Manufacturing system and method for separating at least one component made from powder material and powder material

Abstract

Manufacturing system (1) for separating at least one component (4) made from powder material (2) and powder material (2), comprising - a trial chamber (6), - Fluid supply means (8) which are arranged and configured to supply the powder material within the process chamber (6) with a fluid such that the powder material forms a fluidized bed (14) with the fluid, and - Disposal equipment arranged and designed to dispose of the fluidized bed (14) from the process chamber (6), - wherein the disposal means have at least one disposal opening (22, 26) which is arranged and designed to discharge the fluidized bed (14) from the process chamber (6), and - wherein at least one disposal opening (22, 26) is arranged laterally, - characterized in that the process chamber has a base plate through which the fluid is supplied, and - characterized by a tilting unit which is arranged and designed to tilt the process chamber about a horizontal axis.

Description

[0001] The invention relates to a manufacturing system and a method for separating at least one component made from powder material and the powder material.

[0002] Manufacturing systems for producing components from powder materials are generally known. These systems employ so-called additive manufacturing processes to produce components layer by layer. One example of an additive manufacturing process is binder jetting (BJ). The importance of binder jetting is continuously increasing because it is suitable for producing small, precise, and complex components at higher production rates.

[0003] In binder jetting, a powder layer is applied to a surface using a recoater, and then a binder is applied to or embedded in the powder layer using a printhead. This selectively bonds the individual powder particles within the layer. This coating and printing process is repeated multiple times to create the component. When using a metallic powder material, this process is also known as metal binder jetting (MBJ).

[0004] After the component has been produced in this way, it is usually cured in an oven. The components are then cleaned of excess powder, debound, and sintered.

[0005] Along the binder jetting process chain, depowdering is currently performed predominantly manually. For reasons of efficiency, quality, and operator safety, it is desirable to automate this process step. The challenge of automation lies in the complexity and instability of the components produced by binder jetting, which typically begin as green compacts that are prone to abrasion, cracking, and / or breakage.

[0006] WO 2017 / 198 335 A1 describes a device and a method for depowdering a component manufactured using a rapid prototyping process, wherein the component is subjected to ultrasonic vibrations to remove the powder material. Furthermore, according to WO 2020 / 056 355 A1, the powder can be removed using compressed air and / or vacuum technology. EP 3144081B1 describes a method using magnetorheological fluids. DE 20 2020 004 634 U1 describes a sandblasting process. The approaches mentioned above either reduce the quality of the component or involve a high degree of manual labor. DE 10 2012 106 141 A1 discloses a method for unpacking a component manufactured using an additive manufacturing process. DE 199 37 260 A1 discloses a method for producing a three-dimensional object in several steps.US patent 2021 / 0060651 A1 discloses techniques for depowdering additively manufactured components. DE 102018200588 A1 discloses a method and a device for manufacturing sand components. AT 520736 A4 discloses a method for unpacking a 3D printed part.

[0007] It is therefore an object of the invention to provide a manufacturing system and a method for separating at least one component manufactured from powder material and the powder material, which reduce or eliminate one or more of the aforementioned disadvantages. In particular, it is an object of the invention to provide a solution with which powder material can be removed from a manufactured component, enabling high component quality, a high degree of automation, and / or a low health risk to the operator.

[0008] This problem is solved by a manufacturing system and a method according to the features of the independent claims. Further advantageous embodiments of these aspects are specified in the dependent claims. The features listed individually in the claims and the description can be combined with one another in any technologically meaningful way, and further embodiments of the invention are shown.

[0009] According to a first aspect of the invention, the aforementioned problem is solved by a manufacturing system for separating at least one component made of powder material and powder material, comprising a process chamber, fluid supply means arranged and configured to supply the powder material within the process chamber with a fluid such that the powder material forms a fluidized bed with the fluid, and disposal means arranged and configured to dispose of the fluidized bed from the process chamber, wherein the disposal means have at least one disposal opening arranged and configured to discharge the fluidized bed from the process chamber, and wherein the at least one disposal opening is arranged laterally, characterized in that the process chamber has a base plate through which the fluid is supplied, and characterized by a tilting unit arranged and configuredto tilt the process chamber around a horizontal axis.

[0010] The invention is based on the finding that a fluidized bed can be formed by introducing a fluid into the essentially unconnected powder particles of the powder material, and that this fluidized bed can advantageously be removed from the process chamber. Thus, the powder material can be automatically conveyed out of the process chamber. Furthermore, the at least one manufactured component is essentially free of powder material and can be removed for a subsequent process, such as curing.

