Modularly Constructed SLM or SLS Processing Machine

Abstract

A processing machine includes a plurality of radiating modules disposed in a row, and a process chamber module configured to releasably attach to the plurality of radiating modules. The process chamber module includes a process chamber defining a processing field, a construction platform, a powder coater, and a powder reservoir. The powder coater is configured to apply a powder material layer-by-layer in a direction of the construction platform within the processing field. The powder reservoir is configured to infeed the powder material to the powder coater. Each radiating module includes a respective energy beam source configured to generate an energy beam, and a respective beam guide configured to guide the energy beam in a direction of the construction platform within a portion of the processing field. The portions of the processing field of two adjacent radiating modules partially overlap.

Claims

1. A processing machine comprising: a process chamber module comprising: a process chamber defining a processing field, a construction platform, a powder coater configured, during operation of the processing machine, to apply a powder material layer-by-layer in a direction of the construction platform within the processing field, and a powder reservoir configured, during operation of the processing machine, to infeed the powder material to the powder coater; and a plurality of radiating modules, wherein each radiating module comprises: a respective energy beam source configured, during operation of the processing machine, to generate an energy beam, and a respective beam guide arranged, during operation of the processing machine, to guide the energy beam in a direction of the construction platform within a portion of the processing field, wherein the process chamber module is configured to releasably attach to the plurality of radiating modules, the plurality of radiating modules are disposed in a row, and the portions of the processing field of two respective adjacent radiating modules partially overlap.

2. The processing machine of claim 1, wherein a width of the construction platform is approximately equal to a collective width of the portions of processing field of the plurality of radiating modules.

3. The processing machine of claim 1, wherein at least one of the radiating modules is configured to operate as a master module, wherein at least another one of the radiating modules is configured to operate as a slave module, wherein the slave module is controlled by the master module.

4. The processing machine of claim 1, wherein at least one of the radiating modules comprises a respective optical sensor having a detection range, wherein the detection range of the optical sensor of the radiating module at least partially overlaps the portion of the processing field of another radiating module adjacent to the radiating module.

5. The processing machine of claim 1, wherein each radiating module comprises a respective a controller interface configured to connect to a controller interface of another radiating module.

6. The processing machine of claim 1, wherein at least one of the radiating modules or the process chamber module comprises one or more reference structures indicating an attachment position of the process chamber module relative to the plurality of radiating modules.

7. The processing machine of claim 1, wherein the process chamber module is configured to connect, during operation, to one or more supply sources exclusively through at least one radiating module of the plurality of radiating modules.

8. The processing machine of claim 1, wherein at least one of the radiating modules of the plurality of radiating modules comprises a controller, and wherein the process chamber module is connected to the controller.

9. The processing machine of claim 1, wherein the process chamber module defines a process chamber window, wherein the process chamber window is configured, during operation of the processing machine, to receive at least one energy beam from the plurality of radiating modules.

10. The processing machine of claim 1, wherein the process chamber module and/or the at least one radiating module of the plurality of the radiating modules are mounted on rollers or friction bearings.

11. The processing machine of claim 1, wherein the processing machine is a laser processing machine, wherein the energy beam sources of the plurality of radiating modules are lasers, and wherein the beam guides of the plurality of radiating modules are arranged to deflect laser beams generated from the lasers with respect to two-dimensions.

12. The processing machine of claim 1, wherein the process chamber is gas-tight, and wherein the process chamber comprises a gas inlet and a gas outlet.

13. The processing machine of claim 1, wherein the process chamber module comprises: at least one screen inclined at an angle in relation to a horizontal and arranged, during operation of the processing machine, to block at least a portion of the powder material, and at least one collection container disposed below the at least one screen and configured, during operation of the processing machine, to collect at least a portion of the powder material not screened by the screen.

14. The processing machine of claim 13, wherein the at least one screen is mounted so as to be mechanically movable.

15. The processing machine of claim 14, further comprising a drive configured, during operation of the processing machine, to move the at least one screen according to an oscillating pattern.

16. The processing machine of claim 13, wherein the process chamber module comprises: a self-contained powder circuit comprising the at least one screen, and at least one conveying section configured, during operation of the processing device, to infeed the powder material that has been screened by the at least one screen into the powder reservoir.

