Plant comprising at least one apparatus for additively manufacturing three-dimensional objects

Abstract

Plant (1) comprising at least one apparatus (2-4) for additively manufacturing three-dimensional objects by means of successive layerwise selective irradiation and consolidation of layers of a build material which can be consolidated by means of an energy source, which plant (1) comprises at least one module (5) separably connected or connectable with the apparatus (2-4), wherein the plant (1) comprises at least one tunnel structure (7) through which the at least one module (5) is moveable in a tunnel transport direction (10).

Claims

1. A plant comprising: at least one apparatus for additively manufacturing three-dimensional objects by means of successive layerwise selective irradiation and consolidation of layers of build material; at least one tunnel structure passing through the at least one apparatus; at least one module separably connected with the at least one apparatus, wherein the at least one module is moveable in a tunnel transport direction through the at least one tunnel structure; and, wherein the at least one module is further moveable inside the at least one apparatus in a first direction and a second direction to move into and out of a plurality of different module positions within the at least one apparatus, wherein the first direction and the second direction differ from the tunnel transport direction, and wherein the plurality of different module positions within the at least one apparatus comprise one or more buffer positions and one or more work positions.

2. The plant of claim 1, wherein the at least one apparatus comprises at least two work positions arranged on opposite sides of the at least one tunnel structure.

3. The plant of claim 1, wherein the at least one apparatus comprises at least one buffer position and at least one work position disposed on opposite sides of the at least one tunnel structure.

4. The plant of claim 1, wherein the first direction is substantially opposite the second direction.

5. The plant of claim 1, wherein the at least one module is moveable in a loading direction when moving from the at least one tunnel structure to one of the one or more work positions, and is moveable in an unloading direction when moving from the one of the one or more work positions back to the at least one tunnel structure.

6. The plant of claim 1, wherein the at least one module is moveable in a buffer direction when moving from the at least one tunnel structure to one of the one or more buffer positions, and is moveable in an unbuffer direction when moving from one of the one or more buffer positions back to the at least one tunnel structure.

7. The plant of claim 1, wherein at least one apparatus comprises three buffer positions.

8. The plant of claim 7, wherein the three buffer positions can hold three different types of modules.

9. The plant of claim 7, wherein the at least one apparatus comprises at least three work positions corresponding to the three buffer positions.

10. The plant of claim 1, wherein the at least one module comprises a build module, a dose module, and/or an overflow module.

11. The plant of claim 1, wherein the at least one module is moveable into and/or out of the at least one apparatus via the at least one tunnel structure.

12. The plant of claim 1, wherein the at least one apparatus for additively manufacturing three-dimensional objects by means of successive layerwise selective irradiation and consolidation of layers of build material comprises a plurality of apparatus for additively manufacturing three-dimensional objects by means of successive layerwise selective irradiation and consolidation of layers of build material, and wherein the plurality of apparatuses are connected via the at least one tunnel structure.

13. The plant of claim 1, wherein the at least one tunnel structure passing through the at least one apparatus comprises a first tunnel structure passing through a first apparatus and a second tunnel structure passing through a second apparatus, and wherein the first tunnel structure and the second tunnel structure are connected.

14. The plant of claim 1, wherein the at least one tunnel structure extends beyond an entrance and/or exit of the at least one apparatus.

15. The plant of claim 14, further comprising at least one outer buffer region arranged in advance and/or behind the at least one apparatus.

16. The plant of claim 15, further comprising a mobile transfer unit adapted to transfer the at least one module between a pre-processing station and the at least one tunnel structure in the outer buffer region arranged in advance of the at least one apparatus.

17. The plant of claim 15, further comprising a mobile transfer unit adapted to transfer the at least one module between a post-processing station and the at least one tunnel structure in the outer buffer region arranged behind the at least one apparatus.

18. The plant of claim 1, wherein the plant is adapted to individually load modules into the at least one tunnel structure depending on at least one vacancy parameter relating to the one or more modules, the one or more work positions, and/or the one or more buffer positions.

19. The plant of claim 1, wherein the plant is adapted to load the at least one tunnel structure with at least two modules in a predefined order.

Description

(1) Exemplary embodiments of the invention are described with reference to the FIG. The FIG. are schematic diagrams, wherein

(2) FIG. 1 shows an inventive plant according to a first embodiment;

(3) FIG. 2 shows an inventive plant according to a second embodiment; and

(4) FIG. 3 shows an inventive plant according to a third embodiment.

(5) FIG. 1 shows a plant 1 comprising three apparatuses 2, 3, 4 for additively manufacturing three-dimensional objects by means of successive layerwise selective irradiation and consolidation of layers of a build material which can be consolidated by means of an energy source, for example a laser beam or an electron beam. The plant 1 comprises a plurality of modules 5 that can for example be built as dose modules, build modules and overflow module. Dose modules are used in the additive manufacturing process performed via the plant 1 to provide build material in the additive manufacturing process, whereas build modules are adapted to receive the build material provided via the dose modules and to provide a build chamber in which the object is additively built by selectively irradiating layers of build material. Build material that is provided via the dose module and is not received within the build module, i.e. excess build material, is received within an overflow module. Hence, three corresponding modules 5 (dose module, build module, overflow module) may form a triplet 6.

