System for additively producing three-dimensional objects
11014294 · 2021-05-25
Assignee
Inventors
Cpc classification
B22F12/80
PERFORMING OPERATIONS; TRANSPORTING
B22F10/28
PERFORMING OPERATIONS; TRANSPORTING
B22F12/88
PERFORMING OPERATIONS; TRANSPORTING
B33Y30/00
PERFORMING OPERATIONS; TRANSPORTING
B33Y40/00
PERFORMING OPERATIONS; TRANSPORTING
B22F12/90
PERFORMING OPERATIONS; TRANSPORTING
B29C64/379
PERFORMING OPERATIONS; TRANSPORTING
B29C64/20
PERFORMING OPERATIONS; TRANSPORTING
Y02P10/25
GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
B29C64/153
PERFORMING OPERATIONS; TRANSPORTING
International classification
B29C67/00
PERFORMING OPERATIONS; TRANSPORTING
B29C64/379
PERFORMING OPERATIONS; TRANSPORTING
B33Y30/00
PERFORMING OPERATIONS; TRANSPORTING
B29C64/153
PERFORMING OPERATIONS; TRANSPORTING
B33Y40/00
PERFORMING OPERATIONS; TRANSPORTING
Abstract
System (1) for additive manufacturing of three-dimensional objects (2), comprising: a movable modular functional unit (12a-12d), a tunnel structure (21), an apparatus (3) which is configured for additive manufacturing of a three-dimensional object (2) by successive layerwise selective exposure and consequent solidification by means of an energy beam (5) of construction material layers which have been formed, wherein the apparatus (3) comprises a connecting portion (26), by means of which the apparatus (3) can be or is connected to the tunnel structure (21) so that a modular functional unit (12a-12d) can be moved starting from the apparatus (3) into the tunnel structure (21) or vice versa, a filling and/or emptying device (13) which is configured for filling with construction material (4) a reception space of a functional unit (12a-12d) moved into a filling section (14) of the filling. and/or emptying device (13).
Claims
1. A system for additive manufacturing of three-dimensional objects, the system comprising: at least one movable modular functional unit comprising a reception space for receiving construction material and/or an additively manufactured object; a tunnel structure comprising at least one tunnel portion, wherein at least one movable modular functional unit can be moved through the at least one tunnel portion; at least one apparatus for additive manufacturing of a three-dimensional object, wherein the apparatus is connected to the tunnel structure such that the at least one movable modular functional unit can be moved from the apparatus into the tunnel structure and/or from the tunnel structure into the apparatus; and, a filling and/or emptying device configured to fill and/or empty the at least one movable modular functional unit with construction material, wherein the filling and/or emptying device is connected with the tunnel structure such that the at least one movable modular functional unit can be moved from the filling and/or emptying device into the tunnel structure and/or from the tunnel structure into the filling and/or emptying device.
2. The system of claim 1, wherein the at least one apparatus and the filling and/or emptying device are physically separated by the tunnel structure.
3. The system of claim 1, wherein the tunnel comprises an enclosed cross-section.
4. The system of claim 3, wherein the enclosed cross-section comprises a round or polygonal cross-sectional area.
5. The system of claim 3, wherein at least a portion of the tunnel can maintain an inert atmosphere.
6. The system of claim 1, wherein the filling and/or emptying device is arranged in a housing structure that can maintain an inert atmosphere.
7. The system of claim 1, wherein a detection device is assigned to the filling and/or emptying device for: detecting a functional unit moved into a filling section and/or an emptying section of the filling and/or emptying device, and/or detecting at least one status parameter of at least one functional element of a functional unit moved into the filling section and/or an emptying section of the filling and/or emptying device, and/or detecting at least one status parameter within the reception space of a functional unit moved into the filling section and/or an emptying section of the filling and/or emptying device, and/or detecting a filling level of construction material received in the reception space of a functional unit moved into the filling section and/or an emptying section of the filling and/or emptying device, and/or detecting at least one status parameter of construction material received in the reception space of a functional unit moved into the filling section and/or an emptying section of the filling and/or emptying device.
8. The system of claim 1 further comprising an inerting device for inerting at least one reception space of a functional unit moved into the filling section and/or emptying section of the filling and/or emptying device.
9. The system of claim 1 further comprising a sieving device for sieving construction material to be filled into the reception space of a functional unit moved into the filling section and/or emptying section of the filling and/or emptying device.
10. The system of claim 1 further comprising a position-securing device for securing a functional unit moved into the filling section and/or emptying section of the filling and/or emptying device.
