Kind code	B2
Filing date	Sep 29, 2017
Priority date	Sep 30, 2016
Publication date	Sep 7, 2021
Grant date	Sep 7, 2021

Abstract

The present disclosure provides an additive production method of producing an object by metal powder being applied in a production region in layers by an application device. The metal powder is applied to a base member along a construction face and is partially molten by a laser beam and solidified. A continuous conveyor transports the base member with the object in a transport direction away from the construction face. The continuous conveyor further transports the base member with the completed object to a removal region where the object is removed from the continuous conveyor. Support structures are produced on the object and are connected to the base member. The support structures are removed after the removal region has been reached.

First claim

What is claimed is:

1. An additive production method of producing an object, the additive production method comprising:
applying metal powder in a production region in layers, by an application device, to at least one base member along a construction face, wherein the at least one base member and the construction face extend across a bottom plate at an angle relative to a horizontal that is less than an angle of repose of the metal powder, the metal powder being partially melted by a laser beam and subsequently solidified such that support structures extending transversely toward the construction face are produced on the at least one base member and the object is connected to the support structures;
transporting, by at least one continuous conveyor, the at least one base member with the object in a transport direction (T) away from the construction face; and
transporting, by the at least one continuous conveyor, the at least one base member and the support structures with a completed object to a removal region where at least the completed object is removed from the at least one continuous conveyor,
wherein the support structures discharge heat from the completed object to the at least one base member, the support structures being removed from the at least one base member and the completed object after the removal region has been reached.

2. The additive production method according to claim 1 , wherein the at least one base member is removed from the continuous conveyor is a belt conveyor with an open structure, the bottom plate terminates in the removal region, and metal powder trickles through the open structure of the belt conveyor away from the base member and the completed object and is accumulated in a collection container.

3. The additive production method according to claim 1 , wherein the transport direction (T) assumes an angle of a maximum of 30° with respect to a horizontal (H).

4. The additive production method according to claim 1 , wherein the transport direction (T) assumes an angle of a maximum of 30° with respect to a vertical (V).

5. The additive production method according to claim 1 , wherein in the production region, the bottom plate inhibits trickling of powder, and in the removal region metal powder trickles away as a result of gravitational force.

6. The additive production method according to claim 1 , wherein powder is returned from the removal region to the application device.

7. The additive production method according to claim 1 , wherein, before the completed object is removed from the continuous conveyor, production of a next object begins.

8. The additive production method according to claim 1 , wherein the additive production method takes place in a housing containing inert gas.

9. The additive production method according to claim 1 further comprising sidewalls adjoined to sides of the bottom plate.

10. The additive production method according to claim 1 further comprising the step of collecting unused metal powder in a collection container disposed in the removal region.

11. The additive production method according to claim 10 , wherein the collection container is in contact with a storage container via a return line and the unused metal powder is returned to the storage container.

12. The additive production method according to claim 1 , wherein the application device moves parallel with the construction face.

13. The additive production method according to claim 1 , wherein the at least one base member is connected to the at least one continuous conveyor.

Assignees

• Ford Global Tech Llc

Inventors

• Koch Raphael
• Alves Bruno

Classifications

• B23K26/342 Primary

  Build-up welding · CPC title

• B22F10/73

  of powder · CPC title

• B22F10/40

  Structures for supporting workpieces or articles during manufacture and removed afterwards · CPC title

• B22F10/66

  by mechanical means · CPC title

• B22F10/32

  of the atmosphere, e.g. composition or pressure in a building chamber · CPC title