APPARATUS FOR ADDITIVELY MANUFACTURING OF THREE-DIMENSIONAL COMPONENTS

Abstract

An apparatus for additive manufacturing of three-dimensional components by successive, selective layer-by-layer exposure. Solidifying construction material layers of a construction material can be solidified by means of an energy beam in a process chamber, wherein the process chamber can be flown through or is flown through by an, especially inert, gas flow generated by a flow generation device, wherein with the gas flow and construction material particles resulting a particle mixture can be formed or is formed, wherein the particle mixture includes at least three construction material fractions differing in at least one construction material particle parameter, especially particle size and/or particle density, comprising a separation device, which is provided for separating the respective construction material particle fractions from the particle mixture by means of visual inspection, wherein the separation device comprises at least three separation sections each serving the separation of a certain construction material particle fraction.

Claims

1. An apparatus (1) for additive manufacturing of three-dimensional components by successive, selective layer-by-layer exposure and thus solidifying construction material layers of a construction material (3) that can be solidified by means of an energy beam (5) in a process chamber (7), wherein the process chamber (7) can be flown through or is flown through by an, especially inert, gas flow generated by a flow generation device (9), wherein with the gas flow and construction material particles resulting related to the process a particle mixture (10) can be formed or is formed, wherein the particle mixture (10) includes at least three construction material fractions (11-13) differing in at least one construction material particle parameter, especially particle size and/or particle density, characterized by a separation device (14) that is provided for separating the respective construction material particle fractions (11-13) from the particle mixture (10) by means of visual inspection, wherein the separation device (14) comprises at least three separation sections (15-17) each serving the separation of a certain construction material particle fraction (11-13).

2. The apparatus according to claim 1, characterized in that a first separation section (15) serves the separation of a first construction material particle fraction (11), wherein the first construction material particle fraction (11) includes construction material particles with a particle size that is in terms of a particle size distribution of the construction material (3) defined by a lower and an upper limit particle size or limit particle density lying below the lower limit particle size or the limit particle density, and a second separation section (16) serves the separation of a second construction material particle fraction (12), wherein the second construction material particle fraction (12) includes construction material particles with a particle size or particle density that is in terms of a particle distribution of the construction material (3) defined by a lower and an upper limit particle size or limit particle density lying between the lower and the upper limit particle size or the limit particle density, a third separation section (17) serves the separation of a third construction material particle fraction (13), wherein the third construction material particle fraction (13) includes construction material particles with a particle size or particle density that is in terms of a particle distribution of the construction material (3) defined by a lower and an upper limit particle size or limit particle density lying above the upper limit particle size or limit particle density.

3. The apparatus according to claim 1, characterized in that the separation device (14) is arranged or formed in a powder module (18), especially in a collector or overflow module, wherein the powder module (18) comprises a powder chamber (19), which comprises a powder chamber room (21) defined by powder chamber walls (20).

4. The apparatus according to claim 1, characterized in that a first separation section (15) for separating a first construction material particle fraction (11) comprises a flow portion (22) that can be or is, especially vertically, flown through, by a gas flow, and that communicates with a filter device connected downstream said flow portion, which is provided for separating of construction material particles of the first construction material particle fraction (11) contained in the gas flow by means of filtering.

5. The apparatus according to claim 1, characterized in that a second separation section (16) for separating a second construction material particle fraction (12) comprises a separation element (23), arranged or formed especially within the or a powder module (18).

6. The apparatus according to claim 5, characterized in that a third separation section (17) for separating a third construction material particle fraction (13) is arranged or formed below the second separation section (16).

7. The apparatus according to claim 6, characterized in that between the separation element (23) forming the second separation section (12) for separating a second construction material particle fraction (16) and a powder chamber wall (20) a gap (24) is defined, wherein the gap (24) forms an access opportunity into the third separation section (17).

8. The apparatus according to claim 1, characterized in that the separation element (23) is movably supported in at least one, especially linear, freedom degree of motion relative to the powder chamber wall (20) and/or relative to a bottom of the powder chamber (19), formed especially by a carrying device, wherein the gap (24), especially the inner span and/or length thereof, can be varied by movements of the separation element (23) relative to the powder chamber wall (20) and/or the bottom of the powder chamber (19).

9. The apparatus according to claim 2, characterized in that the third separation section (17), especially the gap (24) forming an access opportunity into the third separation section (17), is in gas downstream direction connected upstream of the second separation section (16), and the second separation section (16) is in gas downstream direction connected upstream of the first separation section (15).

