Method, Device, and Recoating Module for Producing a Three-Dimensional Object

Abstract

A method (V) for producing a three-dimensional object (2) by applying and selectively solidifying a powdery construction material (13) layer by layer includes the steps: a) applying (Z) a layer of the construction material (13) onto a construction field in a working plane (10) by means of a recoating device (14) moving in a moving direction (B) over the working plane, b) selectively solidifying (Y) the applied layer of the construction material (13) at positions, which correspond to a cross-section of the object (2) to be produced, and c) repeating (X) the steps a) and b) until the object is completed.

The construction material is stored during step a) in a recoating unit (40a-e) arranged at the recoating device (14) within a space between two recoating elements (42a, 42b) mutually spaced apart from each other in the moving direction of the recoating device. At least one recoating element (42b) arranged rearward with respect to the moving direction (B) of the recoating device (14) includes a roller (43a, 43b), by means of which the construction material is applied to the working plane.

Claims

1. A method for producing a three-dimensional object by applying and selectively solidifying a powdery construction material layer by layer, including the steps: a) applying a layer of the construction material onto a construction field in a working plane by means of a recoating device moving in a moving direction over the working plane, b) selectively solidifying the applied layer of the construction material at positions, which correspond to a cross-section of the object to be produced, and c) repeating the steps a) and b) until the object is completed, wherein the construction material is stored during step a) in a recoating unit arranged at the recoating device within a space between two recoating elements mutually spaced apart from each other in the moving direction of the recoating device, and at least one recoating element arranged rearward with respect to the moving direction of the recoating device includes a roller, by means of which the construction material is applied to the working plane.

2. A method according to claim 1, wherein the roller is rotated during step a), preferably in such a manner, that its moving direction at the surface of the powder layer is equal to the moving direction of the recoating device.

3. A method according to claim 1, wherein the recoating element, which comprises the roller by means of which the construction material is applied to the working plane, further contains a stripping element, which strips powder adhering to the roller from the roller.

4. A method according to claim 1, wherein the recoating element, which comprises the roller by means of which the construction material is applied to the working plane, further contains a blade device arranged rearward of the roller of the recoating device in the moving direction, which densities the powder.

5. A method according to claim 4, wherein the blade device includes a surface at its bottom side substantially facing the working plane, which is at least in a region thereof oblique with respect to the working plane, and which preferably slopes upwards in a direction towards the associated roller.

6. A method according to claim 1, wherein the recoating element, which is arranged frontward in the moving direction of the recoating device, is formed to be substantially mirror-symmetric with respect to the rearward recoating element.

7. A method according to claim 1, wherein the recoating element, which is arranged frontward in the moving direction of the recoating device, includes a roller, the diameter and/or the rotational velocity and/or the surface characteristics of which is different from the roller of the rearward recoating element.

8. A method according to claim 1, wherein the recoating element which is arranged frontward in the moving direction of the recoating device includes a blade device and no roller.

9. A method according to claim 8, wherein the blade device includes at its bottom side, which substantially faces the working plane, a surface, which is at least in a region thereof oblique with respect to the working plane, and which slopes upwards in a direction towards the rearward recoating element.

10. A method according to claim 1, wherein the frontward and/or the rearward recoating element is height-adjustable completely or in parts.

11. A method according to claim 1, wherein the roller of the frontward and/or rearward recoating element is arranged to be heated.

12. A method according to claim 1, wherein the space arranged between the recoating elements is sized in order to receive an amount of the powdery construction material, which amount is at least sufficient to apply one powder layer, preferably sufficient to apply multiple powder layers.

13. A recoating module for equipping and/or retrofitting a device for producing a three-dimensional object by applying and selectively solidifying a powdery construction material layer by layer, wherein the device comprises: a recoating device suitable for receiving the recoating module and being movable over the working plane for a) applying a layer of the construction material onto a construction field within a working plane, and a solidification device for b) selectively solidifying the applied layer of the construction material at positions, which correspond to a cross-section of the object to be produced, wherein the device is arranged and/or controlled to repeat the steps a) and b) until the object is completed, wherein in the recoating module the construction material is stored within a space between two recoating elements mutually spaced apart from each other in the moving direction of the recoating device, and at least one recoating element, which is arranged rearward in the moving direction of the recoating device, comprises a roller, by means of which the construction material can be applied onto the working plane.