17. The processing machine of claim 1, further comprising a detector configured, during operation of the processing machine, to detect a quantity of the powder material in the powder reservoir.

18. The processing machine of claim 1, further comprising a closable powder inlet configured, during operation of the processing machine, to infeed powder material in a metered manner into the powder reservoir.

19. The processing machine of claim 1, wherein the construction platform is configured to be separable in a gas-tight manner from other elements of the powder circuit.

20. The processing machine of claim 1, further comprising a plurality of process chamber modules, wherein a width of each process chamber module is different than a width of each other process chamber module, the second process chamber module, and wherein a width of each process chamber module is equal to a collective width of at least some of the radiating modules of the plurality of radiating modules when the at least some are disposed in a row.

21. The processing machine of claim 20, wherein each of the radiating modules of the plurality of radiating modules are of identical construction.

22. A processing machine for producing components by a layer-by-layer construction from a material powder and by a layer-by-layer solidification of the material powder by means of at least one energy beam, comprising powder-conducting elements which comprise at least one process chamber having a construction platform and having a powder coater for the layer-by-layer application of a material powder to the construction platform, and a powder reservoir for the material powder to be infed to the powder coater, at least one energy beam source for generating the at least one energy beam, and at least one beam guide for aligning the at least one energy beam toward the material powder that is applied to the construction platform, wherein the processing machine is releasably assembled from a process chamber module which has all powder-conducting elements of the processing machine and at least one radiating module which includes the at least one energy beam source and the at least one beam guide, wherein the processing machine is releasably assembled from the process chamber module and a plurality of radiating modules that are disposed in a row beside one another, wherein the processing part-fields on the construction platform that are in each case covered by the energy beams of two adjacent radiating modules are partially mutually overlapping.

Description

BRIEF DESCRIPTION OF DRAWINGS

[0026] FIG. 1 is a schematic illustrating an example of an SLS or SLM laser processing machine;

[0027] FIG. 2 is a schematic illustrating an example of a process chamber module and a radiating module from which the laser processing machine of FIG. 1 is releasably assembled;

[0028] FIGS. 3A and 3B are schematics illustrating the process chamber module (FIG. 3A) and the radiating module (FIG. 3B) of the laser processing machine of FIG. 1;

[0029] FIG. 4 is a schematic illustrating an example of a SLS or SLM laser processing machine;

[0030] FIG. 5 is schematic illustrating an example of a process chamber module and two radiating modules from which the laser processing machine in FIG. 4 is releasably assembled;

[0031] FIGS. 6A and 6B are schematics illustrating examples of the process chamber module (FIG. 6A) and the radiating modules (FIG. 6B) of the laser processing machine of FIG. 4;

[0032] FIG. 7 is a schematic illustrating an example of a modular system for assembling laser processing machines; and

[0033] FIG. 8 is a schematic illustrating an example of a process chamber and of a powder recovery/preparation of the process chamber module.

DETAILED DESCRIPTION

[0034] In the description of the figures hereunder, the same reference signs are used for the same or functionally equivalent components, respectively.

[0035] The SLS or SLM laser processing machine 1 shown in FIG. 1 serves for producing components by way of a layer-by-layer construction from a material powder 2 and for the layer-by-layer sintering or melting of the material powder 2 by means of at least one laser beam 3.

[0036] The laser processing machine 1 in a manner known includes powder-conducting elements such as, for example, a process chamber 4 having a construction platform 5 and having a powder coater 6 for the layer-by-layer application of a material powder 2 to the construction platform 5, and a powder reservoir 7 for the material powder 2 that is to be infed to the powder coater, and a powder recovery/preparation 8, as well as non-powder-conducting elements such as, for example, a laser 9 for generating the one laser beam 3, and a deflection unit 10 for aligning the laser beam 3 in a two-dimensional manner to the material powder 2 that is applied to the construction platform 5. The laser 9 and the deflection unit 10 are disposed above the process chamber 4.

[0037] In the laser processing machine 1, a component is constructed layer-by-layer by sintering or melting the material powder 2 by means of the laser beam 3. The material powder 2 is applied all-over to the construction platform 5 by the powder coater 6, and the layers are sintered or melted step-by-step into the powder bed by actuating the laser beam 3 according to the layered contour of the component. The construction platform 5 is subsequently lowered by the amount of a layer thickness, and the material powder 2 is applied from anew. This cycle is repeated until all layers of the component have been sintered or applied by melting, respectively.

