Additive manufacturing method

Patent metadata

Field	Value
Publication number	US-11498158-B2
Application number	US-201916356124-A
Country	US
Kind code	B2
Filing date	Mar 18, 2019
Priority date	Mar 19, 2018
Publication date	Nov 15, 2022
Grant date	Nov 15, 2022

Abstract

An additive manufacturing method wherein an object is manufactured by powder being applied layer-by-layer by an application device onto a base along a buildup surface and being bonded in regions to form a matrix. To provide an efficient additive powder bed method, a position of the base is checked by at least one measurement with a sensor device and the position of the base is automatically corrected at least in relation to the application device based on the at least one measurement.

First claim

What is claimed is:

1. An additive manufacturing method, wherein an object is manufactured by powder being applied layer-by-layer by a powder applicator onto a base along a buildup surface and being bonded in a predetermined area to form a matrix comprising:
a position of the base is checked by at least one measurement by a sensor and the position is automatically corrected at least in relation to the power applicator depending on the at least one measurement; and
the sensor is arranged on a robot articulated arm by which it is moved into a measuring position for the respective measurement wherein the robot articulated arm, and corresponding the sensor, is separate from and operates independently of the powder applicator.

2. The additive manufacturing method of claim 1 wherein at least one measurement is carried out by touch with the sensor including a tactile sensor.

3. The additive manufacturing method of claim 2 wherein at least one angle of inclination of the base is automatically corrected depending on the at least one measurement.

4. The additive manufacturing method of claim 1 wherein manufacturing the object is carried out in an inert gas atmosphere.

5. The additive manufacturing method of claim 1 wherein at least one measurement is carried out on one of a construction platform from which the object is removed after it is finished and a prefinished base body arranged on the construction platform that remains connected to the matrix as part of the object.

6. The additive manufacturing method of claim 1 wherein a recess is created inside the object to accommodate an insert part by powder not being bonded in a region provided for the recess with any unbonded powder being removed by a cleaning device arranged on the robot articulated arm.

7. The additive manufacturing method of claim 1 wherein an insert part is inserted into a recess by the robot articulated arm on which an insert part holder is arranged.

8. The additive manufacturing method of claim 1 wherein at least two devices, selected from the sensor, a secondary application device, a cleaning device, and an insert part holder are guided by the robot articulated arm.

9. An additive manufacturing method comprising:
using a powder applicator to apply a powder layer-by-layer onto a base along a buildup surface;
bonding the powder in a predetermined area to form a matrix producing a layer of an object;
providing a robotic arm separate from and operating independently of the powder applicator, the robotic arm carrying a sensor; and
using the robotic arm to position the sensor at a plurality of measuring positions and using the sensor to measure a position of the base;
comparing the measured position of the base to a setpoint value;
correcting the position of the base in relation to the application device based on the measured position of the base when the measured position of the base deviates from the setpoint value; and
using the robotic arm to perform an additional manufacturing process.

10. The method of claim 9 including the base having a construction platform and using the sensor to measure a position of the construction platform; and
instead of correcting the position of the base in relation to the application device correcting the position of the construction platform relative to the application device.

11. The method of claim 9 wherein the sensor includes a tactile sensor.

12. The method of claim 9 including positioning the robotic arm in a readiness position spaced from the powder applicator wherein neither the robotic arm nor the sensor moves with the powder applicator.

13. The method of claim 9 including performing the step of bonding the powder in an inert gas atmosphere.

14. The method of claim 9 including a second powder applicator, the second powder applicator applying powder on a construction platform adjacent to a base body; and
the robotic arm carrying and positioning the second powder applicator.

15. The method of claim 9 including the robotic arm carrying an insert part and inserting said insert part into a recess in the object.

16. The method of claim 9 including a cleaning device for removing unbonded powder; and
the robotic arm carrying and positioning the cleaning device.

17. The method of claim 9 including at least two devices selected from the sensor, a second powder applicator, a cleaning device, and an insert part holder are carried and positioned by the robotic arm.

18. An additive manufacturing method comprising:
using a powder applicator to apply a powder layer-by-layer onto a base along a buildup surface;
bonding the powder in a predetermined area to form a matrix producing a layer of an object;
providing a robotic arm separate from and operating independently of the powder applicator, the robotic arm carrying a sensor, using the sensor to measure a position of the base;
comparing the measured position of the base to a setpoint value; and
correcting the position of the base in relation to the powder applicator based on the measured position of the base when the measured position of the base deviates from the setpoint value.

19. The additive manufacturing method of claim 18 wherein the sensor includes a tactile sensor.

20. The additive manufacturing method of claim 18 including positioning the robotic arm in a readiness position spaced from the powder applicator wherein neither the robotic arm nor the sensor moves with the powder applicator.

Assignees

• Ford Global Tech Llc

Inventors

• Koch Raphael
• Bognar Lars

Classifications

• B22F12/90

  Means for process control, e.g. cameras or sensors · CPC title

• B22F12/55

  Two or more means for feeding material · CPC title

• B22F10/50

  Treatment of workpieces or articles during build-up, e.g. treatments applied to fused layers during build-up · CPC title

• B22F10/32

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

• B22F10/31

  Calibration of process steps or apparatus settings, e.g. before or during manufacturing · CPC title