[0011] In particular, the at least one manufactured component contains essentially no or very little loose powder material, so that the at least one manufactured component can be fed into further process steps with little or no further manual intervention. The inventors have also found that the quality of the component produced in this way is high. Furthermore, it has been shown that such a manufacturing system is essentially fully automatable.

[0012] The manufacturing system includes the process chamber. The process chamber can, for example, be a build chamber. The component can be manufactured within the process chamber using the powder material. Alternatively, the process chamber can be a space within a station independent of the manufacturing machine. The process chamber can essentially consist of a base plate through which the fluid is supplied, so that the chamber has essentially no lateral boundaries.

[0013] The process chamber preferably has a lowerable table with which the bottom of the process chamber can be successively lowered, in particular by a layer thickness. The process chamber can comprise several chamber elements, for example walls and / or a bottom. The joints of the chamber elements are preferably sealed. The process chamber can essentially have a bottom plate through which the fluid is supplied.

[0014] The manufacturing system also includes fluid supply means. These fluid supply means are arranged and designed to supply the powder material within the process chamber with the fluid. This can be achieved, in particular, by creating a fluidized bed between the powder material and the fluid. The formation of a fluidized bed between the powder material and the fluid can, in particular, mean that the powder material is fluidized.

[0015] The fluidized bed is understood to be a mixture of powder material and fluid. The fluid can be, for example, air, nitrogen, argon, and / or water. The fluid supply means can include, for example, a compressed air connection, which is arranged and configured such that compressed air is introduced into the powder material within the process chamber, thus forming the fluidized bed. The fluid can be introduced into the process chamber, in particular, through a base. Alternatively or additionally, the fluid can be introduced through a side wall of the process chamber.

[0016] The manufacturing system also includes the disposal means. These means are arranged and designed to remove the fluidized bed from the process chamber. The disposal means can, for example, be designed as a disposal mechanism. As explained in more detail below, the disposal means can, for instance, be designed as or encompass a disposal opening, allowing the fluidized bed to be conveyed from the process chamber by gravity through this opening.

[0017] A preferred embodiment of the manufacturing system comprises a control device configured to control the fluid supply means such that the fluid has a predefined flow velocity. The fluid flows around the powder and, above a certain flow velocity, generates the fluidized bed. It is particularly preferred that the control device determines the predefined flow velocity depending on a property of the powder material. For example, the powder particle size of the powder material can influence the flow velocity required to form the fluidized bed. Furthermore, the property can be the height of the remaining powder cake, the shape and / or roundness of the powder particles, contamination of the powder with binder, or a property of the curing process, such as temperature and the time between printing and unpacking.

[0018] The control device is coupled to the fluid supply means and / or the disposal means, for example via signal technology.

[0019] Another preferred embodiment of the manufacturing system is characterized in that the fluid supply means include a fluid flow device which is arranged and configured to supply the fluid, in particular at the predefined flow velocity. The fluid flow device may, for example, be a compressed air source, a compressed gas cylinder, a fan and / or a compressor, or comprise one or more of the aforementioned.

[0020] A further preferred embodiment of the manufacturing system is characterized by the fact that the fluid supply means are arranged and configured to provide the fluid with continuous and / or pulsed flow energy. Pulsed fluid flow energy can be set, for example, using a pneumatic control unit. Pulsed fluid flow energy can better loosen adhering or hard-to-reach powder material.

[0021] In another preferred embodiment of the manufacturing system, the fluid supply means are provided to have a fluid-permeable element adjacent to the process chamber, which is arranged and designed to direct the fluid into the process chamber.

[0022] The fluid-permeable element can, for example, be a plate. It is particularly preferred that the fluid-permeable element is designed such that it allows the fluid to pass through in a first direction and essentially prevents the powder material from passing through in a second direction opposite to the first.

[0023] It is further preferred that the fluid-permeable element forms at least a section of the bottom of the process chamber. It is also preferred that the fluid-permeable element forms substantially the entire bottom. The bottom of the process chamber is to be understood in particular as a horizontally oriented section of the process chamber on which the component and the powder material are manufactured or applied. It is further preferred that, in normal operation, the fluid-permeable element directly abuts the powder bed and / or delimits it on at least one side.

[0024] Furthermore, it is preferred that the fluid-permeable element is arranged between the process chamber and a fluid distribution chamber, wherein the fluid can be provided in the fluid distribution chamber.