[0038] As is shown in FIG. 2, the laser processing machine 1 is releasably assembled from a process chamber module 11.sub.1 and from a radiating module 12, wherein the process chamber module 11.sub.1 shown in FIG. 3A includes all powder-conducting elements, that is to say presently the process chamber 4, the construction platform 5, the powder coater 6, the powder reservoir 7, and the powder recovery/preparation 8, and the radiating module 12 shown in FIG. 3B includes the non-powder-conducting elements, that is to say presently the laser 9 and the beam guide 10. The radiating module 12 is preferably embodied so as to be stationary, while the process chamber module 11.sub.1 is mounted so as to be displaceable on rollers 13. Two side plates 14 between which the process chamber module 11.sub.1 can be plug-fitted to an exact fit are fastened to either side on the radiating module 12. The laser beam 3 that exits in a downward manner from the radiating module 12 is coupled into the process chamber 4 by way of a process chamber window 15 on the upper side. The supply of the process chamber module 11.sub.1 with power, water, controller data, etc., is performed exclusively by way of the radiating module 12, wherein the connectors and interfaces required to this end on the process chamber module 11.sub.1 and on the radiating module 12 are not shown. The process chamber module 11.sub.1 per se does not have any dedicated controller for the production of components but is connected to the controller 16 of the radiating module 12. The radiating module 12 thus controls/regulates not only the laser 9 and the deflection unit 10 but also the powder management in the process chamber 4. Furthermore, an external display/operator panel 17 is attached to the radiation module 12.

[0039] Another laser processing machine 1 which is releasably assembled from a process chamber module 11.sub.2 and two radiating modules 12 is shown in FIG. 4. The radiating modules 12 are of identical construction to the radiating module 12 of FIGS. 1 to 3A and 3B, while the process chamber module 11.sub.2 is embodied so as to be double the width of the process chamber module 11.sub.1 of FIGS. 1 to 3A and 3B. The two radiating modules 12 are fastened to one another in a side-by-side manner, and on the end side each have two side plates 14 between which the process chamber module 11.sub.2 is plug-fitted to an exact fit. The two radiating modules 12, in terms of control technology, are connected in the manner of a master/slave concept and are optically inter-referenced in order for the processing field of the process chamber 4 to be distributed among mutually overlapping processing part-fields 18 of the two laser beams 3 of the radiating modules 12.

[0040] Each radiating module 12 has a controller interface (not shown) for connecting to the controller interface of the other radiating module, so as to interconnect the controllers 16 of the two radiating modules 12. For example, the controller interface can be a wireless interface or an electronic machine interface which is disposed on either side on a radiating module 12, so as to connect to the machine interface of an adjacent radiating module 12. The one radiating module 12 is operated as the master module, and the other radiating module 12 is operated as a slave module that is controlled by the master module.

[0041] The two radiating modules 12 each have one optical sensor 19 (for example a camera), the detection range of said optical sensor 19 being configured for detecting at least part of the processing part-field 18 of the respective other radiating module. For example, the master radiating module 12 by means of the laser beam 3 thereof can thus carry out a processing procedure or illuminate fixed calibration points which in turn are detected by the sensor 19 of the adjacent slave radiating module 12, the latter thus calibrating its own positioning in relation to the master radiating module. In the case of further radiation modules that are lined up beside one another, the next slave radiating module can then be calibrated in relation to an already calibrated slave radiating module and so forth until all slave radiating modules have been calibrated in relation to the master radiating module.

[0042] The supply of the process chamber module 11.sub.2 with power, water, controller data, etc., is performed exclusively by way of the radiating modules 12, wherein the connectors and interfaces required to this end on the process chamber module 11.sub.2 and on the radiating modules 12 are not shown in the drawing. The process chamber module 11.sub.2 per se does not have any dedicated controller but is connected to the master controller 16 of the master radiating module 12. The master controller 16 thus controls/regulates not only the laser 9 and the deflection units 10 of the two radiating modules 12 but also the powder management in the process chamber 4. Furthermore, the external display/operator panel 17 which is used for both radiating modules 12 is attached to the radiating modules 12.

