Apparatus, modular system and method for producing three-dimensional workpieces

Abstract

This application relates to equipment, modular systems, and methods for producing three-dimensional workpieces. The equipment for producing three-dimensional workpieces includes: a material supply unit, a layer deposition mechanism, a curing device, a gas supply unit, a process chamber, a moving unit, and a positioning system. The process chamber further includes one or more of an airflow device, a heating unit, a safety device, or a portion thereof, and at least one of the airflow device, heating unit, and safety device or a portion thereof is adapted to operate independently of the movement direction of the process chamber.

Description

[0001] This application is a divisional application of PCT application filed on March 2, 2020, with application number 202080019020.7 (international application number PCT / EP2020 / 055395) entitled "Apparatus and method for producing three-dimensional workpieces", which has entered the Chinese national phase. Technical Field

[0002] The present invention generally relates to a process chamber, equipment, modular system, method, and particularly to safety devices and positioning systems included in the equipment, as well as systems for producing three-dimensional workpieces and / or used in the production of three-dimensional workpieces. Background Technology

[0003] In additive layer methods, a workpiece is produced layer by layer by creating a series of cured and interconnected workpiece layers. These processes can be distinguished by the type of raw materials and / or the method by which said raw materials are cured for the production of the workpiece.

[0004] For example, powder bed melting is an additive manufacturing process that can process powdered raw materials, particularly metals and / or ceramics, into complex three-dimensional workpieces. To do this, a layer of raw material powder is applied to a carrier, and the powder layer is selectively subjected to, for example, laser radiation according to the desired geometry of the workpiece to be produced. The laser radiation penetrates the powder layer, causing heating that melts or sinters the raw material powder particles. Then, the raw material powder layer is continuously applied to the carrier over the laser-processed layer until the workpiece has the desired shape and size. Selective laser melting or laser sintering is particularly useful for producing prototypes, tools, replacement parts, or medical prostheses (e.g., dental or orthodontic prostheses) based on CAD data.

[0005] On the other hand, fused deposition modeling or material jetting represents different types of additive layer processes. In this case, uncured raw material is supplied to a type of printhead that deposits the material onto a carrier, where it is then cured.

[0006] A crucial parameter in additive layer construction methods is the quality of the produced workpiece. Furthermore, production efficiency is paramount, for example, in keeping production cycles as short as possible. Several strategies are known to be available for accelerating the production of individual workpiece layers. However, when producing large workpieces, known solutions do not always achieve the required efficiency and / or quality.

[0007] Therefore, the object of the present invention is, particularly, to improve efficiency during the production of additive layers for (especially large) workpieces, while maintaining a sufficient level of quality.

[0008] The invention is set forth in the independent claims. Preferred embodiments of the invention are summarized in the dependent claims. Summary of the Invention

[0009] We describe an apparatus for producing three-dimensional workpieces using an additive layer construction method. The apparatus includes: a carrier adapted to receive material for producing the three-dimensional workpiece; a material supply unit adapted to supply material to the carrier and / or to a previous material layer located on top of the carrier; a layer deposition mechanism for forming the supplied material into a material layer located on top of the carrier and / or into a material layer located on top of a previous material layer on the carrier; a curing device adapted to cure the material supplied to the carrier and / or to cure the material supplied to the previous material layer located on top of the carrier to produce the three-dimensional workpiece; a gas supply unit adapted to supply a protective gas to a region of the material layer cured by the curing device; and a process chamber. The process chamber includes a gas supply unit and a curing device; a moving unit adapted to move the process chamber relative to a carrier; and a positioning system adapted to determine the position of the process chamber relative to the carrier, wherein the process chamber further includes one or more of the following: an airflow device adapted to form an airflow over the surface of a region of the material layer cured by the curing device; a heating unit adapted to heat the material supplied to the carrier; and a safety device or part thereof adapted to prevent process emissions from being released into the vicinity of the process chamber during equipment operation, wherein at least one of the airflow device, the heating unit, and the safety device or part thereof of the process chamber is adapted to operate independently of the direction of movement of the process chamber.

[0010] In some examples, the process chamber includes a material supply unit and an opening; the material supply unit includes an end portion, particularly a generally annular end portion, located on a first side of the process chamber, wherein the material supply unit is adapted to supply material to a carrier via the end portion, on which the material is processed by the process chamber to produce a three-dimensional workpiece, and the opening is located on the first side of the process chamber for processing the material supplied to the carrier to produce a three-dimensional workpiece, wherein the end portion surrounds the opening.

