Devices and methods for unpacking an object manufactured by layered application

Abstract

Described are devices and methods for unpacking a three-dimensional object, manufactured in a swap container by layer-by-layer application and selective solidification of a powdery structural material, from the structural material that surrounds the object and has remained unsolidified, comprising a turning device that rotates the swap container from an upright position into an unloading position for discharging the unsolidified structural material, wherein the turning device comprises a drive unit by which the three-dimensional object is displaceable into a removal position relative to the swap container), following the unpacking of the unsolidified structural material.

Claims

1. A device for unpacking a three-dimensional object that has been manufactured by layer-by-layer application and selective solidification of a powdery structural material from structural material that surrounds the object that has remained unsolidified, comprising: a turning device configured to rotate a swap container containing the three-dimensional object about a horizontal axis of rotation from an upright position to an unloading position, wherein the swap container is insertable and fixable to the turning device, wherein the turning device comprises a retaining plate on which the swap container can be placed; a drive unit by which the three-dimensional object can be placed in a removal position relative to the swap container, wherein the drive unit is rotatable, together with the turning device, about the axis of rotation; and a clamp by which the swap container is detachably fixed to the retaining plate.

2. The device of claim 1, comprising a substrate plate carrying the three-dimensional object that is movable to the removal position with respect to the swap container by the driver.

3. The device of claim 1, wherein the clamp comprises a first clamping element on the swap container, and a second clamping element on the driver, wherein the clamping elements are configured to engage and detachably brace one another when the swap container is inserted into the turning device.

4. The device of claim 3, wherein the clamp comprises a bracing mechanism in which the first clamping element comprises a capture and orientation pin, and the second clamping element comprises a complementary receptacle, or vice versa.

5. The device of claim 1, wherein the turning device comprises an insertion region or an insertion opening opposite at least one contact surface that is oriented towards the retaining plate that ensures the swap container is correctly positioned when inserted into the turning device.

6. The device of claim 1, wherein the turning device comprises a cover for closing the swap container, the cover comprising a collecting container having a discharge opening.

7. The device of claim 6, wherein in the unloading position of the turning device, the discharge opening of the collecting container is configured to receive the unsolidified structural material, or a suction hose of a suction device is connectable to the discharge opening to remove the unsolidified structural material.

8. The device of claim 6, wherein the cover or a wall portion of the turning device comprises at least one quick-clamping fastener by which the cover can be braced by the swap container while in a closed position.

9. The device of claim 6, wherein the cover is received on at least one wall portion of the turning device and is transferrable from an open position into a closed position.

10. The device of claim 6, wherein the cover comprises a construction volume in which a three-dimensionally manufactured object is arrangeable in a removal position relative to the swap container.

11. The device of claim 1, wherein the drive unit is a lifting cylinder that is driven pneumatically, hydraulically or electrically.

12. The device of claim 11, wherein the drive unit comprises an adjustable stop that limits an extension movement of the lifting cylinder.

13. The device of claim 1, wherein the turning device is driven so as to be rotatable about a longitudinal axis thereof.

14. The device of claim 1, wherein the swap container comprises at least one glove engagement point for manual unpacking using a compressed air device.

Description

DESCRIPTION OF DRAWINGS

(1) FIG. 1 is a schematic view of an unpacking device.

(2) FIG. 2 is a side view of the unpacking device of FIG. 1.

(3) FIG. 3 is a view the unpacking device of FIG. 1, with a swap container with an open cover inserted in a turning device.

(4) FIG. 4 is a view of the unpacking device with a closed turning device in an upright position.

(5) FIG. 5 is a view of the unpacking device with a turning device in an unloading position.

(6) FIG. 6 is a side view the device of FIG. 1 in an upright position with an open cover, following unpacking.

(7) FIG. 7 is a view of an alternative embodiment of the device.

DETAILED DESCRIPTION

(8) FIGS. 1 and 2 show views of an unpacking device 11. The device 11 is intended for unpacking a 3D object 14 (FIG. 3) that is manufactured in a swap container 12 via layer-by-layer application and selective solidification of a powdery structural material. The structural material that surrounds the completed object 14 remains unsolidified. The 3D object 14 is manufactured in a laser sintering device (not shown in greater detail). The laser sintering device includes an exposure device including a laser that generates a laser beam, where the laser beam is deflected by a deflector and is fed through a focusing device and a coupling window in a wall of a process chamber and focused on a working plane of an uppermost layer of the structural material. Linear displacement of the laser beam allows for layered solidification of the structural material and manufacture of a 3D object. The structural material can be a metal powder or the like. Following manufacture of the 3D object 14, the swap container 12 is removed from the laser sintering device and fed to the device 11 for unpacking the unsolidified structural material.

