MANUFACTURING APPARATUS FOR ADDITIVE MANUFACTURING OF THREE-DIMENSIONAL COMPONENTS

Abstract

Disclosed is a manufacturing device for additive manufacturing of three-dimensional elements by layer-by-layer application by at least one coating unit and locally selective solidification of a build-up material by at least one irradiation unit, the manufacturing device including a building shaft and a carrier with a building platform, wherein the element can be built up on the building platform within the building shaft, wherein the building shaft can be changed relatively in height with respect to the building platform and is sealable with respect to the latter during the layer-by-layer application in that during the layer-by-layer application between an inner surface of the building shaft and the carrier a gap is formed such that a part of the build-up material can at least partially penetrate to thereby seal the building shaft with respect to the carrier.

Claims

1. Manufacturing device for additive manufacturing of three-dimensional elements by layer-by-layer application by means of at least one coating unit and locally selective solidification of a build-up material by means of at least one irradiation unit, comprising a building shaft and a carrier as well as a building platform, wherein the element can be built up on the building platform within the building shaft, wherein the building shaft can be changed relatively in height with respect to the building platform and is sealable with respect to the latter and/or the carrier during the layer-by-layer application, in that during the layer-by-layer application between an inner surface of the building shaft and the carrier and/or between an inner surface of the building shaft and the building platform a gap is formed such that a part of the build-up material can at least partially penetrate in order to thereby seal the building shaft with respect to the building platform and/or the carrier.

2. Manufacturing device according to claim 1, characterized in that for sealing purposes, at least in one state, during the layer-by-layer application below the gap and/or below a lower end of the building shaft, a section is formed, which successively increases in size and fills with build-up material.

3. Manufacturing device according to claim 1, characterised in that the building shaft is sealable with respect to the building platform and/or the carrier by means of self-sealing.

4. Manufacturing device according to claim 1, characterized in that the manufacturing device comprises the build-up material, wherein the gap has, at least in sections, a width which is greater than an average particle size.

5. Manufacturing device according to claim 1, characterised in that the gap has, at least in sections, a width of at least 100 nm.

6. Manufacturing device according to claim 1, characterized in that the building shaft is movable relative to the carrier in a carrier shaft extending circumferentially relative to the carrier, wherein a distance between an inner wall of the carrier shaft and an outer wall of the carrier is at least one wall thickness of the building shaft, and/or plus at most 4 mm.

7. Manufacturing device according to claim 1, characterized in that a collection device is provided around the carrier and/or around the carrier shaft and/or at least in sections below a section of the building shaft, in order to collect excess material as soon as the building shaft is arranged above a level of the building platform.

8. Manufacturing device according to claim 1, characterized in that a receiving device is provided for receiving material which is conveyed out of the building shaft during coating.

9. Manufacturing device according to claim 1, characterized in that at least one opening is provided in the building shaft in order to be able to collect or receive excess build-up material below the opening.

10. Manufacturing device according to claim 1, characterized in that the manufacturing device is configured to build up an additional element around the three-dimensional element during the manufacture of the three-dimensional element, wherein the additional element has at least one opening.

11. Manufacturing method for the additive manufacturing of three-dimensional elements by layer-by-layer application by means of at least one coating unit and locally selective solidification of a build-up material by means of at least one irradiation unit, wherein the element is built up on a building platform arranged on a carrier within a building shaft, wherein the building shaft with respect to the building platform is changed in a height and is sealed with respect thereto and/or with respect to the carrier during the layer-by-layer application, in that between an inner surface of the building shaft and the carrier and/or the inner surface of the building shaft and the building platform a gap is formed such that a part of the build-up material can at least partially penetrate to thereby seal the building shaft against the building platform and/or the carrier.

12. Manufacturing method according to claim 11, characterized in that the gap has a width which is greater than an average particle size.

13. Manufacturing method according to claim 11, characterised in that during the manufacture of the three-dimensional element, an additional element is built up around the three-dimensional element, wherein the additional element has at least one opening.

14. Manufacturing method according to claim 11, characterized in that the build-up material is heated locally to at least 300° C.