[0025] Preferably, the fluid-permeable element is arranged vertically below the process chamber. Furthermore, the fluid distribution chamber is preferably arranged vertically below both the fluid-permeable element and the process chamber. Thus, a fluid can be supplied within the fluid distribution chamber, for example via a compressed air connection, which is forced through the fluid-permeable element and into the process chamber by pressure. The fluid distribution chamber is preferably fluidically coupled to a compressed air connection, the outlet of which opens into the fluid distribution chamber.

[0026] Another preferred embodiment provides that the fluid-permeable element consists of or comprises a porous material. For example, the fluid-permeable element can be or comprise a composite material.

[0027] The fluid-permeable element preferably has a plurality of openings through which the fluid can pass. It is particularly preferred that the opening diameter of the openings is smaller than the diameter of powder particles.

[0028] Another preferred embodiment of the manufacturing system is characterized by the fact that the fluid supply means have at least one fluid supply line which is arranged and designed to direct the fluid into the process chamber.

[0029] The at least one fluid supply line can be provided as an alternative or supplement to the fluid-permeable element described above. It is particularly preferred that a plurality of fluid supply lines are provided for directing the fluid into the process chamber. At least one fluid supply line can, for example, be routed through the bottom of the process chamber.

[0030] Another preferred embodiment of the manufacturing system is characterized by the fact that the disposal means have at least one disposal opening which is arranged and designed to direct the fluidized bed out of the process chamber.

[0031] The disposal opening can be designed, for example, as a disposal channel or a disposal pipe. The disposal opening is preferably closable and / or openable. The fluidized bed, which exhibits fluidic properties, can be disposed of by gravity through such a disposal opening.

[0032] It is preferred that the at least one disposal opening extends through the fluid distribution chamber. If the fluid distribution chamber is arranged vertically below the process chamber, such an arrangement of the at least one disposal opening enables a compact design.

[0033] By designing the disposal opening as a disposal line extending through the fluid distribution chamber, the fluidized bed can be disposed of from the process chamber, even though the fluid distribution chamber is located below the process chamber, which is advantageous for forming an efficient fluidized bed.

[0034] Furthermore, preferably the at least one disposal opening extends through the fluid-permeable element and through the fluid distribution chamber.

[0035] Another preferred embodiment of the manufacturing system is characterized by the fact that the disposal means have at least one disposal flap with which the at least one disposal opening can be opened and closed.

[0036] It is particularly preferred that the at least one disposal flap can be used to close one outlet of the disposal opening. In a further preferred embodiment of the manufacturing system, the at least one disposal flap is arranged and designed to openably close a lateral disposal opening of the process chamber, so that the fluidized bed can be discharged by gravity through the disposal opening when the closure element is open. The lateral disposal opening is preferably arranged adjacent to the bottom of the process chamber, so that a large proportion of the fluidized bed can be discharged from the process chamber by gravity.

[0037] Furthermore, it may be preferred that the at least one disposal flap is arranged and designed to openably close a disposal opening located in the bottom of the process chamber, so that the fluidized bed can be disposed of by gravity through the disposal opening when the closure element is open.

[0038] A preferred embodiment of the manufacturing system is characterized by the fact that the at least one disposal flap is coupled to the control device via a signal connection, and the control device is configured to close and / or open the disposal opening with the disposal flap. The disposal flap preferably includes a drive mechanism.

[0039] Furthermore, it is preferred that the manufacturing system includes an extraction unit arranged and designed to extract the fluidized bed from the process chamber. Such an extraction unit has the advantage that the fluidized bed can be disposed of from the process chamber essentially completely.

[0040] In a further preferred embodiment of the manufacturing system, the process chamber is arranged to be tiltable in the direction of the at least one disposal opening. For this purpose, the manufacturing system preferably includes a tilting unit designed and configured to tilt the process chamber about a horizontal axis. Furthermore, it is preferred that the process chamber be arranged to rotate.

[0041] Another preferred embodiment of the manufacturing system comprises a solidification unit for bonding powder particles contained in the powder material. It is particularly preferred that the solidification unit is designed to apply a binder to a powder bed surface. Preferably, the solidification unit includes a print head.

[0042] According to another aspect, the aforementioned task is solved by a method for separating at least one component made of powder material and the powder material in a process chamber of a manufacturing system according to one of the previously described embodiments, comprising the steps of: applying a fluid to the powder material in such a way that the powder material forms a fluidized bed with the fluid, and disposing of the fluidized bed from the process chamber through a lateral disposal opening.

[0043] The powder material is treated with the fluid, particularly after the production of at least one component. Production is preferably carried out using a binder jetting technology.

[0044] The process and its possible further developments exhibit characteristics and process steps that make them particularly suitable for use in the manufacturing system and its further developments. For further advantages, implementation variants, and implementation details of the process and its possible further developments, please also refer to the previously provided description of the corresponding characteristics and further developments of the manufacturing system.