(6) FIG. 1 further shows that apparatus 2-4 comprises a tunnel structure 7 that extends through the respective apparatus 2-4, wherein the tunnel structures 7 of the individual apparatuses 2-4 are connected to each other forming a common tunnel structure. Hence, a module 5 can be inserted into the tunnel structure 7 of the apparatus 2 via an entrance 8 and can be removed from the apparatus 2 via an exit 9. As can be derived from FIG. 1, the exit 9 of the tunnel structure 7 of the apparatus 2 is (directly) connected to the entrance 8 of the tunnel structure 7 of the apparatus 3. Analogously, the exit 9 of the tunnel structure 7 of the apparatus 3 is connected to the entrance 8 of the tunnel structure 7 of the apparatus 4. Via the exit 9 of the tunnel structure 7 of the apparatus 4 the modules 5 may be removed from the common tunnel structure.

(7) FIG. 1 further shows that the modules 5 can be moved through the tunnel structures 7 via a tunnel transport direction (depicted via arrow 10). The apparatuses 2-4 comprise multiple module positions 11-13 and 14-16. The module positions 11-13 are arranged on one side of the tunnel structure 7 and the module positions 14-16 are arranged on the other, in particular the opposite, side of the tunnel structure 7. In the exemplary embodiment that is depicted in FIG. 1, the module positions 11-13 are built as buffer positions, whereas the module positions 14-16 are built as work positions. Hence, a module 5 that is moved in the tunnel structure 7 of the apparatus 2-4 can be moved from the tunnel structure 7 along a buffer direction 17 into one of the module positions 11-13 (buffer positions), for instance. As the module positions 11-13 are vacant in the exemplary embodiment did in FIG. 1, the modules 5 that are moved into the tunnel structure 7 of the apparatus 2 will be moved into the corresponding module positions 11-13 as a triplet 6. The corresponding work positions 14-16 are occupied via respective modules 5.

(8) In this exemplary embodiment, the work position 14 may be deemed as dose position, the work position 15 may be deemed as build position and the work position 16 may be deemed as overflow position, wherein a dose module is arranged in the module position 14 (dose position), a build module is arranged in the module position 15 (build position) and an overflow module is arranged in the module position 16 (overflow position). Thus, if the additive manufacturing process that is currently performed using the module positions 14-16 is finished, the modules 5 being arranged in the module positions 14-16 can be removed from the module positions 14-16 via an unloading direction 18 (depicted via arrow). Subsequently, the modules 5 being arranged in the module positions 11-13 (buffer positions) can be moved along a loading direction 19 into the module positions 14-16 (work positions). Self-evidently, the module positions 11-13 can be “refilled” with corresponding modules 5 being moved from the tunnel structure 7 into the module positions 11-13 along a buffer direction 17.

(9) It is also possible to individually load/unload modules 5, as depicted in the apparatus 3. A module 5 is moved into the tunnel structure 7 of the apparatus 3, wherein the module position 11 is vacant and the module position 14 is also vacant. As the module position 14 is a work position, as described before, the module 5, for example a dose module, can instantly be moved along the loading direction 19 into the module position 14. Hence, the module position 11 stays vacant and can be “refilled” with a corresponding module 5 being moved from the tunnel structure 7 to the module position 11 along buffer direction 17, as described before with respect to the apparatus 2.

(10) Further, it is indicated that the module 5 being arranged in the module position 15 needs to be a changed. To change the module 5 being arranged in the module position 15, the module 5 is being moved from the module position 15 to the tunnel structure 7 along the unloading direction 18 and the module 5 being arranged in the module position 12 (buffer position for the module position 15) is moved along loading direction 19 into the module position 15.

(11) With respect to the apparatus 4, as depicted in FIG. 1, it is also possible to change the modules 5. For example, if the additive manufacturing process performed in the apparatus 4 is finished, the modules 5 being arranged in the work positions, i.e. the module positions 14-16 are removed along the unloading direction 18 into the tunnel structure 7 from where the modules 5 can be removed from the plant 1 following the tunnel transport direction 10 leaving the exit 9 of the tunnel structure 7 of the apparatus 4. Subsequently, the modules 5 being arranged in the module positions 11-13 can be moved along loading direction 19 from the corresponding module positions 11-13 (buffer positions) into the module positions 14-16 (work positions) in that the additive manufacturing process can be performed.

(12) FIG. 2 shows a plant 1 according to a second embodiment, wherein the plant 1 again comprises apparatuses 2-4 and wherein multiple modules 5 are used in an additive manufacturing process that is performed via the apparatuses 2-4. In the exemplary embodiment depicted in FIG. 2, each apparatus 2-4 comprises two sets of module positions 14-16, i.e. two sets of work positions, as described before. In other words, each module 5 being transported along tunnel transport direction 10 in the tunnel structure 7 can be moved to either one of the module positions 14-16, wherein two module positions 14, two module positions 15 and two module positions 16 are arranged to both sides of the tunnel structure 7 in each apparatus 2-4. Thus, two separate additive manufacturing processes can be performed via each apparatus 2-4 simultaneously or in parallel, respectively.