[0011] As described throughout this disclosure with respect to various exemplary implementations, the process chambers typically involve movable process chambers. In particular, this enables the production of large workpieces, whereby the process chamber is moved to different locations to process the material to be produced.

[0012] In some examples, the generally annular end portion, which may be applied according to some implementation, may thus include a generally circular end portion, a generally elliptical end portion, or a generally oval end portion.

[0013] The generally annular end portions enable the supply of material to the carrier from the annular portion; that is, the material is supplied not from the central location surrounded by the end portions, but only from the edge regions where the end portions are arranged.

[0014] The first side of the process chamber can be associated with the bottom side of the process chamber.

[0015] In some examples, the opening located on the first side of the process chamber may include a generally circular opening.

[0016] A particularly advantageous feature is a material supply unit comprising a generally annular end portion located on a first side of a process chamber, from which material is supplied to a carrier, on which the material is processed by the process chamber to produce a three-dimensional workpiece. This is because supplying material from the annular end portion to the carrier allows for omnidirectional material supply, particularly since the process chamber has no preferred direction of movement above the carrier and will not supply material to the carrier during that movement. Thus, the annular end portion is superior to, for example, a rectangular end portion, because in the case of a rectangular end portion, it may be impossible to achieve uniform material distribution across the carrier from all parts of the end portion, particularly from any corner of such a rectangular end portion. This can lead to irregularities when supplying a single layer of material to the carrier, which can be avoided by using an annular end portion.

[0017] Furthermore, as described above, when the process chamber moves above the carrier, the annular end portion prevents the presence of a preferred orientation.

[0018] In some examples, the material supplied to the carrier by the material supply unit may be a powdered material, particularly a metal and / or ceramic raw material. In some examples, the material may be supplied to the carrier by printing the material using, for example, a printhead, which deposits the material onto the carrier, and then the material is cured on the carrier (e.g., during or after the material is deposited onto the carrier), or subsequently cured using other means such as a curing apparatus, which may use, for example, radiation (e.g., a laser) or a particle beam to cure the material.

[0019] Throughout this disclosure, the process chamber may be a movable process chamber.

[0020] In some examples, the material supply unit includes a bell-shaped structure through which material can be supplied to the carrier, and wherein the end portion forms the end of the bell-shaped structure.

[0021] Therefore, a bell-shaped structure can refer to a material supply unit that gradually narrows from a first side of the process chamber to a second side, opposite to the first side. This gradual narrowing from the first to the second side can include a first degree of narrowing, followed by a second degree of narrowing, where the second degree of narrowing of the material supply unit is greater than the first degree of narrowing (i.e., the narrowing of the material supply unit is accelerated). Different degrees of narrowing produce the bell-shaped structure.

[0022] In some examples, the material supply unit tapers to a negligible or zero width at its end portion. In other words, when the process chamber is placed on the carrier, the material supply unit allows material to be supplied to the carrier through its end portion, which is generally perpendicular to the carrier.

[0023] In some examples, a container for storing material can be provided, thereby allowing the material to be supplied from the container to the material supply unit before it is supplied to the carrier via the end portions. Considering the bell-shaped material supply unit, the material can be supplied to the carrier in a uniform manner through different sections of the end portions. In particular, when the material is arranged within the bell-shaped material supply unit, this uniform supply is achieved due to the material's own weight, resulting in a uniform distribution of the material within the bell-shaped material supply unit, especially within the end portions from which the material is supplied to the carrier. Advantageously, any irregularities in the material supplied to the carrier can be avoided or reduced.

[0024] In some examples, the process chamber includes a multi-walled structure, wherein a first cavity is formed between a first wall and a second wall of the multi-walled structure, the first cavity being included in or connected to a material supply unit. The multi-walled structure may have an opening at a first side of the process chamber (i.e., the location that provides the opening of the process chamber).

[0025] Providing a multi-walled structure can be particularly advantageous because it may eliminate the need for a material supply unit separate from the wall structure of the process chamber, and the material supply unit can supply material to the carrier in a well-defined and uniform manner based on the shape of the multi-walled structure of the process chamber.