(9) The device 11 includes a main frame 16 that supports a turning device 18. The turning device 18 is pivotable about an axis of rotation 19 that is oriented horizontally. The pivot movement of the turning device 18 about the axis of rotation 19 can take place manually, for example using the hand wheel 21 shown in FIG. 1. Alternatively, an electrically, pneumatically, or hydraulically actuated drive (not shown in greater detail) can be used for process automation.

(10) The turning device 18 includes a retaining plate 23 on which the swap container 12 can be placed. The turning device 18 furthermore includes at least one contact surface 24 oriented so as to be perpendicular to the retaining plate 23. The at least one contact surface 24 is positioned opposite an insertion region 26 of the turning device 18 and functions as a stop or position fixation device when the swap container 12 is inserted into the turning device 18. The turning device 18 furthermore includes lateral wall portions 28 that form a connection to the axis of rotation 19. The contact surfaces 24 can also adjoin the wall portions 28. A cover 31 is above the wall portions 28. The cover 31 is guided so as to be displaceable relative to the wall portions 28. Rod-like guide elements or linear guides, for example, are provided for this purpose. The cover 31 is shown in an open position in FIGS. 1 and 2.

(11) At least one fastener 29 is on the wall portions 28 of the turning device 18. The fastener is used for fixing the cover 31 in a closed position 32 relative to the swap container 12 (FIG. 4). The at least one fastener 29 can be a quick-release fastener, quick-clamping fastener or the like to allow for simple and quick opening and closure. A linear guide 27, along which the cover 31 is displaceable relative to the wall portions 28, can include return elements such as gas springs or the like, so that the cover 31 can be transferred automatically into the open position 30 of FIG. 1 following opening of the at least one fastener 29.

(12) In a first step for unpacking the 3D object 14 within the swap container 12, the swap container 12 is inserted into the turning device 18. Such an inserted position of the turning container 12 in the turning device 18 is shown in FIG. 3. The swap container 12 is received in the turning device 18 in the correct position by the retaining plate 23 and/or the contact surfaces 24.

(13) The turning device 18 includes a drive unit 33 on a lower face. The drive unit 33 includes a lifting cylinder 34 (FIG. 4). The drive unit 33 is rotatable about the axis of rotation 19, together with the turning device 18.

(14) A clamp 36 can be between the swap container 12 and the drive unit 33. A clamp 36 of this kind is shown schematically in FIG. 4. The clamp 36 includes a first clamping element 37 that is can be on a lower face of a piston 38 of the swap container 12 or integrated in a piston 38 of the swap container 12. A second clamping element 39 is opposite the lifting cylinder 34. One of the two clamping elements 37, 39 includes a capture and/or orientation pin 41, and the other clamping element 39, 37 includes a complementary receptacle 42. In another arrangement of the clamping elements 37, 39, the elements are oriented relative to one another and engage automatically with one another. As a result, the piston 38 is fixed to the lifting cylinder 34.

(15) A substrate plate 44 on which the 3D object 14 is constructed is located on the piston 38 of the swap container 12 so as to be replaceable. The first layer of the 3D object 14 is directly connected to the substrate plate 44. The further layers are built up on the first layer to form the object 14.

(16) Following insertion of the swap container 12 into the turning device 18, the cover 31 is transferred into a closed position 32 (FIG. 4). The at least one fastener 29 is closed. Thereupon, the turning device 18 is transferred from the upright position 47 of FIG. 4 into an unloading position 48, shown in FIG. 5, by a rotational movement about the axis of rotation 19. In this case, the turning device 18 can perform a pivot movement of about 180°. In the unloading position 48 or overhead position, the unsolidified structural material can fall into a collecting container 51 on the cover 31. A discharge opening 52 is at the other end of the collecting container 51. The opening can be connected to a collecting container that is located therebelow and is not shown in greater detail. A suction hose 54 can also be connected to the discharge opening 52, via which the compacted structural material can be suctioned out by a suction device 55 and fed to a reservoir. Before the suctioned structural material is fed to the reservoir, the material can also be filtered or sieved to eliminate impurities. As a result, the unsolidified structural material can be used again for a subsequent manufacturing process.