14. A device for producing a three-dimensional object by applying and selectively solidifying a powdery construction material layer by layer, comprising: a recoating device movable over a working plane for a) applying a layer of the construction material onto a construction field within the working plane, and a solidification device for b) selectively solidifying the applied layer of the construction material at positions, which correspond to a cross-section of the object to be produced, wherein the device is arranged and/or controlled to repeat the steps a) and b) until the object is completed, and the recoating device includes a recoating unit in which the construction material is stored within a space between two recoating elements mutually spaced apart from each other in the moving direction of the recoating device, and at least one recoating element, which is arranged rearward in the moving direction of the recoating device includes a roller, by means of which the construction material can be applied to the working plane.

15. A device according to claim 14, wherein the recoating unit is a replaceable recoating module.

Description

[0023] Further features and advantages of the invention are derived from the specification of embodiments by means of the appended drawings.

[0024] FIG. 1 is a schematical view partially illustrated in cross-section of an embodiment of a device for producing a three-dimensional object layer by layer, which is suitable to perform a method according to the invention.

[0025] FIG. 2 is a schematical perspective view of a recoating unit according to a first embodiment of the present invention.

[0026] FIG. 3 is a schematical perspective view of a recoating unit according to a second embodiment of the present invention.

[0027] FIG. 4 is a schematical perspective view of a recoating unit according to a modification of the second embodiment.

[0028] FIG. 5 is a schematical perspective view of a recoating unit according to a third embodiment of the present invention.

[0029] FIG. 6 is a schematical perspective view of a recoating unit according to a fourth embodiment of the present invention.

[0030] FIG. 7 is a schematical block view of the procedural flow of an embodiment of a method according to the invention.

[0031] In the following, an embodiment of a device 1 is explained with reference to FIG. 1, which device 1 is suitable to perform a method according to the invention. The device illustrated in FIG. 1 is a laser sintering or laser melting device 1. In order to construct an object 2, it includes a process chamber 3 having a chamber wall 4.

[0032] In the process chamber 3 a container 5 which is open at the top is arranged having a wall 6. In the container 5 a carrier 7 is arranged being movable in a vertical direction V and at which is mounted a base plate 8, which closes the container 5 at the bottom and thereby forms its base. The base plate 8 may be a plate formed separately from the carrier 7 and which is mounted at the carrier 7, or it may be formed integrally with the carrier 7. Depending on the powder used and the process performed, a construction platform 9 on which the object 2 is constructed may be mounted to the base plate 8. The object 2 may, however, also be constructed on the base plate 8 itself, which then serves as a construction platform. In FIG. 1 the object 2 to be formed in the container 5 on the construction platform 9 is illustrated below a working plane 10 in an intermediate state including multiple solidified layers, surrounded by remaining non-solidified construction material 11.

[0033] The laser sintering device 1 further contains a storage container 12 for receiving a powdery construction material 13 which is solidifiable by means of electromagnetic radiation, and a recoater 14 movable in a horizontal direction H for application of the construction material 13 onto the working plane 10. At its topside the wall 4 of the process chamber 3 includes a coupling-in-window 15 for the radiation 22 which serves to solidify the powder 13.

[0034] The laser sintering device 1 further contains an exposure device 20 having a laser 21, which generates a laser beam 22, which is re-directed through a re-direction device 23 and focused through the coupling-in-window 15 onto the working plane 10 by means of a focusing device 24.

[0035] Further, the laser sintering device 1 includes a control unit 29, by means of which the individual constituent parts of the device 1 are controlled in a coordinated manner in order to perform the construction process. The control unit may include a CPU, which is operated and controlled by a computer program (software). The computer program may be stored separately from the device on a storage medium, from which it may be loaded into the device, particularly into the control unit.