10. The apparatus according to claim 1, characterized by an additional flow generation device (25), which is provided for generating a transport flow influencing the flow of at least the second construction material particle fraction (12) in the direction of the second separation section (16), especially over the gap (24).

11. A method for additive manufacturing of three-dimensional components (2) by successive, selective layer-by-layer exposure and thus solidifying construction material layers of a construction material (3) that can be solidified by means of an energy beam (5) in a process chamber (7), wherein the process chamber (7) is flown through by an, especially inert, gas flow generated by a flow generation device (9), wherein with the gas flow and construction material particles resulting related to the process a particle mixture (10) is formed, wherein the particle mixture (10) includes at least three construction material fractions (11-13) differing in at least one construction material particle parameter, especially particle size and/or particle density, characterized in that for separation of the respective construction material particle fractions (11-13) from the particle mixture (10) a separation device is used, which is provided for separating the respective construction material particle fractions (11-13) from the particle mixture (10) by means of visual inspection, wherein the separation device (14) comprises several, especially at least three, separation sections (15-17) each serving the separation of a certain construction material particle fraction (11-13).

Description

[0030] The invention is explained in more detail by means of exemplary embodiments in the figures of the drawings. In which:

[0031] FIGS. 1-3 each show a schematic diagram of an apparatus according to an exemplary embodiment.

[0032] FIG. 1 shows a schematic diagram of an apparatus 1 according to an exemplary embodiment. The apparatus 1 serves the additive manufacturing of three-dimensional components 2, i.e. for example technical components or technical component groups, respectively, by successive, selective layer-by-layer exposure and thus solidifying construction material layers of a construction material 3 that can be solidified by means of an energy beam 5 generated by an energy beam generation device 4. The apparatus 1 can especially be an SLM apparatus, i.e. an apparatus for performing selective laser melting methods (SLM methods). The energy beam 5 is thus especially a laser beam and the construction material 3 especially a particulate or powdered metal such as for example aluminum, stainless steel or titanium. The selective solidification of respective construction material layers to be solidified is carried out based on component-related construction data. Respective construction data describe the geometric or geometric structural design of the respective component 2 to be additively manufactured. Respective construction data can for example include sliced CAD data of the component 2 to be manufactured.

[0033] The apparatus 1 comprises an inertable process chamber 7. The process chamber 7 can form a part of a housing structure (not denoted in more detail) of the apparatus 1. In the process chamber 7 the functional components required for performing additive construction processes, i.e. especially the energy beam generation device 4 and a coating device 8 that is movably supported as indicated by the horizontally oriented double arrow P1, are arranged or formed for forming construction material layers in a construction plane to be solidified.

[0034] Another functional component of the apparatus 1 is a flow generation device 9 in the form of a blower and/or suction device. The flow generation device 9 is provided for generating a gas flow as indicated by arrows P2 flowing through the process chamber 7. The gas flow is formed by an inert flow gas, i.e. for example argon or nitrogen. The process chamber 7 is thus flown through by the inert gas flow generated by the flow generation device 9. With the gas flow and non-solidified construction material particles resulting related to the process, typically, a particle mixture 10 is formed, which includes at least three construction material fractions 11, 12, 13 differing in at least one construction material particle parameter, especially particle size and/or particle density. The construction material particles resulting related to the process are typically so-called smoke or welding or sintering splashes. The smoke or the welding or sintering splashes comprise a very large range of differently large or dense construction material particles and thus different construction material particle fractions.

[0035] The apparatus 1 further comprises a separation device 14. The separation device 14 is provided for separating the respective construction material particle fractions 11-13 from the particle mixture 10 using visual inspection or inspecting. The separation device 14 comprises three separation sections 15-17 each serving the separation of a certain construction material particle fraction 11-13. Each separation section 15-17 is thus assigned to a certain construction material particle fraction 11-13 that can be separated from the particle mixture 10 using the respective separation section 15-17. The separation of the respective construction material particle fraction 11-13 from the particle mixture 10 is carried out by means of the separation device 14 such that the particle mixture 10 flows through the separation device 14, and that the construction material particles to be assigned to the individual construction material particle fractions 11-13 due to their different construction material particle parameters, especially due to their different particle size or density or the different suspension or layering behavior resulting therefrom can be separated in the respective separation sections 15-17. Typically, the construction material particle fraction 13 with the largest or most dense construction material particles is separated first, then the construction material particle fraction 12 with the second largest or second most dense construction material particles is separated and then the construction material particle fraction 13 with the third largest or third most dense construction material particles is separated.

