METHOD FOR OPERATING AN APPARATUS FOR ADDITIVELY MANUFACTURING THREE-DIMENSIONAL OBJECTS

Abstract

Method for operating an apparatus (1) for additively manufacturing three-dimensional objects (2) by means of successive layerwise selective irradiation and consolidation of layers of a build material (3) which can be consolidated by means of an energy source, comprising the steps: Arranging at least one prefabricated product (12) in a build plane (11), Layerwise applying build material (3) in a manufacturing region (16) that is delimited by at least a first side (14) of the prefabricated product (12) or the build plane (11), particularly bottom sides, and at least one second side (15) of the prefabricated product (12), particularly a side wall of the prefabricated product (12) Selective consolidation of at least one consolidation zone in the manufacturing region (16) dependent on a geometry of an object (2) to be additively built on the prefabricated product (12) Repeating the layerwise application and consolidation until the object (2) is finished

Claims

1. Method for operating an apparatus (1) for additively manufacturing three-dimensional objects (2) by means of successive layerwise selective irradiation and consolidation of layers of a build material (3) which can be consolidated by means of an energy source, characterized by: Arranging at least one prefabricated product (12) in a build plane (11), Layerwise applying build material (3) in a manufacturing region (16) that is delimited by at least a first side (14) of the prefabricated product (12) or the build plate (11).sub.7 and at least one second side (15) of the prefabricated product (12), Selective consolidation of at least one consolidation zone in the manufacturing region (16) dependent on a geometry of an object (2) to be additively built on the prefabricated product (12), and Repeating the layerwise application and selective consolidation.

2. Method according to claim 1, characterized by building at least one wall element (17) that delimits the manufacturing region (16).

3. Method according to claim 1, characterized in that the manufacturing region (16) is delimited by the at least one second side (15) of the prefabricated product (12) and at least one third side (18) of the prefabricated product (12).

4. Method according to claim 1 characterized by connecting the at least one wall element (17) to the prefabricated product (12).

5. Method according to claim 3, characterized by building at least one wall element (17) connecting two prefabricated products (12) and/or two portions of the same prefabricated product (12), and the at least one third side (18) of the prefabricated product (12).

6. Method according to claim 1, characterized in that the prefabricated product (12) comprises a closed contour enclosing a hollow portion.

7. Method according to claim 1, characterized by generating a gas stream in the manufacturing region (16).

8. Apparatus (1) for additively manufacturing three-dimensional objects (2) by means of successive layerwise selective irradiation and consolidation of layers of a build material (3) which can be consolidated by means of an energy source, which apparatus (1) comprises a process chamber (13) in which the additive manufacturing process is performed, characterized in that the apparatus (1) is adapted to manufacture at least one object (2) in at least one manufacturing region (16) on a prefabricated product (12) that is arranged or arrangeable in the process chamber (13), wherein the manufacturing region (16) is delimited on a first side (14), in particular the bottom side, by a build plate (11) or a first side (14) of the prefabricated product (12) and on at least a second side (15) via at least one second side (15) of the prefabricated product (12).

9. Apparatus according to claim 8, characterized by an application unit (7) that is adapted to layerwise apply build material (3) in the at least one manufacturing region (16) in the manufacturing region (16).

10. Apparatus according to claim 8, characterized in that the manufacturing region (16) is at least partially enclosed via the at least one side (14, 15), in particular the at least one second side (15) and the at least one third side (18) of the product.

11. Apparatus according to claim 8, characterized by a print head (4) that comprises an irradiation unit (5), a consolidation device and/or a stream generating unit (6) and/or an application unit (7).

12. Apparatus according to claim 11, characterized in that the consolidation device comprises the irradiation unit (5) adapted to guide an energy beam (8) onto a build plane (9).

13. Apparatus according to claim 11, characterized in that the consolidation device comprises a radiation source, and a binder material application unit adapted to apply binder material onto a build plane (9), wherein the radiation source is adapted to emit radiation for consolidating the binder material and the build material.

14. Apparatus according to claim 8, characterized by a moving unit (10) that is adapted to move the manufacturing region (16) relative to the print head (4).

15. Apparatus according to claim 8, characterized in that the moving unit (10) comprises a gantry, a movable build plate, a multi-axis robot carrying at least one part of an irradiation unit or a hexapod.