(13) As depicted in FIG. 2, the module 5 being inserted into the tunnel structure 7 of the apparatus 2 via the entrance 8 can be moved along loading direction 19 into the module position 14 of the apparatus 2. The module 5 being arranged in the module position 16 of the apparatus 2 can be removed into the tunnel structure 7 of the apparatus 2 along the unloading direction 18. Subsequently, another module 5 of the same type can be inserted into the tunnel structure 7 and moved from the tunnel structure 7 into the now vacant module position 16 along loading direction 19. As can be derived from FIG. 2, the loading direction 19 and the unloading direction 18 are essentially oriented in different, in particular opposing, directions and differ from the tunnel transport direction 10. This also holds true for the exemplary embodiment of the plant 1, as depicted in FIG. 1.

(14) As can further be derived from FIG. 2, the modules 5 being arranged in the module positions 14-16 of the apparatus 3 can be removed as a triplet 6 from the module positions 14-16 and can therefore, be moved along the unloading direction 18 into the tunnel structure 7 of the apparatus 3. The removed modules 5 may be moved along tunnel transport direction 10 along the tunnel structure 7 of the apparatus 3 into the tunnel structure 7 of the apparatus 4 and thereby, can exit the plant 1 via the exit 9 of the tunnel structure 7 of the apparatus 4.

(15) Subsequently, fresh modules 5 may be inserted into the now vacant triplet of module positions 14-16 and another additive manufacturing process can be performed in the apparatus 3.

(16) Further, FIG. 2 shows that the triplet 6 of modules 5 in the tunnel structure 7 of the apparatus 4 may be moved along the loading direction 19 into the triplet of vacant module positions 14-16 of the apparatus 4. The plant 1 is adapted to load the triplet 6 of modules 5 in the into the tunnel structure 7 and move the triplet 6 along the tunnel transport direction 10 into the apparatus 4 in that the triplet 6 can be loaded into the module positions 14-16. Of course, it is also possible to combine the apparatuses 2-4 depicted in the plant 1, according to the embodiment depicted in FIG. 1 with apparatuses 2-4 depicted in the embodiment according to FIG. 2. Hence, apparatuses 2-4 with buffer positions can arbitrarily be combined with apparatuses 2-4 comprising work positions on both sides of the tunnel structure 7.

(17) FIG. 3 shows a plant 1 according to a third embodiment. The plant 1 depicted in FIG. 3 can be built as a plant 1, as depicted in FIG. 1 or a plant 1, as depicted in FIG. 2 or an arbitrary combination of both plants 1, for example by arbitrarily exchanging different apparatuses 2-4 from both embodiments or arbitrarily exchanging and/or adding and/or omitting and/or combining individual or multiple module positions 11-16.

(18) Additional to the plant 1, as depicted in FIGS. 1, 2 the plant 1, as depicted in FIG. 3, comprises a pre-processing station 20 and a post-processing station 21. Modules 5 may be moved from the pre-processing station 20 via an outer buffer region 22 to the plant 1, in particular to an entrance 8 of the tunnel structure 7 of the apparatus 2, wherein the modules 5 can be arranged in a predefined order in the first outer buffer region 22, for example as they are needed in the additive manufacturing processes, performed via the apparatuses 2-4 of the plant 1.

(19) The plant 1 further comprises a second outer buffer region 23 that connects the exit 9 of the tunnel structure 7 of the apparatus 4 of the plant 1 with the post-processing station 21. In other words modules 5 can be moved along the tunnel transport direction 10 through the tunnel structure 7 of the plant 1 and leave the apparatus 4 via the tunnel structure 7, in particular the exit 9. The modules 5 may be buffered in the second outer buffer region 23 (waiting to be post-processed via the post-processing station 21).

(20) The plant 1, as depicted in FIG. 1, comprises a transport unit 24, for example a conveyor, to move the modules 5 along tunnel transport direction 10 from the pre-processing station 20, to the post-processing station 21. Of course, it is also possible to use mobile transport units to receive the modules 5 from the pre-processing station 20 and move the modules 5 to the tunnel structure 7 of the apparatus 2 and insert the modules 5 into the tunnel structure 7 of the apparatus 2 via the mobile transport units. It is also possible to receive the modules 5 exiting the exit 9 of the tunnel structure 7 of the apparatus 4 and move the modules 5 from the tunnel structure 7 of the apparatus 4 to the post-processing station 21. It is also possible to have a mobile transport unit integrated in each module 5 in that the modules 5 are individually movable via an integrated motor, for instance. Thus, each module 5 can particularly be moved from the pre-processing station 20 through the tunnel structure 7 into each module position 11-16 and from each module position 11-16 into the tunnel structure 7 and along tunnel transport direction 10 towards the post-processing station 21. Of course, arbitrary combinations of moving each module 5 are also feasible.

(21) Self-evidently, the inventive method may be performed on the plant 1, preferably using at least one inventive apparatus 2-4.