CALIBRATION DEVICE FOR AN APPARATUS FOR ADDITIVELY MANUFACTURING OF THREE-DIMENSIONAL OBJECTS

Abstract

Calibration device (1) for an apparatus for additively manufacturing of three-dimensional objects, which calibration device (1) comprises at least one determination unit (2, 3) and at least one calibration unit (16, 17), wherein the at least one determination unit (2) is adapted to determine at least one geometrical parameter of a carrying element (4) of a powder module and wherein the at least one calibration unit (17) is adapted to, in particular automatically, adjust an application unit (5) of the apparatus dependent on the at least one determined geometrical parameter of the carrying element (4) and/or wherein the at least one determination unit (3) is adapted to determine at least one geometrical parameter of an application unit (5) of the apparatus and wherein the at least one calibration unit (16) is adapted to, in particular automatically, adjust a carrying element (4) of a powder module dependent on the at least one determined geometrical parameter of the application unit (5).

Claims

1. Calibration device (1) for an apparatus for additively manufacturing of three-dimensional objects, which calibration device (1) comprises at least one determination unit (2, 3) and at least one calibration unit (16, 17), wherein the at least one determination unit (2) is adapted to determine at least one geometrical parameter of a carrying element (4) of a powder module and wherein the at least one calibration unit (17) is adapted to, in particular automatically, adjust an application unit (5) of the apparatus dependent on the at least one determined geometrical parameter of the carrying element (4) and/or wherein the at least one determination unit (3) is adapted to determine at least one geometrical parameter of an application unit (5) of the apparatus and wherein the at least one calibration unit (16) is adapted to, in particular automatically, adjust a carrying element (4) of a powder module dependent on the at least one determined geometrical parameter of the application unit (5).

2. Calibration device according to claim 1, characterized in that the at least one geometrical parameter is determined via an optical determination unit (2, 3) and/or a tactile determination unit (2, 3) and/or a supersonic determination unit (2, 3).

3. Calibration device according to claim 1, characterized in that the determination unit (3) is adapted to determine an orientation of an application element (6) of the application unit (5) relative to an application element carrier (11) or a distance (13) between the application element (6) and the application element carrier (11).

4. Calibration device according to claim 1, characterized in that the calibration unit (17) is adapted to adjust a distance (13) between the application element carrier (11) and an edge (14) of the application element (6) in at least one position along the application element (6).

5. Calibration device according to claim 1, characterized in that the calibration unit (17) is adapted to adjust at least two different distances (13) for at least two positions along the application element (6).

6. Calibration device according to claim 1, characterized in that the distance and/or the orientation are determined via an optical determination unit (2, 3) and/or a tactile determination unit (2, 3) and/or a supersonic determination unit (2, 3).

7. Calibration device according to claim 1, characterized in that the calibration unit (16, 17) and the determination unit (2, 3) form a combined module.

8. Calibration device according to claim 1, characterized in that the calibration device (1) is connected or connectable with the apparatus, in particular integrated in the apparatus.

9. Apparatus for additively manufacturing of 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, characterized by a calibration device (1), in particular a calibration device (1) according to claim 1, which calibration device (1) comprises at least one determination unit (2, 3) and at least one calibration unit (16, 17), wherein the at least one determination unit (2) is adapted to determine at least one geometrical parameter of a carrying element (4) of a powder module and wherein the at least one calibration unit (17) is adapted to, in particular automatically, adjust an application unit (5) of the apparatus dependent on the at least one determined geometrical parameter of the carrying element (4) and/or wherein the at least one determination unit (3) is adapted to determine at least one geometrical parameter of an application unit (5) of the apparatus and wherein the at least one calibration unit (16) is adapted to, in particular automatically, adjust a carrying element (4) of a powder module dependent on the at least one determined geometrical parameter of the application unit (5).

10. Apparatus according to claim 9, characterized in that the calibration device (1) is arranged externally to the apparatus or the calibration device (1) is at least partially, in particular the calibrating unit, integrated in the apparatus.