[0045] Preferred embodiments are explained by way of example with reference to the accompanying figures: They show: Fig. 1: a schematic, two-dimensional view of an exemplary embodiment of a manufacturing system; Fig. 2: a schematic, two-dimensional view of another exemplary embodiment of a manufacturing system; Fig. 3: a schematic, two-dimensional view of another exemplary embodiment of a manufacturing system with a tilting unit; Fig. 4: a schematic, two-dimensional view of another exemplary embodiment of a manufacturing system with a closed disposal flap; Fig. 5: a schematic, two-dimensional view of the in Fig. 4. Manufacturing system shown with an open disposal flap; and Fig. 6: A schematic view of an exemplary procedure.

[0046] In the figures, identical or essentially functionally identical or similar elements are designated with the same reference symbols.

[0047] Fig. Figure 1 shows a manufacturing system 1 for separating a total of six components 4 made from powder material 2 and powder material 2. The manufacturing system 1 includes a process chamber 6 in which the components 4 are manufactured with the powder material 2.

[0048] Manufacturing system 1 includes fluid supply means, which here are designed, among other things, as a fluid supply line 10 to a fluid distribution chamber 18. The fluid 12 entering the fluid distribution chamber 18 through the fluid supply line 10 is distributed within the fluid distribution chamber 18. A fluid-permeable element 20 is arranged vertically above the fluid distribution chamber 18. The fluid-permeable element 20 can, for example, be a porous plate.

[0049] The process chamber 6 is arranged vertically above the fluid-permeable element 20. As a result, the fluid 12 located in the fluid distribution chamber 18 passes through the fluid-permeable element 20 into the process chamber 6, so that the powder material 2 inside the process chamber 6 is exposed to the fluid 12.

[0050] By applying the fluid 12 to the powder material 2 within the process chamber 6, the powder material 2 forms a fluidized bed 14 with the fluid 12. In other words, the powder material 2 is fluidized with the fluid 12.

[0051] Fluidized bed 14 is disposed of from process chamber 6 using the provided disposal materials. Fig. The disposal means are designed, among other things, as disposal openings 22 and 26. The fluidized bed can be disposed of from the process chamber 6 through the disposal openings 22 and 26. In order to control the discharge of the fluidized bed 14 or the powder material 2, a first disposal flap 24 and a second disposal flap 28 are also provided, with which the disposal openings 22 and 26 can be closed.

[0052] It is preferred that the first disposal flap 24 and / or the second disposal flap 28 is / are coupled to the control device 50 by means of a signal and that the control device is configured to open and / or close the disposal flaps 24, 28.

[0053] The in Fig. The manufacturing system 1 shown in Figure 3 comprises a tilting unit 32, such that the process chamber 6 is arranged to tilt towards the disposal opening 22. By tilting the process chamber 6, the fluidized bed 14 can be advantageously disposed of from the process chamber 6.

[0054] The in Fig. The manufacturing system 1 shown in Figure 4 comprises a plurality of disposal openings 34-44 arranged in the floor 30 of the process chamber 6, which are arranged and designed such that the fluidized bed 14 can be disposed of by gravity through the disposal openings 34-44. To enable control of the disposal, the manufacturing system 1 has a disposal flap 46 which is hinged around the joint 48.

[0055] In the Fig. Figure 5 shows the disposal flap 46 open, clearly showing that the fluidized bed 14 can be disposed of through the disposal openings 34-44. The disposal openings 34-44 are designed as disposal channels extending through the fluid-permeable element 20 and the fluid distribution chamber 18.

[0056] In a manufacturing system 1 shown above, the fluid supply line 10 can be connected to a Fig. The fluid flow device 52 shown in Figure 5 is fluidically connected, wherein the fluid flow device 52 is arranged and configured to provide the fluid 12, in particular with a predefined flow velocity and / or a predefined fluid pressure.

[0057] Fig.Figure 6 shows a schematic procedure. In step 100, a component 4 is produced from a powder material 2. This can be done, for example, by applying a binder. The underlying process can be, for example, binder jetting, and in particular, metal binder jetting. In step 102, the powder material 2 is treated with a fluid 12 such that the powder material 2 forms a fluidized bed 14 with the fluid 12. In step 104, the fluidized bed 14 is removed from the process chamber 6.

[0058] The manufacturing system 1 and the corresponding process described above enable the production of components 4 in a powder bed and the subsequent removal of the powder material 2 from the environment of the components 4 or from the components 4 themselves, without the components 4 being significantly affected by the removal of the powder material 2.

