Additive Manufacturing Method

Patent metadata

Field	Value
Publication number	US-2019283183-A1
Application number	US-201916356124-A
Country	US
Kind code	A1
Filing date	Mar 18, 2019
Priority date	Mar 19, 2018
Publication date	Sep 19, 2019
Grant date	—

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 an application device 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 device and the position is automatically corrected at least in relation to the application device depending on the at least one measurement; and the sensor device 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 device, is separate from and operates independently of the application device.

2 . The additive manufacturing method of claim 1 wherein at least one measurement is carried out by touch with the sensor device 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 powder is applied on a construction platform adjacent to a base body by an application device arranged on the robot articulated arm.

7 . 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.

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

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

10 . An additive manufacturing method comprising:
using an application device 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 application device, the robotic arm carrying a sensor device; and using the robotic arm to position the sensor device at a plurality of measuring positions and using the sensor device 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.

11 . The method of claim 10 including the base having a construction platform and using the sensor device 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.

12 . The method of claim 10 wherein the sensor device includes a tactile sensor.

13 . The method of claim 10 including positioning the robotic arm in a readiness position spaced from the application device wherein neither the robotic arm nor the sensor device moves with the application device.

14 . The method of claim 10 including performing the step of bonding the powder in an inert gas atmosphere.

15 . The method of claim 10 including a second application device, the second application device applying powder on a construction platform adjacent to a base body; and
the robotic arm carrying and positioning the second application device.

16 . The method of claim 10 including the robotic arm carrying an insert part and inserting said insert part into a recess in the object.

17 . The method of claim 10 including a cleaning device for removing unbonded powder; and
the robotic arm carrying and positioning the cleaning device.

18 . The method of claim 10 including at least two devices selected from the sensor device, a secondary application device, a cleaning device, and a holding device are carried and positioned by the robotic arm.

Assignees

• Ford Global Tech Llc

Inventors

• Koch Raphael
• Bognar Lars

Classifications

• B29C64/153

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

• B29C64/371

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

• B29C64/343

  Metering · CPC title

• B28B1/001

  Rapid manufacturing of 3D objects by additive depositing, agglomerating or laminating of material (selective deposition modelling of metallic powder B22F10/00; rapid manufacturing of 3D objects in general and in particular of plastics B29C64/00) · CPC title

• B29C64/393

  for controlling or regulating additive manufacturing processes · CPC title