11. Apparatus according to claim 9, characterized by a control unit (8) adapted to assign a calibrated application unit (5) to a manufacturing process the corresponding carrying element (4) is used in, wherein the adjustment of the application unit (5) has been performed dependent on the at least one geometrical parameter of the corresponding carrying element (4).

12. Apparatus according to claim 9, characterized by a control unit (8) adapted to assign a calibrated carrying element (4) to a manufacturing process the corresponding application unit (5) is used in, wherein the adjustment of the carrying element (4) has been performed dependent on the at least one determined geometrical parameter of the corresponding application unit (5).

13. Apparatus according to claim 9, characterized in that the calibration device (1) is adapted to, in particular automatically, adjust the application element (6) and/or the carrying element (4) with the application element (6) arranged inside the apparatus and/or the carrying element (4) inside the powder module and/or the calibration device (1) is adapted to determine the at least one geometrical parameter of the carrying element (4) with the carrying element (4) arranged inside the apparatus and/or the at least one geometrical parameter of the application unit (5) with the application unit (5) arranged inside the apparatus.

14. Apparatus according to claim 9, characterized in that the calibration device (1) is adapted to set a defined offset value to the determined geometrical parameter.

15. Method for operating at least one calibration device (1) for an apparatus for additively manufacturing three-dimensional objects, in particular a calibration device (1) according to claim 1, characterized in that at least one geometrical parameter of a carrying element (4) of a powder module is determined and an application unit (5) of the apparatus is, in particular automatically, adjusted dependent on the at least one determined geometrical parameter of the carrying element (4) and/or at least one geometrical parameter of an application unit (5) of the apparatus is determined and a carrying element (4) of a powder module is, in particular automatically, adjusted dependent on the at least one determined geometrical parameter of the application unit (5).

Description

[0045] Exemplary embodiments of the invention are described with reference to the FIGURE. The sole FIGURE is a schematic diagram and shows an inventive determination device.

[0046] The sole FIGURE shows a calibration device 1 for an apparatus for additively manufacturing of three-dimensional objects (not shown), which calibration device 1 comprises two determination units 2, 3, wherein the determination unit 2 is adapted to determine a geometrical parameter of a carrying element 4, in particular a build plate, and the determination unit 3 is adapted to determine a geometrical parameter of an application unit 5, in particular an application element 6, e.g. a coater blade.

[0047] The determination unit 2 comprises an optical sensor (not shown) adapted to determine a height of the carrying element 4 (depicted by an arrow 7). The determination unit 2 may transfer the determination results, in particular the height of the carrying element 4 to a control unit 8. The determination unit 2 may determine the height of the carrying element 4 in multiple positions of the carrying element 4. Thus, the determination unit 2 may determine whether the surface of the carrying element 4 comprises a slope or is inclined with respect to a holding structure 9.

[0048] The determination unit 3 also comprises an optical sensor 10, wherein the determination unit 3 is adapted to measure the height (depicted by an arrow 12) of the application element 6. The determination unit 3 is also adapted to measure an orientation of the application element 6 relative to an application element carrier 11 the application element 6 is connected with. In particular, the determination unit 3 may determine a distance 13 between an edge 14 of the application element 6 and a surface 15 of the application element carrier 11. Of course, another reference point or another reference plane than the surface 15 of the application element carrier 11 can also be used. The edge 14 of the application element 6 faces the carrying element 4 or the build plane, respectively, with the application element 6 in a coating condition in which build material is applied onto the build plane via the application element 6. The determination unit 3 may transfer the results of the determination of the geometrical parameter of the application element 6 to the control unit 8.

[0049] The calibration device 1 may comprise a drive means (not shown) adapted to drive the determination unit 3 in that the distance 13 can be measured in multiple positions along the application element 6. Further, the quality of the edge 14 of the application element may be determined along the length of the application element 6.

[0050] The calibration device 1 comprises two calibration units 16, 17 that are adapted to, in particular automatically, adjust the carrying element 4 or the application unit 5, respectively. The calibration unit 16 is assigned to, in particular automatically, adjusting carrying elements 4, wherein it is possible that dependent on the at least one geometrical parameter of the application element 6 determined via the determination unit 3 an automated adjustment of the carrying element 4 or the holding structure 9 holding the carrying element 4 is possible. The calibration unit 16 may therefore, interact with the carrying element 4 or the holding structure 9 in that an upper surface 18 of the carrying element 4 may be positioned relative to the holding structure 9.

