Method for producing three-dimensional components

Patent metadata

Field	Value
Publication number	US-2017368757-A1
Application number	US-201615541345-A
Country	US
Kind code	A1
Filing date	Jan 12, 2016
Priority date	Jan 14, 2015
Publication date	Dec 28, 2017
Grant date	—

Abstract

The invention relates to a method for producing three-dimensional components ( 14 ) by successively solidifying layers of a powder construction material ( 9 ) which can be solidified by means of electromagnetic radiation ( 18 ), in particular bundled radiation such as laser radiation or electron radiation, at the locations corresponding to the respective cross-section of the component ( 14 ), in particular an SLM (selective laser melting) or SLS (selective laser sintering) method. A device ( 1 ) comprising a support device ( 7 ), the height of which can be adjusted within a construction chamber ( 6 ), is provided for supporting the component ( 14 ), comprising a coating device ( 12 ) for applying layers of the construction material ( 9 ) onto the support device or onto a previously formed layer and comprising an irradiating device ( 15 ) for irradiating layers of the construction material ( 9 ) in some regions in order to solidify the layers. A surface ( 13 ) section to be coated is scanned with respect to the evenness of the section prior to the application of a new layer, and in the event of an unevenness which exceeds a known tolerance range, the unevenness is removed or leveled out.

First claim

1 . A method for producing three-dimensional components ( 14 ) by successive solidification of layers of a powder-type construction material ( 9 ) that can be solidified using electromagnetic radiation ( 18 ), especially directional radiation such as laser radiation or electron beam radiation, on the positions corresponding to the respective cross-section of the component ( 14 ), especially selective laser melting (SLM) or selective laser sintering (SLS), wherein an apparatus ( 1 ) with a height movable carrying device ( 7 ) for carrying the component ( 14 ) is provided within a construction chamber ( 6 ), comprising a coating device ( 12 ) for applying layers of the construction material ( 9 ) onto the carrying device or a layer previously applied, and an irradiation device ( 15 ) for irradiating layers of the construction material ( 9 ) in sections, to solidify said layers, characterized in that prior to the application of a new layer, a portion of the surface ( 13 ) to be coated is scanned regarding the evenness thereof, and, in case of unevennesses exceeding a certain range of tolerance, said unevennesses are removed or smoothed out.

2 . The method according to claim 1 , characterized in that a portion of the surface to be coated is scanned using a sensor and unevenness coordinates are detected.

3 . The method according to claim 2 , characterized in that the locally determined unevennesses are specifically locally removed or smoothed out using the unevenness coordinates determined.

4 . The method according to claim 1 , characterized in that the scanning of the surface ( 13 ) to be coated is carried out optically.

5 . The method according to claim 1 , characterized in that the scanning of the surface ( 13 ) is carried out by an acoustic method, especially an ultrasonic method.

6 . The method according to claim 1 , characterized in that unevennesses determined are removed mechanically where they are localized.

7 . The method according to claim 6 , characterized in that the mechanical removal is carried out using a smoothening roll ( 40 ).

8 . The method according to claim 1 , characterized in that unevennesses determined are melted off.

9 . The method according to claim 1 , characterized in that mechanical unevennesses are rolled.

10 . The method according to claim 9 , characterized in that the rolling process is carried out after a phase of locally heating the unevennesses.

11 . The method according to claim 1 , characterized in that the scanning of the surface ( 13 ) to be coated is carried out prior to each coating process.

12 . The method according to claim 1 , characterized in that the scanning of the surface ( 13 ) to be coated is carried out in edge or overhang sections of the component only.

13 . The method according to claim 1 , characterized in that a delamination of layers of the component ( 14 ) already solidified is detected by the scanning.

14 . The method according to claim 1 , characterized in that between the scanning processes a plurality of coating processes is carried out.

15 . The method according to claim 1 , characterized in that a mechanical removing device ( 40 , 41 ) can be controlled over the surface ( 13 ) to be removed in x- and y-directions.

16 . The method according to claim 1 , characterized in that a detection and/or removing process regarding a construction layer determined as uneven and/or partially removed and regarding the related x- and y-coordinates and the layer number (z-coordinate in component) is automatically stored in a quality management protocol that is created for the respective component ( 14 ).

17 . The method according to claim 16 , characterized in that next to the x- and y-coordinates, the type of removal and/or the removal depth are also automatically stored.

Assignees

• Cl Schutzrechtsverwaltungs Gmbh

Inventors

• Herzog Frank

Classifications

• B29C64/153 Primary

  using layers of powder being selectively joined, e.g. by selective laser sintering or melting · CPC title

• B29C64/393 Primary

  for controlling or regulating additive manufacturing processes · CPC title

• B33Y10/00 Primary

  Processes of additive manufacturing · CPC title

• B29C64/214

  Doctor blades · CPC title

• B33Y50/00

  Data acquisition or data processing for additive manufacturing · CPC title