11. The system of claim 1 further comprising a control device for controlling operation of: the filling and/or emptying device, and/or a temperature control device, and/or an inerting device, and/or a sieving device, and/or a positing-securing device.
12. The system of claim 11, wherein the control device controls operation based at least on feedback from at least one detection device.
13. The system of claim 1 further comprising an actuating device for actuating the at least one movable modular functional unit through the tunnel structure.
14. The system of claim 1, wherein at least one movable modular functional unit comprises a construction module comprising a reception space for receiving a construction plate, wherein the construction plate is movable with respect to the movable modular functional unit.
15. The system of claim 1, wherein at least one movable modular functional unit comprises a metering module comprising a metering device for metering construction material.
16. The system of claim 1, wherein at least one movable modular functional unit comprises an overflow module for receiving non-solidified construction material when additive manufacturing the three-dimensional object.
17. The system of claim 1, wherein at least one movable modular functional unit comprises a handling module for receiving the three-dimensional object.
Description
(1) The invention is explained in more detail with the aid of exemplary embodiments in the figures of the drawing, in which:
(2)
(3)
(4)
(5)
(6) The system comprises one or more stationary apparatus(es) 3 (“construction station”) for additive manufacturing of three-dimensional objects 2 by successive layerwise selective exposure and consequent solidification of individual construction material layers of a solidified construction material 4 by means of at least one energy beam 5 (more specific functional details of the apparatus 3 may be found in
(7) The apparatus 3 comprises all the functional component parts required in order to carry out additive construction processes. Corresponding functional component parts include a layering device for forming construction material layers to be selectively exposed in a construction plane 7, and an exposure device 9, for example comprising one or more exposure elements 8 formed or comprising one or more laser diode elements, for generating an energy beam 5 for selective exposure of a construction material layer to be selectively exposed, formed in a construction plane 7 by means of the layering device. The functional component parts are typically arranged in a housing structure 10, defining a process chamber 11, of the apparatus 3. The process chamber 11 can be inerted, i.e. a protective gas atmosphere, for example an argon atmosphere, and/or a particular pressure level can be formed and maintained.
(8) The system 1 comprises a plurality of modular functional units 12. The modular structure of the functional units 12 derives from a housing structure (not represented in detail), to be referred to as a “module”, which (essentially) determines the outer geometrical configuration of the respective functional unit 12 and in which the respective functional constituent parts of the respective functional unit 12 are accommodated.
(9) A first exemplary functional unit 12a is configured as a construction module. Such a construction module comprises a construction or support plate (not represented in detail) which is mounted movably, in particular height-adjustably, in a chamber-like reception space (not represented in detail), which is also to be referred to as a “construction chamber”, relative to a base body of the construction module, and on which additive construction of at least one three-dimensional object 2 can be carried out. In the scope of the additive manufacturing of three-dimensional objects 2, such a construction module is used for positioning an object 2 to be manufactured while an additive construction process is being carried out, cf. the apparatus 3 shown in
(10) A second exemplary functional unit 12b is configured as a metering module. Such a metering module comprises a chamber-like reception space (not represented in detail) configured in order to receive construction material 2 to be solidified in the scope of additive manufacturing of a three-dimensional object, and a metering device (not represented in detail) for metering a particular amount of construction material 2 to be solidified from the reception space. In the scope of the additive manufacturing of three-dimensional objects 2, such a metering module is used for providing (metering) a particular amount of construction material 2 to be solidified, which is distributed uniformly in a construction plane 7 by means of a layering device 6 so as to form a defined construction material layer, cf. the apparatus 3 shown in
(11) A third exemplary functional unit 12c is configured as an overflow module. Such an overflow module comprises a chamber-like reception space (not represented in detail) configured in order to receive construction material 4 not solidified in the scope of additive manufacturing of a three-dimensional object 2. In the scope of the additive manufacturing of three-dimensional objects 2, the overflow module is used in particular to receive construction material 4 which is to be or has been removed from the process chamber 11 of the apparatus 3. The system 1 may be associated with a plurality of corresponding third functional units 12c.
(12) A fourth exemplary functional unit 12d is configured as a handling module. Such a handling module comprises at least one chamber-like reception space (not represented in detail) configured in order to receive at least one additively manufactured object 2. A possibility for accessing or reaching into the reception space in order to “unload” the object 2 may be provided by means of a suitable interface (not shown). The accessing or reaching may be carried out by an operator (“glove box”) or by means of a robot. The system 1 may be associated with a plurality of corresponding fourth functional units 12d.