[0036] A first separation section 15 serves the separation of a first construction material particle fraction 11, which (significantly) includes construction material particles with a particle size or particle density that is in terms of a particle distribution of the construction material 3 defined by a lower and an upper limit particle size or limit particle density lying below the lower limit particle size or particle density. The first construction material particle fraction 11 includes especially the smoke particles. A second separation section 16 serves the separation of a second construction material particle fraction 12, which (significantly) includes construction material particles with a particle size or particle density that is in terms of a particle distribution of the construction material 3 defined by a lower and an upper limit particle size or limit particle density lying between the lower and the upper limit particle size or the limit particle density. The second construction material particle fraction 12 includes especially the, typically already partially molten, undersize particles. A third separation section 17 serves the separation of a third construction material particle fraction 13, which (significantly) includes construction material particles with a particle size or particle density that is in terms of a particle size distribution of the construction material 3 defined by a lower and an upper limit particle size or limit particle density lying above the upper limit particle size or the limit particle density. The third construction material particle fraction 13 includes especially the, typically already partially molten, oversize particles. The terms undersize particles and oversize particles refer to a sieving process usual until now, in which the construction material particles (undersize particles) of the second construction material particle fraction 12 were separated from the construction material particles (oversize particles) of the third construction material particle fraction 13.

[0037] For an exemplary particle size distribution of a construction material 3 having a particle size between 10 and 45 or 50 m the following applies: The first construction material particle fraction 11 includes construction material particles having a particle size below 10 m, the second construction material particle fraction 12 includes construction material particles having a particle size between 10 m and 45 m, and the third construction material particle fraction 13 includes construction material particles having a particle size above 45 m.

[0038] The separation device 14 or the separation sections 15-17 associated with that are arranged or formed in a powder module 18. The powder module 18 is a collector or overflow module, which when performing additive manufacturing processes can be filled with non-solidified construction material 3. The powder module 18 comprises a powder chamber 19, which comprises a powder chamber room 21 defined by powder chamber walls 20. The powder chamber room 21 is at least laterally limited by the powder chamber walls 20. At the bottom, the powder chamber room 21 can be limited by a carrying device (not shown). The carrying device can be a powder chamber plate or a powder chamber table having stored thereon such a plate. The carrying device is typically movably supported between two end positions, i.e. between an upper end position (related to the height of the powder module) and a lower end position, relative to the powder chamber 19; the movable support of the carrying device is typically realized by an especially (electro) motor operated drive or actuator device coupled with the carrying device.

[0039] The first separation section 15, which serves the separation of the first construction material particle fraction 11 from the particle mixture 10, comprises a flow portion 22 flown through by a gas flow, e.g. vertical, which forms an, e.g. vertically, oriented flow channel. The flow portion 22 communicates with a filter device (not shown) that is connected downstream of that portion and is typically also forming a functional component of the apparatus 1. The filter device is provided for separating the construction material particles of the first construction material particle fraction 11 contained in the gas flow from the gas flow by means of filtering. The first separation section 15 is arranged or formed within the process chamber 7 extending at least partially, e.g. vertically, through the process chamber 7.

[0040] Apparently, the first separation section 11 is arranged above the second separation section 12. The construction material particles that can be separated from the particle mixture 10 in the first separation section 11this is typically a gas flow resulting from the particle mixture 10, from which the second and the third construction material particle fraction 12, 13 was already separated by means of the remaining separation sections 16, 17are typically smoke particles, which are separated from the gas flow by means of the filter device.

[0041] The second separation section 16, which serves the separation of the second construction material particle fraction 12 from the particle mixture 10, comprises a separation element 23 arranged within the powder module 18, i.e. within the powder chamber room 21. The separation element 23 defines an upper powder chamber (sub) room lying above said element and a lower powder chamber (sub) room lying below said element.

[0042] In the exemplary embodiment the separation element 23 has, cross-sectionally seen, an L-shaped angled geometric structural design. The long leg 23a of the L is (significantly) oriented horizontally and extends from a first (left) powder chamber wall 20 towards a second (right) powder chamber wall 20 that is arranged opposite said first wall. The short leg 23b of the L is (significantly) oriented vertically. Overall, it is a lying L. With the two legs 23a, 23b of the L and the first powder chamber wall 20 a (pocket-like) collecting section for construction material particles of the second construction material particle fraction 12 to be separated is defined.

