Apparatus for additively manufacturing of three-dimensional objects

Patent metadata

Field	Value
Publication number	US-11760024-B2
Application number	US-201815987801-A
Country	US
Kind code	B2
Filing date	May 23, 2018
Priority date	Jul 21, 2017
Publication date	Sep 19, 2023
Grant date	Sep 19, 2023

Abstract

Apparatus ( 1 ) for additively manufacturing of three-dimensional objects by means of successive layerwise selective irradiation and consolidation of layers of a build material ( 13 ) which can be consolidated by means of an energy beam, comprising at least one module ( 2 ) moveable between at least two positions along a travel path, wherein a stream generating unit ( 6 ) is configured to create a stream of process gas ( 7 ) onto the module ( 2 ) at least partly along the travel path ( 5 ) of the module ( 2 ) between the first and the second position ( 3, 4 ).

First claim

The invention claimed is:

1. An apparatus for additively manufacturing three-dimensional objects by successive layerwise selective irradiation and consolidation of layers of a build material with an energy beam, the apparatus comprising:
a process chamber;
at least one module moveable between a first position and a second position along a travel path, the at least one module comprising a powder chamber;
a stream generating unit configured to generate a stream of process gas onto the at least one module at least partly along the travel path of the at least one module between the first position and the second position, wherein the at least one module is located at least partly inside the process chamber in the first position and is located outside the process chamber in the second position;
a guiding structure arranged above the travel path, the guiding structure extending from the first position to the second position, the guiding structure configured to guide the process gas along the travel path and to distribute the process gas to the powder chamber of the at least one module during movement of the at least one module along the travel path from the first position to the second position, wherein the process gas is distributed to the powder chamber via a plurality of gas outlets arranged along the guiding structure from the first position to the second position; and
a control unit for controlling opening and closing of the plurality of gas outlets dependent on a current location of the at least one module, wherein only gas outlets of the plurality of gas outlets above the current location of the at least one module are opened by the control unit, and gas outlets of the plurality of gas outlets not above the current location of the at least one module are closed by the control unit to ensure that only the gas outlets above the current location of the at least one module are opened to replenish the process gas in a layer of the process gas inside the powder chamber of the at least one module.

2. The apparatus according to claim 1 , wherein the at least one module comprises a dose module.

3. The apparatus according to claim 1 , wherein the stream generating unit comprises the guiding structure.

4. The apparatus according to claim 1 , wherein the guiding structure comprises a channel.

5. The apparatus according to claim 1 , wherein each of the plurality of gas outlets is configured as a nozzle.

6. The apparatus according to claim 1 , wherein the guiding structure distributes the process gas onto the powder chamber of the at least one module continuously or at predefined locations along the travel path.

7. The apparatus according to claim 1 , wherein the control unit is configured to control at least one flow property from gas outlets of the plurality of gas outlets above the current location of the at least one module.

8. The apparatus according to claim 7 , wherein the at least one flow property comprises at least one of:
a gas pressure;
a gas flow rate;
a gas flow velocity; or
a temperature.

9. The apparatus according to claim 7 , further comprising at least one sensor, wherein the control unit is configured to control the at least one flow property dependent on sensor information from the at least one sensor.

10. The apparatus according to claim 7 , further comprising at least one sensor configured to determine sensor information relating to an amount of process gas in the vicinity of the module and/or inside the powder chamber of the at least one module, wherein the control unit is configured to receive the sensor information and to control the at least one flow property depending on the sensor information.

11. The apparatus according to claim 1 , further comprising a cover of the at least one module, wherein the cover is removable and configured to cover the powder chamber of the at least one module in the first and/or the second position, and wherein the stream generating unit is configured to create the stream of process gas at least partly into the powder chamber of the at least one module.

12. The apparatus according to claim 1 , wherein in the second position the at least one module is located at least partly inside at least one of:
a handling station;
a refill station; or
a filtering station.

13. The apparatus according to claim 12 , wherein the travel path runs at least partly inside a tunnel structure.

14. The apparatus according to claim 1 , wherein the at least one module comprises a build module.

15. The apparatus according to claim 1 , wherein the at least one module comprises an overflow module.

16. A plant for additively manufacturing three-dimensional objects by successive layerwise selective irradiation and consolidation of layers of a build material with an energy beam, the plant comprising:
a first apparatus;
a second apparatus;
at least one module moveable between a first position and a second position along a travel path;
a stream generating unit configured to generate a stream of process gas onto the at least one module at least partly along the travel path between the first position and the second position, wherein the at least one module is located at least partly inside the first apparatus in the first position and is located at least partly inside the second apparatus in the second position;
a guiding structure above the travel path, the guiding structure extending from the first position to the second position, the guiding structure configured to guide the process gas along the travel path and to distribute the process gas to a chamber of the at least one module during movement of the at least one module along the travel path, wherein the process gas is distributed to the powder chamber via a plurality of gas outlets arranged along the guiding structure from the first position to the second position; and
a control unit for controlling opening and closing of the plurality of gas outlets dependent on a current location of the at least one module, wherein only gas outlets of the plurality of gas outlets above the current location of the at least one module are opened by the control unit, and gas outlets of the plurality of gas outlets not above the current location of the at least one module are closed by the control unit to ensure that only the gas outlets above the current location of the at least one module are opened to replenish the process gas in a layer of the process gas inside the powder chamber of the at least one module.

Assignees

• Cl Schutzrechtsverwaltungs Gmbh
• Concept Laser Gmbh

Inventors

• Schödel Frank
• Stammberger Jens

Classifications

• B33Y40/00 Primary

  Auxiliary operations or equipment, e.g. for material handling · CPC title

• B29C64/371 Primary

  using an environment other than air, e.g. inert gas · CPC title

• B33Y50/02

  for controlling or regulating additive manufacturing processes · CPC title

• B22F12/90

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

• B22F12/80

  Plants, production lines or modules · CPC title