(13) As is revealed below, a respective functional unit 12a-12d may be moved to and fro between various stationary, i.e. not movable, constituent parts of the system 1, which are typically connected firmly to a base.
(14) The system 1 comprises one or more stationary filling and/or emptying device(s) 13. The filling and/or emptying device 13 is configured for filling a reception space of a functional unit 12a-12d moved into a filling section 14 of the filling and/or emptying device 13 with construction material 4, and/or for emptying construction material 4 contained in a reception space of a functional unit 12a-12d moved into an emptying section 14 of the filling and/or emptying device 13. The filling and/or emptying device 13 may be referred to as a “filling station”, at least in respect of corresponding filling processes.
(15) The filling and/or emptying device 13 is formed in an inertable housing structure 20. An inert atmosphere or a particular pressure level, i.e. for example an elevated or reduced pressure, may be formed and maintained in the housing structure 20.
(16) In the filling section 14, it is possible to fill a reception space of a functional unit 12a-12d moved into the filling section 14 with construction material 4. In the detail shown in
(17) In the emptying section 15, it is possible to empty construction material 4 from a reception space of a functional unit 12a-12d moved into the emptying section 15. In the detail shown in
(18) The filling and/or emptying device 13 may hold a plurality of (chemically) different construction materials 4, so that individual filling of different functional units 12a-12d with different construction materials 4 is possible. A first functional unit 12a-12d moved into the filling section 14 may for example be filled with a steel powder, and a second functional unit 12a-12d moved into the filling section 14 may for example be filled with an aluminum powder. Similarly, individual emptying of different functional units 12a-12d is possible; (chemically) different construction materials 4 may therefore be emptied from different functional units 12a-12d and stored, processed further, etc., separately from one another.
(19) The system 1 furthermore comprises a tunnel structure 21. The tunnel structure 21 comprises a plurality of tunnel portions 22, in which or through which the functional units 12a-12d can be moved. Formed or arranged in a respective tunnel portion 22, there is at least one movement path 22, along which a functional unit 12a-12d can be moved through the tunnel portion 22. It is possible to form or arrange a plurality of movement paths 23 in a tunnel portion 22, at least in sections, i.e. for example movement paths 23 arranged next to one another, in particular parallel, in one or more planes. A corresponding movement path allows guided movement of a functional unit 12a-12d in or through the respective tunnel portion 22.
(20) With the aid of
(21) The tunnel portions 22 may be inertable, i.e. an inert atmosphere, a particular pressure level, i.e. for example an elevated or reduced pressure, may be formed and maintained in it.
(22) The function of the tunnel structure 21, or the tunnel portions 22 associated therewith, is to connect different stationary constituent parts of the system 1, i.e. for example apparatuses 3 and the filling and/or emptying device 13, to one another directly or indirectly, i.e. for example with the interposition of at least one further tunnel portion 21 and/or a further stationary constituent part of the system 1. The connection of respective stationary constituent parts of the system 1 allows movement of respective functional units 12a-12d to and fro between respective stationary constituent parts of the system 1. Movements of respective functional units through the tunnel structure 21 are, in particular, possible in a fully automated manner. By means of one or more tunnel portions 22, for example, a stationary apparatus 3 (“construction station”) may be connected to the stationary filling and/or emptying device 13 (“filling station”).
(23) In order to move respective functional units 12a-12d, the system 1 comprises a conveyor device 24 coupled to a (motor) drive device, by means of which a drive force setting a functional unit 12a-12d in motion can be generated. The conveyor device 24 may comprise a conveyor means 25, which is arranged or formed on the tunnel structure side (cf.
(24) It is also conceivable for the conveyor device 24 to comprise respective conveyor means 25, which are arranged or formed on the functional unit side and are configured in order to set the functional units 12a-12d equipped with them in motion (cf.
(25) The selection of a movement path of one or more functional units 12a-12d between respective stationary constituent parts of the system 1 may be made on the basis of particular prioritizations of particular functional units 12a-12d. For higher-prioritized functional units 12a-12d, movement paths 23 which are of shorter length or are faster may be selected than for lower-prioritized functional units 12a-12d. Equally well, higher-prioritized functional units 12a-12d may be moved with a higher speed in comparison with lower-prioritized functional units 12a-12d.