[0036] FIG. 2 shows a schematical perspective view of a recoating unit 40a which is included in the recoater 14.

[0037] The recoating unit 40a contains a holder 41, through which it can be mounted at the re-coater 14 (for example at an actuator unit of the recoater 14 not being illustrated). The recoating unit 40a further contains two substantially parallel and plate-shaped recoating elements 42a, 42b, which extend substantially perpendicular to the working plane 10 and perpendicular to the moving direction B of the recoater 14, and which are mutually spaced apart in the moving direction B of the recoater 14. In FIGS. 2 through 6 the moving direction B of the recoater 14 extends transversely into the plane of the drawing, such that the recoating element 42a is the forward recoating element in the movement direction B and the recoating element 42b is the rearward recoating element.

[0038] Both recoating elements 42a, 42b being mutually spaced apart from each other delimit a space in and against the moving direction B, respectively, and which serves to receive powdery construction material 13 from the storage container 12. This space is also limited in a direction transverse to the moving direction B, which is, however, not shown in the figures for the purpose of clarity. The space arranged between the recoating elements 42a, 42b is large enough in order to receive an amount of powder, which amount is sufficient to apply at least one powder layer, preferably to apply multiple layers.

[0039] In order to apply the powder received in the space between the recoating elements 42a, 42b, i.e., construction material 13, onto the working plane 10, each recoating element includes at its bottom side (i.e., the side facing into the direction of the working plane 10) a rotatably supported roller 43a, 43b, having a longitudinal axis (=rotational axis) extending parallel to the working plane 10 and transverse to the moving direction B of the recoater 14. Moreover, strippers 44a, 44b are arranged at the inner faces of each recoating element 42, 42b (i.e., on a side facing towards the other recoating element, respectively), for example in the form of thin metal sheets or Kapton strips, which bridge the gap above the rollers 43a, 43b. Finally, a drive (not shown in the figures, for example a motor-based drive, a gear rack drive or a wire drive) is provided in order to effect rotation of the rollers 43a, 43b.

[0040] In operation, in order to apply a powder layer, the carrier 7 is at first lowered by a height difference, which corresponds to the desired layer thickness. Employing the recoater 14 a layer of the powdery construction material 13 is then applied. The application is carried out at least over the whole cross-section of the object 2 to be produced, preferably over the complete construction field, i.e., the region of the working plane 10 which is positioned within the top opening of the container 5. Subsequently, the cross-section of the object 2 to be produced is scanned by the laser beam 22, such that the powdery construction material 13 is solidified at positions, which correspond to the cross-section of the object 2 to be produced. These steps are repeated until the object 2 is completed and can be removed from the construction space.

[0041] The application of the powder layer is carried out by moving the recoater 14 horizontally in the moving direction B over the working plane 10. Therein, it is at first moved to the storage container 12, where it receives a predetermined amount of powder and stores it within the space between the recoating elements 42a, 42b. Thereafter it is moved over the construction field. Thereby, a layer of the powdery construction material 13 received between the recoating elements 42a, 42b remains on the construction field, wherein the thickness of the layer corresponds to the vertical distance between the bottom side of the rollers 43a, 43b and the topside of the carrier 7 or of the layer which has previously been applied, i.e., the height difference by which the carrier has previously been lowered. Since the space arranged between the recoating elements 42a, 42b is large enough in order to receive an amount of powder, which is sufficient to at least apply one powder layer, preferably to apply multiple layers, it is possible to perform one, or multiple application movements without a necessity to be moved back intermittently to the storage container 12 for receiving new powder.

[0042] During the movement of the recoater 14 the rollers 43a, 43b are effected to be rotated. By means of this a homogenously smoothened layer is achieved. The strippers thereby prevent that due to the rotation of the rollers powder accesses the previously applied and smoothened layer from the highest point at the roller (or a higher position, respectively).

[0043] The rotational velocity of the rollers is preferably adjustable in a stepless manner. The direction of rotation is thereby selected such that the moving direction of the rollers at the surface of the powder is equal to the moving direction of the recoater 14 (so-called counter-rotating roller). The shear effect achieved thereby increases the effect of breaking-up the agglomerates.

