APPARATUS FOR ADDITIVELY MANUFACTURING THREE-DIMENSIONAL OBJECTS

Abstract

Apparatus (1) 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 beam, with a stream generating unit (2) configured to generate a stream of a process gas (3) being capable of being charged with particles (4), in particular non-consolidated particulate build material and/or smoke and/or smoke residues, generated during operation of the apparatus (1) and a filter unit (5) configured to separate particles (4) from the stream of process gas (3), wherein the filter unit (5) comprises a filter chamber (6) with at least one filter element (7) at least partly arranged in the streaming path of the generated stream of process gas (3), wherein particles (4) in the stream of process gas (3) are separated from the process gas (3) by the filter element (7).

Claims

1. Apparatus (1) 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 beam, with a stream generating unit (2) configured to generate a stream of a process gas (3) being capable of being charged with particles (4), in particular non-consolidated particulate build material and/or smoke and/or smoke residues, generated during operation of the apparatus (1) and a filter unit (5) configured to separate particles (4) from the stream of process gas (3), wherein the filter unit (5) comprises a filter chamber (6) with at least one filter element (7) at least partly arranged in the streaming path of the generated stream of process gas (3), wherein particles (4) in the stream of process gas (3) are separated from the process gas (3) by the filter element (7), characterized by a particle reception chamber (13, 26, 28) separably connected or connectable to a particle outlet (11) of the filter chamber (6) and configured to receive the particles (4) separated from the process gas (3).

2. Apparatus according to claim 1, characterized in that the particle reception chamber (13, 26, 28) is separable from the filter chamber (6) via a separation means, in particular a valve (14), wherein a connection between the filter chamber (6) and the particle reception chamber (13, 26, 28) is closed, whereby the filter chamber (6) and the particle reception chamber (13, 26, 28) remain mechanically connected and/or the particle reception chamber (13, 26, 28) is separable in that the particle reception chamber (13, 26, 28) is mechanically disconnected from the filter chamber (6).

3. Apparatus according to claim 1, characterized in that the particle reception chamber (13, 26, 28) is located below the filter chamber (6).

4. Apparatus according to claim 1, characterized in that the filter unit (5) comprises at least one particle guide element (10), in particular built as a funnel or funnel shaped, configured to guide particles (4) from the filter chamber (6) to or towards the particle reception chamber (13, 26, 28) that are separated from the stream of process gas (3) by the filter element (7).

5. Apparatus according to claim 1, characterized in that the particle reception chamber (13, 26, 28) is separably connected to the particle outlet (11) of the filter unit (5) by at least one valve (14).

6. Apparatus according to claim 5, characterized in that at least one valve (14) is a split valve, in particular a split butterfly valve, and/or at least two disc valves are provided, wherein a first disc valve is controlled pneumatically and a second disc valve is controlled manually.

7. Apparatus according to claim 1, characterized in that the particle reception chamber (13, 26, 28) is movable, in particular drivable, in a disconnected state.

8. Apparatus according to claim 1, characterized in that at least one process gas outlet (9) of the filter unit (5) is arranged upstream of a process gas inlet (16) of the stream generating unit (2).

9. Apparatus according to claim 1, characterized by a passivation unit (20) connected or connectable with the particle reception chamber (13, 26, 28), wherein the passivation unit (20) is configured to fill passivating material (21), preferably water, into the particle reception chamber (13, 26, 28).

10. Apparatus according to claim 9, characterized in that the particle reception chamber (13, 26, 28) comprises a fill level indicator (22) configured to indicate a fill level of particles (4) and/or passivating material (21) inside the particle reception chamber (13, 26, 28).

11. Filter unit (5) for an apparatus (1) 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 beam, in particular an apparatus (1) according to claim 1, characterized by a particle reception chamber (13, 26, 28) separably connected or connectable to a particle outlet (11) of the filter chamber (6) and configured to receive the particles (4) separated from the process gas (3).

12. Filter unit (5) according to claim 11, characterized in that the particle reception chamber (13, 26, 28) is separable from the filter chamber (6) via a separation means, in particular a valve (14), wherein a connection between the filter chamber (6) and the particle reception chamber (13, 26, 28) is closed, whereby the filter chamber (6) and the particle reception chamber (13, 26, 28) remain mechanically connected and/or the particle reception chamber (13, 26, 28) is separable in that the particle reception chamber (13, 26, 28) is mechanically disconnected from the filter chamber (6).

13. Filter unit (5) according to claim 11, characterized in that the particle reception chamber (13, 26, 28) is located below the filter chamber (6).

14. Filter unit (5) according to claim 11, characterized in that the filter unit (5) comprises at least one particle guide element (10), in particular built as a funnel or funnel shaped, configured to guide particles (4) from the filter chamber (6) to the particle reception chamber (13, 26, 28) that are separated from the stream of process gas (3) by the filter element (7).

