Device for the production of a three-dimensional object in layers

Abstract

After the manufacturing of an object by layer-wise solidification from a powder, this object is displaced into a container together with the powder surrounding the object, and is closed by a plate, which is positioned below the object during the manufacturing of the object.

Claims

1. An improved apparatus for layer-wise manufacturing of a three-dimensional object within a construction space in which the three-dimensional object is manufactured, wherein the improvement comprises: a container which is separate from the construction space and which receives the manufactured object and a non-solidified powder surrounding the object upon completion of a build process, wherein the container surrounds a volume sufficient to receive therein the manufactured object and the non-solidified powder around the object upon completion of the build process while the object remains within the construction space, the container being open at its bottom so as to encompass a build area within which the object was constructed, a drive mechanism having a carrier plate, a build plate upon which the object is built being carried by the carrier plate, the carrier and build plates being separable from each other, the drive mechanism lowering the build plate within the construction space during the build process as layers are consecutively provided and solidified in layer-wise manufacture, and raising the build plate and carrier plate when the build process is completed, the container being adapted to be fit around the build plate while the build plate remains within the construction space whereby the manufactured object and the non-solidified powder surrounding the object can be moved into the container through the open bottom upon completion of the build process by the drive mechanism, the build plate being received in the container in sealing engagement therewith to close the open bottom, whereby the closed container with the manufactured object and the non-solidified powder therein is removable from the construction space leaving the drive mechanism and carrier plate within the construction space.

2. The apparatus according to claim 1, wherein the build plate has an area which substantially corresponds to the area of the open bottom of the container.

3. The apparatus according to claim 1, wherein the build plate is detachably arranged upon the carrier plate for layer-wise manufacturing of the three-dimensional object, and the container is closed on all sides, top and bottom when the build plate is received in the container.

4. The apparatus according to claim 1, wherein the drive mechanism, by which the object is lowered step by step during the layer-wise manufacturing, directly engages the build plate.

5. A device for removing an object which has been built through additive manufacture in layer-wise build-up of a powder build material, the object and non-solidified powder being contained within a construction space having a planar build area at an upper end of the construction space, comprising: a removable container having an open bottom, the container having an interior volume sufficient to receive the manufactured object and surrounding non-solidified powder upon completion of the build process, the container being separate from the construction space and not being employed during the build process, a drive mechanism for moving a build plate which is received within the construction space, the drive mechanism moving the build plate downwardly relative to the build area during manufacture, and upwardly at the conclusion of manufacture, the container being adapted so as to fit with its open bottom over the build area to receive the build plate, such that the drive mechanism can insert the object on the build plate and surrounding non-solidified powder within the container through the open bottom with the object and surrounding non-solidified powder still within the construction space, and a closure for the open bottom closing the container bottom upon inserting the object and surrounding non-solidified powder therein, wherein the container is removable from the construction space upon closing.

6. The device of claim 5, wherein the carrier plate is part of the drive mechanism, and the build plate is the closure when placed in sealing engagement with the container to thereby close the container open bottom.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

(1) In the following the invention is explained in more detail by means of three drawings.

(2) FIG. 1 shows in a cross sectional view a device according to the invention. The cutting line extends approximately axially centred through the building area.

(3) The manufactured object 1 is constructed in a known manner on a ground plate 3 surrounded by a powder bed 2.

(4) The ground plate 3 is adversely connected with a carrier plate 4. The connection between the ground plate 3 and the carrier plate 4 is formed as being detachable. In the illustrated view, the nature of the detachable connection is not illustrated in detail, since it is not relevant for the function of the present invention, which kind of detachable connection is actually applied. Form-fit or positive locking connections are possible as well as frictional or non-positive connections (for example adhesive, vacuum, or bayonet connections). The carrier plate 4 is provided to be movable up and down by means of a drive not illustrated.

(5) Above the building plane 5 there is mounted a container 6. The container 6 is open on a side oriented towards the building plane, and has a cross section, which corresponds to the cross section of the building area. The container 6 is positioned with respect to the building plane 5, such that its inner wall is flush with the inner wall of the construction space.

(6) The container 6 is seated in a holder 7, which is provided to be displaceable in a direction parallel to the building plane 5 by means of a drive not shown. During the manufacturing operation the container 6 is located outside of the beam path of the energy source serving for solidifying the powder.

(7) Having completed the manufacturing operation, the container is positioned above the building area. For sealing, a circumferentially extending packing 8 is pro-vided, which seals the gap between the holder 7 and the building plane 5.

(8) FIG. 2 shows the elements known from FIG. 1, wherein the ground plate 3 and the object 1 manufactured on this ground plate 3 is displaced vertically above into the container 6 in conjunction with the powder 2. Due to the insertion, a raise of air pressure may occur in the container 6, which may optionally be discharged through a valve 9 in a controlled manner.

(9) FIG. 3 shows a situation, after the carrier plate has been displaced vertically down again. For this purpose, the detachable connection between ground plate 3 and carrier plate 4 has been released before. The ground plate 3 remained in the container 6 due to friction between the outer edge of the ground plate 4 and the inner wall of the container 6.

(10) The ground plate 3 is inserted into the container 6 such far, that the lower edge of container 6 may be flanged. This flanging reliably effects, that the ground plate 3 remains together with the manufactured object 1 or the powder 2 within the container 6 during a further transport.

(11) In a preferred, not illustrated embodiment of the present invention, there is not provided a separate carrier plate. The drive, which has been provided in the previous embodiments for the lowering of the carrier plate, herein directly engages the closure element, such that a detachable connection is present between the closure element and the drive. In order to remove the container after completion of the object together with the object from the construction space, the container is closed with the closure element and subsequently, the detachable connection between the closure element and the drive is released.

INDUSTRIAL APPLICABILITY

(12) The invention is industrially applicable upon the layer-wise manufacturing of objects.