[0044] Since the roller in the recoating unit does not have an object to transport powder from a storage container over the complete construction field, but rather the powder is supplied from a top direction via the intermediate space between both recoating elements, the roller diameter may considerably be reduced as compared with the afore-mentioned prior art and the values which had been disclosed therein ranging from 50 mm up to 80 mm, are reduced for example to 10 mm to 18 mm.

[0045] The recoating unit 40a shown in FIG. 2 is formed to be substantially mirror-symmetric. Thus, an application may be carried out opposite to the moving direction B shown in FIG. 2 in the same manner as in the moving direction B.

[0046] Both recoating elements of the recoating unit 40a may, however, also include rollers which are different from each other, which may for example deviate from each other in its diameter and/or its rotational velocity and/or its surface characteristics. By means of that, different kinds of layer applications may be performed depending on the recoating device direction. For example, a pre-application of a layer can be effected initially in one direction of the recoating device, and subsequently a post-application of a layer may then be effected in the opposite direction, which are both carried out with distinct parameters.

[0047] FIG. 3 shows an recoating unit 40b according to a second embodiment. This recoating unit 40b deviates from the recoating unit 40a shown in FIG. 2 in that only the rearward recoating element 42b as seen in the moving direction B of the recoater 14 contains a roller 43b, but the frontward recoating element 42a does not contain a roller.

[0048] The frontward recoating element 42b instead includes a blade device 45a, which in the simplest case as shown in the figure, is formed by a prolongation of the plate-shaped recoating element 42a into the bottom direction. This blade may serve on the one side to smoothen the solidified sections of the previous powder layer and to remove projecting parts. On the other side, however, different kinds of layer applications may be performed depending on the recoating device direction similar to the afore-mentioned unsymmetric arrangement of the recoating unit 40a.

[0049] In the recoating unit 40b shown in FIG. 3 the bottom side 46a of the blade device 45a facing the working plane 10 is parallel to the working plane 10. Thus, a low-shear powder application without densification can be achieved.

[0050] In an recoating unit 40c shown in FIG. 4 according to a modification of the second embodiment, the bottom side 46b of the blade device 45b facing the working plane 10 extends at an angle with respect to the working plane 10. Therein, the bottom side slopes upwards in the direction towards the rear recoating element 42, i.e., opposite to the recoating device direction B shown in FIG. 4. Thus, upon application of a layer opposite to direction B, i.e., a powder application by the blade device 45b, a densification of the applied powder is achieved.

[0051] The bottom side of the blade device may also be arranged such that it includes a section extending parallel to the working plane as well as a section extending at an angle with respect to the working plane. In addition to an inclined face, the section not extending parallel to the working plane or the whole bottom side of the blade device may also include a convex rounding, or a multiple-edged surface adapted to a convex rounding.

[0052] The expression “blade device” is herein not restricted to a prolongation of the plate-shaped recoating element 42a into a bottom direction. A blade device may rather also include a separate blade, a ridge, a knife, a brush, a doctor blade, or the like.

[0053] FIG. 5 shows an recoating unit 40d according to a third embodiment. This recoating unit 40d deviates from the recoating unit 40a shown in FIG. 2 in that both recoating elements 42a, 42b each include an additional blade device 47a, 47b at their outer faces facing away from each other. The bottom sides 48a, 48b of the additional blade devices 47a, 47b are positioned lower than the bottom sides of the rollers 43a, 43b by a predetermined height value. Since the blade devices 47a, 47b are positioned rearward of the rollers in case of a powder application using the rollers (in the application direction B for the roller 43b, and opposite to the application direction B for the roller 43a), these blade devices 47a, 47b may serve to further densify the powder layer applied by the rollers.