15. Filter unit (5) according to claim 11, characterized in that the particle reception chamber (13, 26, 28) is separably connected to the particle outlet (11) of the filter unit (5) by at least one valve (14).

16. Filter unit (5) according to claim 15, characterized in that at least one valve (14) is a split valve, in particular a split butterfly valve, and/or at least two disc valves are provided, wherein a first disc valve is controlled pneumatically and a second disc valve is controlled manually.

17. Filter unit (5) according to claim 11, characterized in that the particle reception chamber (13, 26, 28) is movable, in particular drivable, in a disconnected state.

18. Filter unit (5) according to claim 11, characterized by a passivation unit (20) connected or connectable with the particle reception chamber (13, 26, 28), wherein the passivation unit (20) is configured to fill passivating material (21), preferably water, into the particle reception chamber (13, 26, 28).

19. Filter unit (5) according to claim 18, characterized in that the particle reception chamber (13, 26, 28) comprises a fill level indicator (22) configured to indicate a fill level of particles (4) and/or passivating material (21) inside the particle reception chamber (13, 26, 28).

20. Plant (24) for additively manufacturing of three-dimensional objects, comprising a plurality of apparatuses (1) 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 beam, according to claim 1, wherein the particle outlets (11) of at least two filter units (5) are connected to at least one common particle guide means (25, 27) connected to at least one common particle reception chamber (26, 28).

21. Plant according to claim 20, characterized by a passivation unit (20) configured to generate a stream of passivating material (21) or a stream of fluid containing passivating material (21) between an inlet of the common particle guide means (25, 27) to the common particle reception chamber (26, 28).

22. Plant according to claim 21, characterized in that the particles (4) separated in the at least two filter units (5) of the at least two apparatuses (1) are conveyed to the common particle reception chamber (26, 28) via the stream of passivating material (21) or the stream of fluid containing passivating material (21).

Description

[0031] Exemplary embodiments of the invention are described with reference to the Fig. The Fig. are schematic drawings, whereby

[0032] FIG. 1 shows a principle drawing of an apparatus for additively manufacturing three-dimensional objects according to an exemplary embodiment;

[0033] FIG. 2 shows a detail of an apparatus for additively manufacturing three-dimensional objects according to an exemplary embodiment;

[0034] FIG. 3 shows a filter unit of an apparatus for additively manufacturing three-dimensional objects according to an exemplary embodiment;

[0035] FIG. 4 shows a filter unit of an apparatus for additively manufacturing three-dimensional objects according to an exemplary embodiment; and

[0036] FIG. 5 shows a plant comprising two apparatuses for additively manufacturing three-dimensional objects according to an exemplary embodiment.

[0037] FIG. 1 shows an apparatus 1 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 beam. The apparatus 1 comprises a stream generating unit 2 configured to generate a stream of a process gas 3 (indicated by arrows) being capable of being charged with particles 4, in particular non-consolidated particulate build material and/or smoke and/or smoke residues, generated during operation of the apparatus 1 and a filter unit 5 configured to separate particles 4 from the stream of process gas 3. The filter unit 5 comprises a filter chamber 6 with at least one filter element 7 at least partly arranged in the streaming path of the generated stream of process gas 3, wherein particles 4 in the stream of process gas 3 are separated from the process gas 3 by the filter element 7.

[0038] The process gas 3 enters the filter chamber 6 via a process gas inlet 8 and exits the filter chamber 6 via a process gas outlet 9. As can be seen from FIG. 1 the filter element 7 is arranged inside the fill the chamber 6 between the process gas in that 8 and the process gas outlet 9. The filter element 7 has a cylindrical shape, wherein particles 4 that are conveyed via the stream of process gas 3 into the filter chamber 6 come in contact with the filter element 7 and are thereby separated from the stream of process gas 3. The separated particles 4 fall down due to gravity and come in contact with a surface of a particle guide element 10 that is essentially funnel-shaped. The particle guide element 10 guides the particles 4 to a particle outlet 11 of the filter chamber 6. The particle outlet 11 of the filter chamber 6 is separately connected to a particle inlet 12 of a particle reception chamber 13 of the filter unit 5.

[0039] FIG. 1 further shows that in the region of the particle outlet 11 and in the region of the particle inlet 12 a valve 14 is provided. Therefore, the connection between the filter chamber 6 and the particle reception chamber 13 of the filter unit 5 can be disconnected via the valves 14. In other words the opening or closing state of the valves 14 controls whether particles 4 can pass from the filter chamber 6 into the particle reception chamber 13 via the particle outlet 11 and the particle inlet 12.

[0040] As can further be derived from FIG. 1 the particle reception chamber 13 can be disconnected from the filter chamber 6 of the filter unit 5 (depicted via a dashed line 15). Hence, it is possible, to close the valves 14 and therefore separate the particle reception chamber 13 from the filter chamber 6. Afterwards, the particle reception chamber 13 can be mechanically disconnected from the rest of the filter unit 5 and can be moved away, for example to a station in which the particle reception chamber 13 is cleaned and/or emptied.