15. System comprising the manufacturing device according to claim 1, as well as the build-up material.

16. System according to claim 15, characterized in that a mean particle size of the build-up material is at least 50 nm and/or at most 300 μm.

Description

[0085] In the following, the invention is described by means of execution examples which are explained in more detail with reference to the figure.

[0086] Hereby show:

[0087] FIG. 1 a schematic sectional view of a manufacturing device according to the invention;

[0088] FIG. 2 a detail of the manufacturing device according to FIG. 1 in a state differing from FIG. 1;

[0089] FIG. 3 the detail according to FIG. 2 in a further, differing, state;

[0090] FIG. 4 a schematic cross-section of a section of a further embodiment of a manufacturing device according to the invention;

[0091] FIG. 5 a detail analogous to FIG. 4 of a further embodiment of the manufacturing device;

[0092] FIG. 6 the detail according to FIG. 4 in a differing state;

[0093] FIG. 7 the detail according to FIG. 4 in a further, differing state;

[0094] FIG. 8 the detail according to FIG. 4 in a further, differing state;

[0095] FIG. 9 a detail analogous to FIG. 2 with an additional object;

[0096] FIG. 10 the detail according to FIG. 9 in a further, differing state.

[0097] FIG. 11 an enlarged detail of the embodiment according to FIGS. 1 to 3.

[0098] In the following description, the same reference numerals are used for same parts and parts having the same effect.

[0099] FIG. 1 shows a manufacturing device according to the invention in cross-section (partly purely schematic, which is represented by dashed lines). The manufacturing device comprises a housing 10, an irradiation unit 11 as well as a coating unit 12.

[0100] Furthermore, the manufacturing device comprises a building shaft 13, a building platform 14 as well as a carrier 15 for the building platform 14. In the state (initial state of a corresponding manufacturing process) according to FIG. 1, a gap 30 is formed between an inner wall 16 of the building shaft 13 and the carrier 15. Build-up material 17 (shown in FIG. 2) can run into this gap 30 during layer-by-layer application by the coating unit 12.

[0101] On the outside opposite the building shaft 13 is a carrier shaft 18, so that altogether (a hollow cylindrical) receiving space 19 is formed between carrier 15 and carrier shaft 18, in which the building shaft 13 can be moved in relation to the carrier 15.

[0102] Specifically, the carrier 15 can be lowered relative to the building shaft 13 for this purpose (or vice versa, the building shaft 13 can be raised, or both).

[0103] In FIG. 2, a state is shown in which the manufacturing device is when the manufacturing process is finished or at least almost finished. Here, the 3-dimensional object 20 as well as non-consumed build-up material 17 can also be seen. The material flowing into the gap 30 (which becomes successively shorter in the vertical direction) during the transition between the states according to FIGS. 1 and 2 fills here almost the entire receiving space 19 between the carrier 15 and an inner wall 21 of the carrier shaft 18.

[0104] In a concrete embodiment, the carrier shaft 18 forms a one-piece (possibly monolithic) body with the carrier 15 (as well as a horizontal transition section 22 or bottom of the receiving space 19). However, the carrier shaft 18 (possibly including transition section 22 or without transition section 22) can also be arranged as a separate element (element) (but is preferably firmly connected to the carrier 15).

[0105] Before the start of a manufacturing process (that is in the state according to FIG. 1), the gap 30 can possibly be completely filled with build-up material (by “overdosing”). A section 31 (pocket) between the lower end of the gap 30 and bottom 22 can also be filled with build-up material. This can then result in self-inhibition due to gravity. This section 31 (pocket) is comparatively small (in vertical direction) in the initial state, so that only little build-up material is needed to fill it. In the ongoing manufacturing process, the carrier is lowered and further build-up material flows (loosely) through the inner gap 30 into section 31 (the pocket), whereby this is filling further. This is illustrated again in the detail according to FIG. 11.

[0106] The building shaft 13 has a flange section 23 which projects above the carrier shaft 18 and during the manufacturing process is preferably flush with the uppermost, most recently applied layer in each case.