Description

[0027] Exemplary embodiments of the invention are described with reference to the Fig. The Fig. are schematic diagrams, wherein

[0028] FIG. 1 shows a first embodiment of an inventive method performed on an inventive apparatus in side view;

[0029] FIG. 2 shows a second embodiment of the inventive method performed on the inventive apparatus in side view;

[0030] FIG. 3 shows the second embodiment in top view;

[0031] FIG. 4 shows a third embodiment of the inventive method performed on the inventive apparatus in side view;

[0032] FIG. 5 shows the third embodiment in top view; and

[0033] FIG. 6 shows a fourth embodiment of an inventive method performed on an inventive apparatus in side view.

[0034] FIG. 1 shows an apparatus 1 for additively manufacturing three-dimensional objects 2 by means of successive layerwise selective irradiation and consolidation of layers of a build material 3 which can be consolidated by means of an energy source. In this exemplary embodiment (optional) the apparatus 1 comprises a print head 4 with an irradiation unit 5, a stream generating unit 6 and an application unit 7. The irradiation unit 5 is adapted to generate and guide an energy beam 8 onto a build area 9, i.e. a plane in which build material 3 is arranged to be selectively irradiated via the energy beam 8. The stream generating unit 6 is adapted to generate a stream of (inert) gas, in particular over the build area 9. The stream of gas can, inter alia, be charged with residues generated in the additive manufacturing process, such as build material particles, soot, smoke or smolder, for instance.

[0035] The build material application unit 7 is adapted to layerwise apply build material 3 in the build plane 9. The print head 4 is coupled with a moving unit 10 that is adapted to move the print head 4 relative to a build plane 11, for example a build plate, in particular a metal plate onto which the build material 3 can be applied. As can further be derived from FIG. 1, a prefabricated product 12 is arranged on the build plane 11, i.e. in a process chamber 13 (optional), which is the chamber in which the additive manufacturing process may be performed. Of course, it is also possible to perform an additive manufacturing process without a process chamber 13, e.g. when non-reactive build material is used. FIG. 1 further shows that a first side 14 of the build plane 11 and a second side 15 of the prefabricated product 12 delimit a manufacturing region 16 in which the additive manufacturing process is performed. In other words, build material 3 can be applied in the manufacturing region 16, which build material 3 can be selectively irradiated via the energy beam 8 to form or build the three-dimensional object 2, which is connected to the prefabricated product 12 at the second side 15 of the prefabricated product 12. The prefabricated product 12 can, inter alia, be built as metal cuboid or any other body of arbitrary material and geometry.

[0036] The term build area may especially refer to the area in which an actual layer of build material is applied to be consolidated, whereas the term build plane may refer to the plane that carries the non-consolidated build material 3 and the object 2.

[0037] The manufacturing region 16 is further delimited by a wall element 17 which delimits, particularly encloses, the manufacturing region 16. For example, the wall element 17 is connected to the prefabricated product 12 and delimits the manufacturing region 16 in that the object 2 can be connected to the prefabricated product 12 and can be additively manufactured in the additive manufacturing process. Of course, multiple wall elements 17 can be built in the additive manufacturing process to delimit the manufacturing region 16. Further, the wall elements 17 can be built simultaneously with the object 2, for example in a layerwise successive manner. It is also possible to build the wall elements 17 separately, in particular in advance to the additive manufacturing process in which the three-dimensional object 2 is manufactured.

[0038] FIG. 2 shows a second embodiment of the inventive method performed on the inventive apparatus 1 in side view. Hence, same numerals are used for same parts. In the second embodiment, a ring-shaped or cylinder-shaped prefabricated product 12, as can be derived from the top view depicted in FIG. 3, is used in the additive manufacturing process. In this exemplary embodiment the prefabricated product 12 is ring-shaped and arranged on the build plane 11 in the process chamber 13 of the apparatus 1. Hence, three-dimensional objects 2 can be additively built inside the manufacturing region 16 which is delimited by the first side 14 of the build plane 11 and the second side 15 of the prefabricated product 12. In this embodiment, the second side 15 of the prefabricated product 12 is the inner circumference of the ring-shaped prefabricated product 12.