[0026] We further describe an apparatus, particularly the apparatus described above, wherein a process chamber comprises a multi-walled structure, the apparatus being used to produce three-dimensional workpieces via an additive manufacturing method. The process chamber includes a gas extraction unit and / or a gas introduction unit, wherein a second cavity is formed between a third and a fourth wall of the multi-walled structure, wherein the second cavity is arranged radially outward of a first cavity along a direction away from the central portion of the process chamber, and wherein the second cavity is included in, or coupled to, the gas extraction unit and / or the gas introduction unit, the gas extraction unit and / or the gas introduction unit being configured to extract gas from and / or introduce gas to the central portion of the process chamber. This can be particularly advantageous because a protective gas can be extracted from the interior of the process chamber, thereby providing a sealing effect to the second cavity. Furthermore, by providing a second cavity between the third and fourth walls of the multi-walled structure, whereby the second cavity is included in or connected to a gas extraction unit, the extraction of gas, such as a protective gas, from the interior of the process chamber does not affect the material layer already deposited on the carrier, and the material layer can be processed to produce a three-dimensional workpiece before the walls of the process chamber reach the material as the process chamber moves above the carrier. Additionally or alternatively, providing a gas extraction unit and / or a gas introduction unit may be particularly advantageous, as the gas extraction unit and / or gas introduction unit can be used to regulate and / or equalize the pressure within the process chamber.

[0027] In some examples, the second wall is integral with the third wall (i.e., identical).

[0028] In some examples, a third cavity is formed between the fifth and sixth walls of the multi-walled structure, wherein process gases (e.g., protective gases) are introduced into and / or extracted from the process chamber through the third cavity. The third cavity may be formed based on the inner wall of the process chamber.

[0029] The fifth and / or sixth wall may be integral with any of the aforementioned walls of the multi-wall structure (i.e., identical).

[0030] In some examples, the curing apparatus includes a radiation (e.g., laser) and / or particle source. In some examples, the curing apparatus may include an optical module, such as a beam-control optics device including one or more deflectable mirrors. It should be understood that the process chamber may include an optical module and a radiation source, with the optical module disposed at the process chamber and the radiation source disposed remotely to the process chamber via a radiation conductor. When a process chamber including a curing apparatus is involved, this means that the process chamber may also include only an optical module for directing radiation to the material.

[0031] Setting up a material supply unit and curing device in the process chamber can advantageously enable the material to be deposited and cured relatively quickly on top of the carrier.

[0032] In some examples, the curing device is typically arranged parallel to the opening located on the first side of the process chamber.

[0033] In some examples, the curing apparatus is offset from the central axis of the process chamber, which is defined as perpendicular to the plane defined by the opening of the process chamber and passing through the center point of the opening. Thus, in some examples, the curing apparatus may be tilted relative to the opening of the process chamber (and / or tilted relative to the carrier on which the material to be processed is supplied).

[0034] When the material supply unit includes a bell-shaped structure, it may be particularly advantageous to position the curing device off-center from the central axis of the process chamber. The material to be processed for producing three-dimensional workpieces is supplied to the bell-shaped structure via a container positioned above the process chamber. This offset of the curing device relative to the central axis of the process chamber allows the container to be centrally positioned above the curing device, ensuring a symmetrical material supply from the container to the material supply unit. This results in a uniform distribution of material within the material supply unit, particularly at the end portions. This allows material to be supplied uniformly from the end portions to the carrier along their entire circumference.

[0035] In some examples, the layer deposition mechanism is arranged on a first side of the process chamber and is adapted to form the supplied material into a layer on top of the carrier. Thus, the layer deposition mechanism allows the material deposited on the carrier by the material supply unit to be smooth. In some examples, the layer deposition mechanism includes a layer deposition lip and / or a layer deposition brush and / or layer deposition blades.

[0036] In some examples, the layer deposition mechanism is arranged adjacent to the first cavity (i.e., directly adjacent to or within a small distance of the first cavity) and located radially inside the first cavity (i.e., towards the center of the process chamber) to control the supply of material to the carrier through the first cavity via the layer deposition mechanism. This means that the layer deposition mechanism can be arranged between the end portion of the material supply unit and the opening located on the first side of the process chamber.

[0037] This can be particularly advantageous because the layer deposition mechanism can also be used to prevent undesirable material leakage from the material supply unit. This is achieved through a clamping effect, which occurs in the gap between the layer deposition mechanism and the first cavity due to the numerous contact points between the material particles. Furthermore, the material clamped in this gap also prevents gas from leaving the process chamber.