[0043] FIG. 7 shows a modular system 20 for assembling laser processing machines 1, said modular system 20 being composed of a plurality of process chamber modules 11.sub.1, 11.sub.2, 11.sub.3 of different widths, and from a plurality of radiating modules 12 of identical construction. The width of the process chamber module 11.sub.1 herein corresponds to the width of a radiating module 12, the width of the process chamber module 11.sub.2 corresponds to the width of two radiating modules 12, and the width of the process chamber module 11.sub.3 corresponds to the width of n (n≧3) radiating modules 12. Moreover, the modular system 20 also has at least two side plates 14 and at least one external display/operator panel 17. Depending on the desired size of the process chamber, the respective process chamber module 11.sub.1, 11.sub.2, 11.sub.3 is selected, and the respective number of radiating modules 12 are lined up beside one another. In the lining up of the radiating modules 12, the controller 16 of each further connected radiating module 12 follows the controller 16 of the first radiating module 12, the latter thus defining the master module.

[0044] As is shown in FIG. 8, the process chamber 4 of the process chamber modules 11.sub.1 to 11.sub.3, with the exception of a gas inlet 31 and a gas outlet 32, can be embodied so as to be gas-tight, so as to be able to evacuate the process chamber 4 or to purge the process chamber 4 with an inert gas.

[0045] Furthermore, a screen 33 is provided that is inclined at an angle in relation to the horizontal and a collection container 34 is provided that is disposed below the at least one screen 33 in such a manner that material powder 2 that is not capable of being screened moves in a manner aided by gravity along the one screen 33 and is collectable in the collection container 34. The screen 33 is advantageously driven by a drive 35 so as to move in an oscillating manner. The material powder 2 in the process chamber module is conducted in a self-contained powder circuit which includes the at least one screen 33 and at least one conveying section (not shown) for infeeding the material powder 2 that has been screened by the at least one screen 33 into the powder reservoir 7. The construction platform 5 is preferably embodied so as to be separable in a gas-tight manner from other elements of the powder circuit.

[0046] The powder reservoir 7 furthermore includes detection means 36, for example a balance, for detecting the quantity of powder, and a closable powder inlet 37 for infeeding powder in a metered manner into the powder reservoir 7 or into the powder circuit. For example, a cartridge with a material powder 2 can be connected to the powder inlet 37. The detection means 36 weighs the material powder 2 remaining in the powder reservoir 7 or powder circuit, respectively, following the production of a component, and opens the powder inlet 37 on demand.

[0047] Moreover, supply stations (not shown) to which the process chamber module 11.sub.1 to 11.sub.3 can be connected and which, like the radiating module 12, have a power, water, gas, and/or data connector, can be provided. Powder preheating/component cooling can be carried out with power in a regulated manner by the process chamber 4; water can likewise be used for the cooling of components or for cooling other elements of the process chamber. This function can be performed either by a simple controller in the process chamber 4 or by controlling the supply station via a data connector. The gas connector can provide a protective gas atmosphere in the process chamber 4, for example when the component is to be retrieved.

[0048] Whether controllers required for the process chamber modules are accommodated in this module or in the radiating modules and supply stations depends in particular on whether the radiating modules are rather used in a docked manner as a master and slave, or rather used individually. However, there will usually be more process chamber modules than radiating modules, since the process chamber modules are preferably always used for only one material, and only those process chamber modules are used with the materials required at any given time. There will furthermore be process chamber modules in which the component is being cooled or powder is being preheated. It can thus be more favorable for only the radiating stations to be equipped with a controller for the application of powder in the process chamber module than for all process chamber modules to be thus equipped. The same applies in an analogous manner to controllers for other functions of the powder circuit/heaters, etc. In the case of very wide process chamber modules, in which a plurality of radiating modules are always required, it would however be more favorable for only the process chamber modules to be equipped with controllers for the process chamber module rather than for each radiating module to be thus equipped. It can also be advantageous for the controller to be embodied so as to be modular, and for the radiating modules or the process chamber modules to be equipped with controllers, depending on production.

[0049] A number of embodiments have been described. Nevertheless, it will be understood that various modifications may be made without departing from the spirit and scope of the invention. Accordingly, other embodiments are within the scope of the following claims.