[0054] Similar to the recoating units 40b and 40c, each of the bottom sides of the additional blade devices may be arranged such that these are parallel to the working plane (as shown in FIG. 5 with respect to the example of the bottom side 48b of the blade device 47b), such that these extend at an angle with respect to the working plane (as shown with respect to the example of the bottom side 48a of the blade device 47a, which is sloped upwards in a direction towards the associated roller 43a), or such that these include a section extending parallel to the working plane as well as a section extending at an angle with respect to the working plane. Thus, the same effects as shown with respect to the recoating units 40b and 40c are achieved.

[0055] In addition to an inclined face, the section extending not parallel to the working plane, or the whole bottom side of the blade device may also include a convex rounding or a multiple-edged surface adapted to a convex rounding. Also herein, the expression “blade device” may include a blade, a ridge, a knife, a brush, a doctor blade or the like.

[0056] Similar to the recoating unit 40a shown in FIG. 2 also the recoating unit 40e may be arranged to be substantially mirror-symmetric, or may include rollers deviating from each other.

[0057] FIG. 6 shows a recoating unit 40e according to a fourth embodiment. In the recoating unit 40e the recoating element 42b includes an additional blade device 47b as shown with respect to the recoating unit 40d shown in FIG. 5, while the recoating element 42a includes only a blade device 45b instead of a roller as shown with respect to the recoating unit 40c shown in FIG. 4.

[0058] Also in other cases features of the various embodiments may be combined with each other where appropriate.

[0059] In the above-described embodiments the recoating unit is described in each case as a replaceable recoating module, which is mounted at the recoater and may be released from the same. However, the recoating unit may also be formed integrally with the recoater.

[0060] The arrangement as a replaceable recoater module has, however, an additional advantage in that different recoater modules according to the above-described embodiments may be provided and can be quickly and flexibly replaced with each other. Besides mechanical quantities such as the distance between the recoating elements or the diameter of the rollers also the surface characteristics of the rollers or the achievable roller temperatures or rotational velocities may for example be varied. Therein, the recoating module to be used may be selected according to the kind of the powder used.

[0061] The shape of the recoating elements is not restricted to the described plate shapes and the orientation perpendicular to the working plane. The recoating elements may have an arbitrary shape and position, which are suitable to limit a space for receiving a powdery construction material. In particular, the lateral limitation of the powder storage in and/or opposite to the movement direction of the recoater may also be solely formed by the roller, if it has a sufficiently large diameter.

[0062] One of the recoating elements or both may be arranged to be height-adjustable.

[0063] A roller or both rollers may be arranged to be heated.

[0064] FIG. 7 shows in a schematical block illustration the procedural flow of an embodiment of a method V according to the invention. Therein it is referred to the numerals in the previous figures. In a first step Z a layer of construction material 13 is applied to a construction field within a working plane 10 by means of an recoating device 14 (according to the invention) moving in a moving direction B over the working plane 10. In a second step Y the applied layer of the construction material 13 is selectively solidified at positions which correspond to a cross-section of the object 2 to be produced. Both steps Z and Y are repeated by repetitions X until the object 2 is finished. This finishing is denoted as a last step W.

[0065] Even when the present invention has been explained by means of a laser sintering device or a laser melting device, respectively, it is not restricted to laser sintering or laser melting. it can rather also be applied to arbitrary methods for producing a three-dimensional object by applying and selectively solidifying a powdery construction material layer by layer.

[0066] The laser may for example comprise a gas or solid body laser or any other kind of laser. Generally, any device can be used to selectively input energy onto a layer of the construction material. Instead of a laser an electron beam or any other energy or radiation source may be used, which is suitable to solidify the construction material. The invention may also be applied to the selective mask sintering, wherein an extended light source and a mask are used, or may be applied to the absorption or inhibition sintering, respectively.

[0067] Instead of inputting energy, the selective solidification of the applied construction material may also be performed by means of 3D-printing, for example by applying an adhesive. Generally the invention is related to the production of an object by means of applying and selectively solidifying a powdery construction material layer by layer independent from the kind and manner in which the construction material is solidified.

[0068] Various kinds of powder may be used, in particular metal powder, plastic powder, ceramic powder, sand, filled or mixed powders.