[0038] In some examples, the device further includes a first seal disposed on a first side of the process chamber and between the end portion and the opening to generate a first gas vortex when the process chamber is in use. This can be particularly advantageous because the first gas vortex reduces process gas leakage (protective gas leakage) inside the process chamber. A gas extraction unit may be arranged radially outside the first seal such that gas that can travel from the interior of the process chamber and through particles disposed in the first chamber of the material supply unit can be extracted by a defined vacuum.

[0039] In some examples, the device further includes a second seal disposed on a first side of the process chamber and radially outward of the second cavity. Thus, the second seal can be arranged directly adjacent to the second cavity or disposed at a predetermined distance from the second cavity. During use of the process chamber, the second seal can cause additional gas vortices, which advantageously prevents excessive gas from the surrounding area of ​​the process chamber from being extracted via a gas extraction unit disposed radially outward of the first seal.

[0040] In some examples, the device further includes a third seal disposed on a first side of the process chamber and radially outward of the end portion of the material supply unit to generate a second gas vortex when the process chamber is in use.

[0041] Each gas vortex slows the airflow until only reduced airflow occurs between different regions of the process chamber. These regions can thus be defined as being separated by the first and second seals and by the interior of the process chamber and different cavities.

[0042] In some examples, the material supply unit includes a material supply geometry adapted to uniformly distribute the material to be supplied to the carrier in the end portions of the material supply unit. Thus, the material supply geometry can include a cylindrical shape, a triangular shape, or a free-form shape. The material supply geometry is adapted to provide the same or substantially the same material height along the entire circumference of the material supply unit. This advantageously allows for the achievement of the same or substantially the same pressure conditions along the entire circumference of the material supply unit, particularly in the end portions of the material supply unit. This enables uniform distribution of material when supplying it to the carrier, particularly when moving the process chamber in different directions on the carrier.

[0043] In some examples, the device further includes an annular screen coupled to or integrated with the material supply unit, wherein the screen is adapted to uniformly distribute the material to be supplied to the carrier in the end portion of the material supply unit. This further enables the material to be uniformly distributed along the entire circumference of the material supply unit, particularly in the end portion.

[0044] In some examples, the first cavity includes segments for supplying different materials to the carrier through different sections of the end portion. In some examples, segmentation may result in two to four segments. It should be understood that other numbers of segments may be provided due to segmentation. The supply of material to the carrier by the material supply unit can be omnidirectional, and in some examples, the (protective) airflow within the process chamber can be altered so that material can be supplied to the carrier as the process chamber moves above the carrier. Segmentation can advantageously enable the supply of different materials to the carrier during the material supply process. For example, this can be achieved by moving the process chamber above the carrier in a specific direction and supplying material to the carrier, with the material arranged in a segment positioned on one side of the process chamber, wherein the process chamber is movable. Additionally or alternatively, the process chamber can be rotated in a specific direction, enabling the deposition of material stored in one(s) of a particular segment(s).

[0045] Therefore, in some examples, material can be supplied to the carrier from one of the different sections of the end portion, depending on the direction of movement of the process chamber above the carrier. This allows for easy modification of the material to be supplied to the carrier at specific locations.

[0046] In some examples of the device, a first material having a first particle size can be supplied to the carrier through a first section of different segments, and a second material having a second particle size can be supplied to the carrier through a second section of different segments, the second particle size being different from the first size, wherein the second segment is different from the first segment.

[0047] Therefore, different materials can be provided in different regions of the carrier, allowing the materials to be used for different purposes. In some examples, the material can be used to produce a three-dimensional workpiece. Alternatively or additionally, in some examples, different materials can be used to fill a specific volume above the carrier, so that the material is not processed to produce a three-dimensional workpiece. Alternatively or additionally, in some examples, a particular material can be used for isolation purposes (e.g., thermal isolation and / or electrical isolation).

[0048] In some examples of the apparatus, where the process chamber includes an airflow device arranged on a first side of the process chamber, the airflow device includes a process gas introduction unit and a process gas extraction unit (e.g., a process gas suction unit), arranged opposite to each other for introducing process gas (e.g., a protective gas) into and extracting process gas (e.g., a protective gas) from the process chamber (to flow on the carrier), respectively. The apparatus further includes a moving mechanism adapted to change the position of the process gas introduction unit and the process gas extraction unit on the first side of the process chamber. This may be particularly advantageous considering the omnidirectional supply and curing process of the material deposited on the carrier. Thus, the moving mechanism can change the position of the process gas introduction unit and the process gas extraction unit along the end portion of the material supply unit. Consequently, the process gas introduction unit and the process gas extraction unit can each be arranged radially inward of the end portion of the material supply unit.