[0043] The third separation section 17, which is provided for separating the third construction material particle fraction 13, is arranged or formed below the second separation section 12. More specifically, the third separation section 17 is arranged or formed in the lower powder chamber (sub) room located below the separation element 23. In order to create an access opportunity into the third separation section 17, between the separation element 23, i.e. between the free end of the separation element 23 (formed by the short leg 23b) and the powder chamber wall 20 (opposite said element) a gap 24 is defined that forms an access opportunity into the third separation section 17.

[0044] From the arrangement and formation of the separation sections 15-17 described above it follows that the third separation section 17, especially the gap 24 forming an access opportunity into the third separation section 17, is connected upstream of the second separation section 16 in gas downstream direction, and the second separation section 16 is connected upstream of the first separation section 15 in gas downstream direction. The particle mixture 10 flowing through the separation device 14 thus at first passes the third separation section 17, in which a separation of the third construction material particle fraction 13 is carried out, or the gap 24 forming an access opportunity into the third separation section 17, then passes the second separation section 16, in which a separation of the second construction material particle fraction 12 is carried out, and then passes the first separation section 15, in which a separation of the first construction material particle fraction 11 is carried out.

[0045] The apparatus 1 can optionally comprise an additional flow generation device 25. The additional flow generation device 25 is provided for generating a transport flow influencing the flow of at least the second construction material particle fraction 12 towards the second separation section 12, especially over the gap 24. With the additional flow generation device 25 the flow, especially the flow rate, of the particle mixture 10 flowing through the separation device 14 can specifically be (locally) affected. By a specific impact of the flow of the particle mixture 10, the separation of respective construction material particle fractions 11-13 can in turn specifically be impacted. For example, certain construction material particles, which without impact of the flow of the particle mixture 10 would be separated in the third separation section 17, can be separated by impacting the flow of the particle mixture 10 in the second separation section 16. The additional flow generation device 25 typically comprises at least one, especially nozzle-like, flow generation element (not denoted in more detail), by which a, typically inert, additional protective gas flow can be generated.

[0046] FIG. 2 shows a schematic diagram of an apparatus 1 according to another exemplary embodiment. In contrast to the exemplary embodiment according to FIG. 1, the separation element 23 is here movably supported in one, especially linear, freedom degree of motion relative to the powder chamber wall 20. Accordingly, the gap 24, especially the inner span thereof, can be varied by movements of the separation element 23 relative to the powder chamber wall 20. Consequently, the separation device 14 can be adjusted by varying the gap 24 to different construction material particle fractions 11-13 or to different particle mixtures 10 including different construction material particle fractions 11-13. Movements of the separation element 23 can for example be, as indicated by the double arrow P3, sliding movements along an, especially horizontal, trajectory. Of course, swiveling motions around an, especially horizontally oriented, swiveling axis would also be conceivable. Alternatively or complementary, the separation element could also be movably supported in an, especially linear, freedom degree of motion relative to the bottom of the powder chamber 19. Movements of the separation element 23 can in any case be realized by an, especially (electric) motor operated, drive device (not shown) coupled with said element.

[0047] FIG. 3 shows a schematic diagram of an apparatus 1 according to another exemplary embodiment. In contrast to the exemplary embodiments according to FIG. 1, 2, here the separation element 23 has, cross-sectionally seen, a V-shaped angled geometric structural design. Also with the V-shaped angled geometric design a pocket-like collecting section for construction material particles of the second construction material particle fraction 12 to be separated is defined.

[0048] FIG. 4 shows a schematic diagram of an apparatus 1 according to another exemplary embodiment. In contrast to the exemplary embodiments according to FIG. 1-3, here the separation element 23 has, cross-sectionally seen, a curved geometric structural design. Also with the curved geometric design a pocket-like collecting section for construction material particles of the second construction material particle fraction 12 to be separated is defined.

[0049] With the apparatuses 1 shown in the exemplary embodiments a method for additive manufacturing of three-dimensional components 2 by successive, selective layer-by-layer exposure and thus solidifying construction material layers of a construction material 3 that can be solidified by means of an energy beam 5 in a process chamber 7, wherein the process chamber 7 is flown through by an, especially inert, gas flow generated by a flow generation device 9, wherein with the gas flow and construction material particles resulting related to the process a particle mixture 10 is formed, wherein the particle mixture 10 includes at least three construction material fractions 11-13 differing in at least one construction material particle parameter, especially particle size or particle density can be implemented. The method is characterized in that for separating the respective construction material particle fractions 11-13 from the particle mixture 10 a separation device 14 is used, which is provided for separating the respective construction material particle fractions 11-13 from the particle mixture 10 by means of visual inspection, wherein the separation device 14 comprises at least three separation sections 15-17 each serving the separation of a certain construction material particle fraction 11-13.