[0051] Further, it is possible that dependent on the at least one geometrical parameter of the carrying element 4, in particular the height, an adjustment of the application unit 5 is performed. Thus, the calibration unit 17 may interact with positioning means 19 connecting the application element 6 to the application element carrier 11. Thus, the distance 13 may be changed by interacting with the positioning means 19. In particular, the application element 6 may be extended or retracted with respect to the application element carrier 11 by interacting with the positioning means 19.

[0052] Thus, the distance 13 of the edge 14 of the application element 6 from the surface 15 of the application element carrier 11 may be changed dependent on the at least one geometrical parameter of the carrying element 4, in particular the height of the carrying element 4 (depicted by the arrow 7). After the distance 13 has been set, the positioning means 19 can be locked via lock nuts 20.

[0053] As can further be derived from the FIGURE, the calibration device 1 forms a combined module, wherein the carrying element 4 can be measured and the application unit 5 can be adjusted and vice versa.

[0054] It is also possible to have the calibration device 1 only comprise one determination unit 2, 3 and one calibration unit 16, 17 or two determination units 2, 3 and only one calibration unit 16, 17. For example, the calibration device 1 may comprise a determination unit 2 adapted to determine the at least one geometrical parameter of the carrying element 4, in particular the height of the carrying element 4. Dependent on the determined geometrical parameter of the carrying element 4, the distance 13 of the application element 5 can be adjusted, that defines the distance 13 between the edge 14 of the application element 6 and a base surface 15 of the application element carrier 11 (and thereby defines the relative position in a coating state). The adjustment of the distance 13 could be based on a manufacturer specific standard distance. Additionally, the distance 13 can be determined via the determination unit 3.

[0055] Accordingly, it is also possible to have the calibration device 1 determine the distance 13 via the determination unit 3 and, in particular automatically, adjust the carrying element 4 via the calibration unit 16. Of course, the calibration can be verified via the determination unit 2.

[0056] Further, a display unit (not shown) may be assigned to the determination unit 3, in particular to the optical sensor 10, wherein the display unit, preferably a monitor, is adapted to display the data captured by the optical sensor 10. For example, the display unit may be used to display the data captured by the optical sensor 10 to a user in real-time. Thus, the image of the edge 14 of the application element 6 recorded via the optical sensor 10 may be display to a user in real-time. Additionally, a user input interface (not shown) may be provided that is adapted to receive an input of a user, wherein the user input interface is adapted to transmit the user input to the control unit 8. Thus, the application element 6 may be adjusted dependent on the user input. The user may therefore, view the captured data that are displayed via the display unit and adjust the application element 6 accordingly.

[0057] Thus, according to the determined geometrical parameter of the carrying element 4, the distance 13 of the application element 5 can be adjusted by the user. The user may position the determination unit 3 in a defined position relative to the edge 14 of the application element 6, e.g. to a section of the edge 14 near the lower left corner of the application element 6. The optical sensor 10 allows for measuring the distance 13 in the corresponding position, which can be display to the user via the display unit.

[0058] The position of the edge 14 relative to the determined geometrical parameter of the carrying element 4, e.g. the height of the carrying element 4, is then displayed to the user, wherein the user may manually adjust the positioning means 19 and the lock nuts 20 according to the displayed position of the edge 14. The same procedure may be repeated for at least one other part of the edge, e.g. near the lower right corner of the application element 6. After the positioning of the application element 6, in particular the edge 14 is finished, the user may verify the adjustment of the edge 14 via the determination unit 3.

[0059] The calibration device 1 may be arranged inside an apparatus for additively manufacturing three-dimensional objects, in particular inside a process chamber (not shown). This allows for performing the calibration routine inside the apparatus without the need of bringing the carrying element 4 or the application unit 5 out of the process atmosphere inside the process chamber.

[0060] Of course, the inventive method may be performed on the calibration device 1.