[0049] In some examples, the airflow device may include one or more nozzles as airflow introduction units, particularly for introducing gas in a generally unidirectional direction over the surface area of ​​the material layer to be cured. The airflow device may also include, for example, one or more flow straighteners for establishing a unidirectional flow in the form of laminar flow.

[0050] In some examples, the device further includes a generally circular structure comprising a groove, wherein the structure is arranged radially inward of the process gas introduction unit and the process gas extraction unit, toward the central portion of the process chamber, and wherein the structure including the groove is adapted to guide process gas from the process gas introduction unit to the process gas extraction unit. In some examples, the device further includes a generally semi-circular section configured to cover the groove at a location preventing process gas from entering the interior portion of the process chamber. The semi-circular section is rotatable in a plane parallel to the opening of the process chamber, thereby allowing adjustment of the airflow direction, particularly dynamically. In some examples, the process chamber can thus be moved in all directions during material supply and / or curing processes, and in some examples, the airflow can thus be adjusted to be continuously opposite to the direction of movement of the process chamber above the carrier. Thus, the (generally) circular shape may include a (generally) elliptical shape or a (generally) oval shape.

[0051] In some examples, the apparatus further includes a particle collector adapted to collect particles of material supplied to the carrier, but which are not included in the three-dimensional workpiece to be produced. Thus, particles not included in the three-dimensional workpiece may refer to, for example, splattered particles, particularly those from the curing process but ejected during said curing process. The particle collector may include a shovel. In some examples, the particle collector may be arranged in a sickle-shaped manner and horizontally in front of the process gas extraction unit and positioned radially inward of the process gas extraction unit. Thus, the particle collector can specifically collect oxide particles, oversized particles, and other residues from the additive manufacturing process. These particles and residues can be removed from the particle collector by rotating the process chamber to tilt the particle collector, particularly from areas different from the areas where material is deposited onto the carrier to produce the three-dimensional workpiece.

[0052] As described above, in some examples, the particle collector is arranged adjacent to the process gas extraction unit (i.e., directly adjacent to or within a certain distance of the process gas extraction unit) and located radially inside the process gas extraction unit. Thus, in some examples, the particle collector can move together with the gas extraction unit and / or gas introduction unit (particularly, it can rotate parallel to the plane of the opening of the process chamber). Additionally or alternatively, the particle collector can be arranged adjacent to the gas introduction unit.

[0053] In some examples, the apparatus further includes a process gas filter, which (i) is arranged adjacent to the process gas extraction unit (i.e., directly adjacent to or within a certain distance of the process gas extraction unit) and located radially inside the process gas extraction unit and / or (ii) is integrated with the process gas extraction unit. Thus, in some examples, the process gas filter may be arranged directly above the particle collector. The gas filter advantageously allows for the direct filtration of small particles and / or material (e.g., powder) deposits and / or condensates from the process gas at the process chamber. Therefore, another filter outside the process chamber may be redundant.

[0054] We further describe a process chamber, particularly as described in one or more of the examples above, for producing three-dimensional workpieces using an additive manufacturing method. The process chamber includes a heating unit (e.g., a radiant heating unit or an irradiation unit) arranged (i) within an internal portion of the process chamber and / or (ii) radially inward and / or radially outward adjacent to the annular end portion of a material supply unit (i.e., adjacent to the annular end portion and sharing a common boundary) or adjacent to the annular end portion of the material supply unit (i.e., adjacent to the annular end portion and having a gap between the heating unit and the annular end portion), wherein the heating unit (e.g., a radiant heating unit or an irradiation unit) is adapted to heat material supplied to a carrier. In some examples, the heating unit (e.g., a radiant heating unit or an irradiation unit) may have a circular or generally circular shape. Thus, a (generally) circular shape may include a (generally) elliptical shape or a (generally) oval shape. In some examples, the heating unit (e.g., a radiant heating unit or an irradiation unit) may be coaxially aligned with the central axis of the process chamber, wherein the central axis is defined as perpendicular to the plane defined by the opening of the process chamber and passing through the center point of the opening. This can advantageously allow for uniform (or gradient) heating (particularly preheating before curing and / or postheating after curing) of materials that can be processed to produce three-dimensional workpieces. In some examples, the heating unit (e.g., a radiant heating unit or an irradiation unit) may include one or more of the following: one or more infrared light sources, one or more laser diodes, one or more vertical-cavity surface-emitting lasers, one or more UV light sources, one or more LEDs, other types of lasers, and one or more induction heating devices.