(26) The control of all the movements of the functional units 12a-12d moved in the tunnel structure 21 is carried out by means of a central control device 28, which expediently communicates, for example on the basis of radio, directly or indirectly with respective functional units 12a-12d, which to this end may be equipped with suitable communication devices (not represented in detail). In the control device 28, there is expediently all the information relevant for the movement of respective functional units 12a-12d inside the tunnel structure 21, i.e. in particular respective movement information, i.e. for example speed information, respective position information, i.e. for example start and target information, respective prioritization information, etc. The control of the movements of the functional units 12a-12d moved in the tunnel structure 21 may be carried out in a fully automatic way.
(27) In order to be connected to the tunnel structure 21, the stationary constituent parts of the system 1 comprise a connecting portion 26, by means of which they can be or are connected to the tunnel structure 21. With the aid of
(28) In respective stationary constituent parts of the system 1, i.e. for example in the apparatus 3 or in the filling and/or emptying device 13, a tunnel section 22 of the tunnel structure 21 is likewise arranged or formed, which communicates via the respective connecting portion 26 with a tunnel portion 22 arranged or formed outside the respective stationary consituent part of the system 1 (cf.
(29)
(30) The filling and/or emptying device 13 shown in
(31) The detection device 28 may be configured in order to detect a functional unit 12a-12d moved into the filling section 14 and/or into the emptying section 15. By means of the detection device 28, it is therefore possible to detect whether a functional unit 12a-12d is moved into the filling or emptying section 14, 15. In the event that a functional unit 12a-12d moved into the filling and/or emptying section 14, 15 is detected, it is furthermore possible to detect which type of functional unit 12a-12d is specifically involved. The detection of a functional unit 12a-12d moved into the filling section or emptying section 14, 15, or its type, may for example be carried out optically, i.e. for example by means of an optical scanning process, or mechanically, i.e. for example by means of detecting the weight of the functional unit 12a-12d acting on a weight sensor 30 arranged or formed in a filling and/or emptying section 14, 15.
(32) The detection device 29 may (also) be configured in order to detect at least one status parameter, in particular the operability, of at least one functional element of a functional unit 12a-12d moved into the filling or emptying section 14, 15. By means of the detection device 28, it is therefore possible to detect particular status parameters, i.e. in particular the operability, of particular functional elements of a functional unit 12a-12d. For the example of a construction module (cf. first functional unit 12a), it is for example possible to detect whether there is correct operability of the movably mounted constructional support plate 27. To this end, the detection device may for example send suitable control information to a drive (not shown) coupled to the movably mounted construction or support plate 27, and for example carry out position-resolved and/or time-resolved detection (monitoring) of a movement of the construction plate 27 under the drive conditions determined by the control information.
(33) The detection device 29 may (also) be configured in order to detect at least one, especially physical, status parameter inside a reception space, filled in particular at least in sections with construction material 4, of a functional unit 12a-12d moved into the filling or emptying section 14, 15. By means of the detection device 29, particular status parameters, i.e. in particular physical status parameters, i.e. for example atmosphere, pressure, humidity, temperature, etc. may be detected inside reception spaces on the functional unit side. For the example of a metering or overflow module (cf. second, third functional units 12b, 12c), for example, it is possible to detect which atmosphere, pressure, humidity, temperature, etc. there is inside the respective reception space. The detection of corresponding status parameters may be carried out by means of suitable detection elements (not shown), for example configured in the manner of a measurement probe, which detect corresponding status parameters by means of an interface provided therefor on the functional unit side. An interface on the functional unit side may, for example, be produced through an access possibility on and/or in a reception space on the functional unit side.
(34) The detection device 29 may (also) be configured in order to detect a status parameter, especially physical status parameter of a construction material 4 which is contained in a reception space of a functional unit 12a-12d moved into the filling or emptying section 14, 15. By means of the detection device 29, in general particular status parameters, i.e. in particular physical status parameters, i.e. for example density, humidity, temperature, etc. of a construction material 4 contained inside a reception space on the functional unit side may be detected. For the example of a metering or overflow module (cf. second, third functional units 12b, 12c), for example, it is possible to detect which density, humidity, temperature, etc. there is for a construction material 4. The detection of corresponding status parameters may again be carried out by means of suitable detection elements (not shown), for example configured in the manner of a measurement probe, which detect corresponding status parameters by means of an interface provided therefor on the functional unit side. An interface on the functional unit side may again, for example, be produced through an access possibility on and/or in a reception space on the functional unit side.