[0039] In other words, it is possible to manufacture the prefabricated product 12 via a conventional manufacturing process, such as milling or drilling or the like. The filigree objects 2 that are to be manufactured in the interior of the prefabricated product 12 cannot be manufactured via conventional manufacturing processes. Hence, the objects 2 are additively manufactured in the manufacturing region 16 which is a delimited by the second side 15 of the prefabricated product 12 and the first side 14 of the build plane 11. Hence, build material 3 can be applied via the application unit 7 in the manufacturing region 16 and can subsequently be irradiated via the energy beam 8 generated and guided via the irradiation unit 5. Simultaneously, a stream of process gas can be generated via the stream generating unit 6, as described before.

[0040] FIGS. 4 and 5 show a third embodiment of the invention in side view (FIG. 4) and top view (FIG. 5), respectively. In this exemplary embodiment, two prefabricated products 12, which are, for example, built as metal cuboids are arranged on the build plane 11 in the process chamber 13 of the additive manufacturing apparatus 1. Hence, the manufacturing region 16 in which the additive manufacturing process is performed is delimited by the first side 14 of the build plane 11, and a second side 15 of each of the prefabricated products 12. In other words, the prefabricated products 12 are arranged in that the second sides of 15 of the prefabricated products 12 face each other and delimit the manufacturing region 16 arranged between the two prefabricated products 12. As can be derived from FIG. 5, the manufacturing region 16 is further delimited by two wall elements 17 that connect the two prefabricated products 12. In this exemplary embodiment each of the wall elements 17 connects the second sides 15 of the two prefabricated products 12. Of course, the shape of the prefabricated products 12, the wall elements 17 and the object 2, as well as the manufacturing region 16 is merely exemplary and can be chosen arbitrarily.

[0041] Hence, the third embodiment allows for generating an additively manufactured three-dimensional object 2 that connects the two prefabricated products 12, wherein each of the prefabricated products 12 may be manufactured with conventional manufacturing processes, such as milling, drilling or the like. The wall elements 17 may be considered as part of the superordinate object that is formed by the prefabricated products 12 and the additively built object 2 or the wall elements 17 may be considered as support structures that can be removed after the manufacturing process is finished. Of course, the second side 15 of the prefabricated product 12 can also be deemed as third side.

[0042] FIG. 6 shows a fourth embodiment of the invention, wherein the prefabricated product 12 comprises U-shape. Thus, the prefabricated product 12, which is placed on the build plane 11 of the a additive manufacturing apparatus 1 in the process chamber 13, comprises a first side 14, a second side 15 and a third side 18 that delimit the manufacturing region 16 in which build material 3 is applied to be irradiated via the energy beam 8 generated via the irradiation unit 5 to form the three-dimensional object 2 in the manufacturing region 16. In other words, it is possible to layerwise apply build material 3 in the manufacturing region 16, which is delimited by at least the first side 14, second side 15 and third side 18 of the prefabricated product 12.

[0043] Of course, it is possible that the prefabricated product 12 comprises further sides that delimit the manufacturing region 16, for example two additional sides perpendicular to the second side 15 and the third side 18 and therefore, essentially arranged parallel to the drawing plane. It is also possible that the open spaces of the prefabricated product 12 are (at least temporarily) closed via wall elements 17, as indicated in FIG. 5.

[0044] Thus, it is possible to layerwise apply build material 3 via the application unit 7 of the print head 4 in the manufacturing region 16 and thereby, additively build the three-dimensional object 2 via selective irradiation via the energy beam 8 that is generated and guided via the irradiation unit 5. Further, the stream generating unit 6 can be used to generate a stream of process gas locally limited in the manufacturing region 16.

[0045] Self-evidently, all details, features and advantages described with respect to the individual embodiments can arbitrarily be exchanged, transferred and combined. In each embodiment more than one manufacturing region 16 can be provided, for example by additively manufacturing multiple objects 2 to at least one of the prefabricated products 12, in particular on different sides of the prefabricated products 12. The region of the build plane 9 in which build material 3 is selectively irradiated and thereby consolidated can also be deemed as consolidation zone. Further, the inventive method may be performed on the inventive apparatus 1, as described before.