(17) In the unloading position, the cover 31 can also sometimes be opened. This is advantageous, for example, if manual cleaning is intended to be performed in this position.

(18) Following unpacking of the 3D object 14, the turning device 18 is transferred into the upright position 47 again, as is shown in FIG. 6. In this case, a rotation of the turning device 18 can take place in the opposite direction of rotation compared with the transfer from the upright position 47 into the unloading position 48. The direction of rotation can also be maintained, with the result that the turning device is rotated fully, by 360°.

(19) While in the upright position 47, the 3D object 14 is transferred, by the drive unit 33, into a removal position 57 with respect to the swap container 12. The lifting cylinder 34 is extended to place the 3D object 14 in the removal position 57. The actuation of the displacement movement of the lifting cylinder 34 can already begin in the unloading position 48 of the turning device 12. The actuation of the displacement movement of the lifting cylinder 34 can take place prior to opening the cover 31, in the upright position 47 of the turning device 12. In the embodiment of FIG. 6, the turning device 18 is transferred into the upright position 47 and the at least one fastener 29 is opened, such that the cover 31 is in a raised position relative to the swap container 12. Thereupon, the lifting cylinder 34 displaces the 3D object 14 to the removal position 47. Subsequently, the substrate plate 44 is removed from the swap container 12, together with the object 14. Alternatively, it is also possible for the entire swap container 12 to be removed from the turning device 18. Likewise, it is also possible for only the object 14 to be removed.

(20) The cover 31 includes a frame (e.g., a tripod) on the outside thereof. A frame of this kind can be used for allowing the cover 31 to assume an independent standing position, for example when the cover is connected to the swap container 12 so as to be completely detachable. It can furthermore be possible for the swap container 12 to be able to be placed into an unloading position 48, if the turning out of an upright position 47 into an unloading position 48, and subsequent suction, is separated. Moreover, the cover 31 can also be securely positioned on the frame together with an attached suction element such as a suction hose.

(21) FIG. 7 shows an alternative embodiment of the device 11 compared with that of FIGS. 1 and 2. The embodiment of FIG. 7 deviates from the above-described embodiment of the turning device 18 in that the cover 31 includes a closed wall portion 61. The wall portion 61 is cylindrical and corresponds to the height of the swap container 12 or approximately to the height of the swap container 12. This makes it possible for the 3D object 14 to be in the removal position 57 relative to the swap container 12 when the cover 31 is closed, and for manual unpacking of the unsolidified structural material using at least one glove engagement point 62. Compressed air is supplied by a compressed-air hose 64 of a compressed-air gun, such that the object 14 can be blown out. Alternatively, a siphon 65 can be used for manually suctioning residual structural material. It is furthermore possible for a removal opening to be in the wall portion 61. Alternatively, a linear guide 27 can raise the cover 31 relative to the swap container 12 such that the container can also be removed from the turning device 18, together with the object 14, in the removal position 57. Variants of the device 11 of FIGS. 1 to 6 also apply for the device 11 shown in FIG. 7.

(22) It is alternatively possible for the turning device 18 to be driven so as to be rotatable about the longitudinal axis thereof, in addition to the actuatable rotational movement about the axis of rotation 19, which is horizontal. This allows for further removal of unsolidified structural material in all spatial directions, optimized to the object's contours.

(23) A vibration device and/or knocking device can act on the swap container 12 or the substrate plate 44. Alternatively or in addition, it is also possible for a vibration device and/or knocking device to act directly on the object 14, for example if the device is inside the cover 31. As a result, the removal of the unsolidified structural material can be further promoted.

(24) Alternatively, the opening and closing movement of the cover 31 relative to the swap container 12 can also be actuated by a drive. This can be in the case of incorporation into process automation.

(25) The device 11 thus allows for quick unpacking, as well as hermetically sealed unpacking of the unsolidified structural material. The device 11 can also be incorporated in an automated process. Furthermore, structural material that is still hot can also be unpacked, as a result of which process optimization is also made possible.

Other Embodiments

(26) A number of embodiments of the invention have been described. Nevertheless, it will be understood that various modifications can be made without departing from the spirit and scope of the invention. Accordingly, other embodiments are within the scope of the following claims.