[0107] FIG. 3 shows the detail according to FIG. 2 in a further state, namely after completion of the object 20. In this state, the building shaft 13 is moved relative to the carrier 15 or the building platform 14 to such an extent that excess build-up material 17 can flow off (run off) between a lower edge 24 of the building shaft 13 as well as the building platform 14. The material possibly then can further (possibly completely) fill the receiving space 19, but can also, if necessary, (additionally) flow beyond the receiving space 19 (and be received, for example, by a further receiving and/or collection device, as shown in further execution examples).

[0108] By means of the gap 30 and the section 31 (pocket), a seal is achieved in a simple manner, as material (see in particular FIG. 1) is prevented from further flowing away due to friction inherent in the build-up material and possibly also due to a gravity from material located on the outside of the building shaft 13. The build-up material thus inhibits itself.

[0109] The build-up material 17 can in each case (see FIGS. 1 and 2) fill a section between inner wall 16 of the building shaft 13 and the carrier 15, and on the other hand a section below a lower edge 24 of the building shaft 13. In addition, if necessary, there can be at least a small section on the outside of the building shaft 13, due to a force resulting from a corresponding build-up material column in the area of the gap 30. FIG. 4 shows a further embodiment of the manufacturing device according to the invention. This corresponds in principle to the embodiment according to FIGS. 1 to 3, wherein additionally a collection device 26 is provided which is arranged around the carrier shaft 18.

[0110] The collection device 26 can be arranged around the carrier shaft 18 and, if necessary, be integrally formed (in particular monolithically) on the latter (or with the latter). It is also conceivable that the collection device 26 is designed as a separate element (element) (but preferably firmly connected to the carrier shaft 13 or at least movable simultaneously therewith). In particular, if the carrier 15 is not lowered, but the building shaft is raised during manufacturing, the collection device 26 can also be formed by a separate (possibly also not firmly connected) element.

[0111] FIG. 5 shows a further embodiment of the manufacturing device according to the invention with one difference compared to the embodiment according to FIG. 4, namely at least one opening 27 for excess build-up material. Through the respective opening 27, excess build-up material (by the coater after passing over the building plane) can flow off into the collection device 26.

[0112] Alternatively or additionally, it may be a function of the opening 27 to create a connection so that no (relative) gas pressure can build up that pushes build-up material up into the space between inner wall of the carrier shaft 18 and outer wall of the building shaft 13.

[0113] FIG. 6 again shows the embodiment according to FIG. 4, whereby the building shaft has been moved (approximately) half the distance compared to the position according to FIG. 7 relative to the carrier.

[0114] FIG. 7 shows a position analogous to FIG. 2 for the embodiment according to FIG. 4.

[0115] FIG. 8 shows a position analogous to FIG. 3 for the embodiment according to FIG. 4.

[0116] In FIG. 8 it can be seen that excess build-up material can also be collected, in particular by the collection device 26 (after removing the building shaft from the carrier).

[0117] FIG. 9 shows again basically the embodiment according to FIG. 4 (in a position analogous to FIG. 7), whereby here, in addition to the object 20, an additional object 28 has been built around the object. FIG. 9 then shows a flow off of the (unsolidified) build-up material below the additional object 28 or in openings in a lower area of the additional object 28.

[0118] For example, a vertical adjustment between building shaft and carrier can be carried out by means of spindle rods (which are driven in rotation). These can, for example, raise the building shaft, whereby the carrier preferably remains at a constant height. Alternatively or additionally, the carrier can be (actively) lowered.

[0119] At this point, it should be noted that all the parts described above, taken on their own and in any combination, in particular the details shown in the drawings, are claimed as embodiments of the invention. Modifications thereof are familiar to the person skilled in the art.

LIST OF REFERENCE SIGNS

[0120] 10 housing [0121] 11 irradiation unit [0122] 12 coating unit [0123] 13 building shaft [0124] 14 building platform [0125] 15 carrier [0126] 16 inner wall [0127] 17 build-up material [0128] 18 carrier shaft [0129] 19 receiving space [0130] 20 object [0131] 21 inner wall [0132] 22 transition section (bottom) [0133] 23 flange section [0134] 24 lower edge [0135] 26 collection device [0136] 27 opening [0137] 28 additional object [0138] 30 gap [0139] 31 section (pocket)