[0041] The stream generating unit 2 that generates the stream of process gas 3 is located downstream of the filter unit 5. In other words a process gas inlet 16 of the stream generating unit 2 is connected to a process gas outlet 9 of the filter unit 5. Therefore, the stream generating unit 2 only takes in process gas 3 that is rinsed of particles 4 via the filter unit 5. The stream of process gas 3 that enters a process chamber 17 of the apparatus 1 therefore, is free of particles 4.

[0042] Additionally the apparatus 1 depicted in FIG. 1 comprises a pressure generating means 18 located topsides of the filter unit 5 and comprises a nozzle that extends into the inside or near the filter element 7. Via the pressure generating means 18 it is possible to generate an overpressure inside the filter chamber 6 to solve particles 4 that accumulated on the surface of the filter element 7.

[0043] FIG. 2 shows an alternative exemplary embodiment of the valve 14 in which the valve 14 is built as a split butterfly valve. Hence, the sealing of the particle reception chamber 13 and the filter chamber 6 and the mechanical disconnection of the particle reception chamber 13 from the rest of the filter unit 5 is integrated into the valve 14 being built as a split butterfly valve.

[0044] FIG. 3 shows an apparatus 1 as described before, wherein the particle reception chamber 13 comprises moving means 19. Therefore, the particle reception chamber 13 is movable via the moving means 19, in particular drivable via a motor connected to the moving means 19. It is further possible to arrange a motor or a driving unit in general, outside or separate to the particle reception chamber 13.

[0045] FIG. 4 shows an apparatus 1 according to another exemplary embodiment. The apparatus 1 is basically built like the apparatus 1 as described before, therefore, the same numerals are used for the same components of the apparatus 1. Deviant from or additional to the apparatuses 1 described before the apparatus 1 depicted in FIG. 4 comprises a passivation unit 20 separably connected with the particle reception chamber 13. The passivation unit 20 is configured to fill passivating material 21 (depicted by an arrow) into the particle reception chamber 13. The passivating material 21 is preferably water, wherein any other passivating material 21 may be used that is configured to passivate the particles 4 inside the particle reception chamber 13, for example passivating material in powder form. To passivate the particles 4 inside the particle reception chamber 13 a valve 14 is provided in the connection between the passivation unit 20 and the particle reception chamber 13. Dependent on an opening state of the valve 14 the passivating material 21 can be filled into the particle reception chamber 13, for example sprayed, wherein the particles 4 can be wetted or moistened.

[0046] FIG. 4 further shows a fill level indicator 22 that is configured to indicate a fill level of particles 4 and/or passivating material 21 inside the particle reception chamber 13. The fill level indicated by the fill level indicator 22 can further be sent to a control unit 23 so that corresponding process steps can be initiated by the control unit 23, such as the initiation of a change and/or a separation of the particle reception chamber 13 from the rest of the filter unit 5. Self-evidently, the control unit 23 may also control the opening state of the valves 14 and any other component of the apparatus 1 necessary for the manufacturing cycle.

[0047] FIG. 5 shows a plant 24 exemplary comprising two apparatuses 1. Of course, the plant 24 can comprise a plurality of apparatuses 1 but for the sake of simplicity only two apparatuses 1 are depicted in this Fig. There are two filter units 5 assigned to the plant 24, wherein the particle outlets 11 of the filter chambers 6 of the filter units 5 are separably connected to a common particle guide means 25. The common particle guide means 25 is configured to convey the particles 4 that are filled in from the filter chambers 6 of the filter units 5 via their particle outlets 11 and are conveyed inside the common particle guide means 25 to a common particle reception chamber 26. Therefore, a passivation unit 20 is assigned to the plant 24 generating a stream of passivating material 21 and/or a stream of fluid containing passivating material 21. The passivating material 21 is filled into the common particle guide means 25 and conveys the particles 4 inserted into the common particle guide means 25 via the particle outlets 11 of the filter units 5 to the common particle reception chamber 26. Thereby, the particles 4 entering the common particle guide means 25 are not only conveyed to the common particle reception chamber 26 but are passivated at the same time as they come in contact with the passivating material 21 as soon as they enter the common particle guide means 25.

[0048] FIG. 5 shows that a second common particle guide means 27 is provided that conveys the particles 4 and the passivating material 21 to a second common particle reception chamber 28. Of course, an arbitrary amount of common particle guide means 25, 27 and common particle reception chambers 26, 28 can be provided. It is also possible, to arrange and connect the various common particle guide means 25, 27 and the various common particle reception chambers 26, 28 in an arbitrary manner.

[0049] All features, advantages and details depicted in the FIGS. 1 to 5 are arbitrarily interchangeable and transferable to all the embodiments.