[0059] This allows components 4 to be manufactured with higher quality. Furthermore, the risk of damage to components 4 is reduced. Another advantage of the manufacturing system 1 and the corresponding process is its high degree of automation. Manual removal of the powder material 2, for example with a compressed air gun, is either unnecessary or significantly reduced. Thus, high-quality components 4 can be manufactured automatically using an additive manufacturing process in a powder bed. REFERENCE MARK 1 Manufacturing system 2 Powder material 4 components 6th Trial Chamber 8 Fluid supply equipment 10 Fluid supply line 12 Fluid 14 Fluidized bed 18 Fluid distribution chamber 20 fluid-permeable element 22 first disposal opening 24 first disposal hatch 26 second disposal opening 28 second disposal flap 30 floor 32 tipping unit 34 Disposal opening 36 Disposal opening 38 Disposal opening 40 Disposal opening 42 Disposal opening 44 Disposal opening 46 Disposal flap 48 joint 50 Control device 52 Fluid flow device

Claims

Manufacturing system (1) for separating at least one component (4) made from powder material (2) and powder material (2), comprising: - a process chamber (6), - fluid supply means (8) arranged and configured to supply the powder material within the process chamber (6) with a fluid such that the powder material forms a fluidized bed (14) with the fluid, and - disposal means arranged and configured to dispose of the fluidized bed (14) from the process chamber (6), - wherein the disposal means have at least one disposal opening (22, 26) arranged and configured to discharge the fluidized bed (14) from the process chamber (6), and - wherein the at least one disposal opening (22, 26) is arranged laterally, - characterized in that the process chamber has a base plate through which the fluid is supplied, and - characterized by a tilting unit arranged and configuredto tilt the process chamber around a horizontal axis. Manufacturing system (1) according to claim 1, comprising a control device (50) which is configured to control the fluid supply means (8) such that the fluid has a predefined flow velocity. Manufacturing system (1) according to one of the preceding claims, wherein the fluid supply means (8) comprise a fluid flow device which is arranged and configured to supply the fluid. Manufacturing system (1) according to one of the preceding claims, wherein the fluid supply means (8) are arranged and configured to supply the fluid with a continuous and / or pulsed flow energy. Manufacturing system (1) according to one of the preceding claims, wherein the fluid supply means (8) comprise a fluid-permeable element (20) adjacent to the process chamber (6), which is arranged and designed to direct the fluid into the process chamber (6). Manufacturing system (1) according to claim 5, wherein the fluid-permeable element (20) forms at least a section of a floor of the process chamber (6). Manufacturing system (1) according to one of claims 5 or 6, wherein the fluid-permeable element (20) is arranged between the process chamber (6) and a fluid distribution chamber (18), wherein the fluid can be provided in the fluid distribution chamber (18). Manufacturing system (1) according to any one of the preceding claims 5 to 7, wherein the fluid-permeable element (20) consists of or comprises a porous material. Manufacturing system (1) according to one of the preceding claims, wherein the fluid supply means (8) have at least one fluid supply line which is arranged and designed to direct the fluid into the process chamber (6). Manufacturing system (1) according to claim 7, wherein the at least one disposal opening (22, 26) extends through the fluid distribution chamber (18). Manufacturing system (1) according to one of the preceding claims, wherein the disposal means have at least one disposal flap (24, 28) with which the at least one disposal opening (22, 26) can be opened and closed. Manufacturing system (1) according to the preceding claim 11, wherein the at least one disposal flap (24, 28) is arranged and designed for opening and closing a lateral disposal opening (22, 26) of the process chamber (6) and / or a disposal opening (22, 26) arranged in the bottom of the process chamber (6), such that the fluidized bed (14) can be disposed of by gravity through the disposal opening (22, 26) when the closure element is open. Manufacturing system (1) according to one of the preceding claims, comprising an extraction unit which is arranged and configured to extract the fluidized bed (14) from the process chamber (6). Manufacturing system (1) according to one of the preceding claims, wherein the process chamber (6) is arranged to be tiltable in the direction of the at least one disposal opening (22, 26). Manufacturing system (1) according to one of the preceding claims, comprising a solidification unit for bonding powder particles contained in the powder material. Method for separating at least one component made from powder material and powder material in a process chamber (6) of a manufacturing system according to one of the preceding claims 1 - 15, comprising the steps: - applying a fluid to the powder material such that the powder material forms a fluidized bed (14) with the fluid, and - disposing of the fluidized bed (14) from the process chamber (6) through a lateral disposal opening (22, 26).

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