(35) Lastly, the detection device 29 may (also) be configured in order to detect a filling level of a construction material 4 in a reception space of a functional unit 12a-12d moved into the filling or emptying section 14, 15. By means of the detection device 29, it is therefore possible to detect filling levels of a construction material 4 contained in a reception space on the functional unit side. For the example of a metering or overflow module (cf. second, third functional units 12b, 12c), it is therefore possible to detect which filling level there is inside the respective reception space. The detection of corresponding filling levels may in this case also be carried out by means of suitable detection elements (not shown), for example configured in the manner of a measurement probe, which detect corresponding filling levels via an interface provided therefor on the functional unit side. An interface on the functional unit side may in this case also be produced, for example, through an access possibility on and/or in a reception space on the functional unit side.
(36) The filling and/or emptying device 13 furthermore comprises particular devices by means of which particular measures may be implemented as a function of the respectively detected detection parameter, for example in order to influence the quality or processability or reusability of construction material 4 with which a reception space on the functional unit side is to be filled, or construction material 4 to be emptied from a reception space on the functional unit side.
(37) The filling and/or emptying device 13 is assigned a temperature control device 31, which is configured for temperature control of a reception space of a functional unit 12a-12d moved into the filling or emptying section 14, 15 and/or for temperature control of a construction material 4 which is received in a reception space of a functional unit 12a-12d moved into the filling or emptying section 14, 15. The temperature control of the reception space, or of the construction material 4, which is typically to be understood as heating, may for example be carried out by means of (direct) temperature control of the functional unit 12a-12d and/or control (activation) of temperature control means (not shown) provided on the functional unit side, i.e. for example heating elements.
(38) Furthermore, the filling and/or emptying device 13 is assigned an inerting device 32, which is configured in order to inert a reception space, filled with construction material 4, of a functional unit 12a-12d moved into the filling or emptying section 14, 15. For inerting of a reception space, the inerting device 31 may suck non-inert gases or gas mixtures, for example air, out of the reception space through suitable connection means (not shown) or interfaces and suction devices (not shown) couplable or coupled thereto, and/or introduce inert gases or gas mixtures, for example argon, carbon dioxide, nitrogen, etc., into the reception space by means of blower devices (not shown) couplable or coupled thereto.
(39) The filling and/or emptying device 13 is furthermore assigned a sieving device 36, which is configured for sieving construction material 4 with which a reception space of a functional unit 12a-12d moved into the filling section 14 is to be filled, and/or for sieving construction material 4 emptied from a reception space of a functional unit 12a-12d moved into the emptying section 15. The motor-drivable sieving device 36 allows sieving of construction material 4 with which a reception space on the functional unit side is to be filled and/or of construction material 4 emptied from a reception space on the functional unit side. The sieving device 36 comprises at least one sieving element (not represented in detail), which is configured for sieving a particular particle size (fraction).
(40) The filling and/or emptying device 13 is furthermore assigned a position-securing device 33, which is configured for securing a functional unit 12a-12d, moved into the filling or emptying section 14, 15 in position. The position-securing device 33 allows exact and stable orientation and arrangement of a functional unit 12a-12d moved into the filling or emptying section 14, 15 relative to the filling and/or emptying section 14, 15. The position-securing device 33 comprises, in particular mechanically and/or magnetically acting, position-securing elements 34, for example in the form a mechanical pins or magnet elements, which act in a position-securing state on the functional unit 12a-12d to be secured, in such a way that it is arranged and oriented exactly and stably.
(41) In order to control the operation of the filling and/or emptying device 13, i.e. also of the temperature control device 31, the inerting device 32, sieving device 36 and the position-securing device 33, the filling and/or emptying device 13 may comprise its own control device 35. The control may be carried out on the basis of at least one detection parameter detected by means of the detection device 29.
(42) Individual, several or all of the features presented in relation to a particular exemplary embodiment may be applied to at least one other exemplary embodiment.
LIST OF REFERENCES
(43) 1 apparatus 2 object 3 apparatus 4 construction material 5 energy beam 6 layering device 7 construction plane 8 exposure elements 9 exposure device 10 housing structure 11 process chamber 12 functional unit 13 filling and/or emptying device 14 filling section 15 emptying section 16 filling device 17 conveyor device 18 emptying device 19 conveyor device 20 housing structure 21 tunnel structure 22 tunnel portion 23 movement path 24 conveyor device 25 conveyor means 26 connecting portion 27 construction/support plate 28 control device 29 detection device 30 weight sensor 31 temperature control device 32 inerting device 33 position-securing device 34 position-securing element 35 control device 36 sieving device