[0055] For example, the heating unit can be used to preheat materials (e.g., metal powders) before curing (e.g., using laser sintering or laser melting) in order to: increase the temperature level to enable a reduction in the voltage supply used to drive the curing apparatus, and / or dry the materials (e.g., powders), and / or increase the adhesion between material (e.g., powder) particles (sintering columns) to passivate reactive materials and / or reduce turbulence and flow of materials outside the process chamber and / or (especially in laser melting processes) reduce smoke or particle transport within the process chamber and / or reduce the material cone for producing three-dimensional workpieces, as the resulting powder deposition can make the material cone angle steeper along the production direction of the three-dimensional workpiece.

[0056] In some examples, the heating unit (e.g., a radiant heating unit or an irradiation unit) can move within an internal portion of the process chamber. In particular, in some examples, the heating unit (e.g., a radiant heating unit or an irradiation unit) can move in a circular manner within an internal portion of the process chamber.

[0057] In some examples, the process chamber further includes one or more conduits for positioning one or more sensors around the periphery of the process chamber to obtain process parameters during the production of a three-dimensional workpiece using the process chamber. This can be particularly advantageous because the process parameters can be adjusted during or after the process, especially during or after the process of forming a single layer of a three-dimensional workpiece using an additive layer construction method.

[0058] We further describe an apparatus for producing three-dimensional workpieces by an additive layer construction method, the apparatus comprising a carrier, a process chamber according to any example described herein, and a moving unit (or an additional external moving device located between a main positioning unit and the process chamber), the carrier being adapted to receive material for producing the three-dimensional workpiece by the additive layer construction method; the moving unit (or the additional external moving device located between the main positioning unit and the process chamber) being adapted to move the process chamber relative to the carrier so as to position different sections of the process chamber relative to the carrier.

[0059] We further describe the apparatus as described above, which includes: a process chamber comprising one or more conduits; and one or more sensors adapted to sense the position of the process chamber relative to a carrier, wherein the apparatus is adapted to generate a sensor signal based on the sensed position of the process chamber relative to the carrier, and wherein a moving unit is adapted to move the process chamber relative to the carrier based on the sensor signal. This advantageously enables the improvement of the position on the carrier where material is supplied and / or where material is cured by the process chamber.

[0060] The mobile unit may include, for example, a Cartesian coordinate robot, a six-axis robot, a seven-axis robot, a SCARA robot, or a parallel manipulator as a hexapod robot.

[0061] We further describe a modular system for use with the aforementioned process chamber or equipment, wherein the modular system includes: a base module (e.g., generally flat), the base module including one or more first elements (e.g., one or more grooves and / or one or more protrusions), the one or more first elements being located on a surface of the base module; and one or more substrate modules for receiving material to be processed for producing a three-dimensional workpiece by an additive layer construction method on the first surface of the substrate modules, wherein the substrate modules include one or more second elements (e.g., one or more grooves and / or one or more protrusions), the one or more second elements being located on a second surface of the substrate modules, wherein the first surface is adjacent to the first... Two opposing surfaces, wherein the shape of the protrusion of the second element is adapted to mate with the first element of the base module for temporarily securing the base module to one or more substrate modules; and one or more modular elements, the one or more modular elements being used to (i) support material when material is received by one or more substrate modules and / or (ii) confine material to a region on one or more substrate modules and / or (iii) support the substrate modules, wherein the modular elements include one or more third elements (e.g., one or more grooves and / or one or more protrusions), wherein the shape of the third elements is adapted to mate with the first element of the base module for temporarily securing one or more modular elements to the base module. Thus, the modular system allows for flexibility during the manufacturing process of three-dimensional workpieces. In particular, supporting the material when it is received by one or more substrate modules allows for compensation of some forces acting on the processed material during the manufacturing process. Confining the material to a region on one or more substrate modules allows for a reduction in the amount of material required to be supplied to the carrier before processing the material to produce the three-dimensional workpiece. Similarly, supporting the substrate modules, in particular, allows for a reduction in the amount of material required to be supplied to the carrier before processing the material to produce the three-dimensional workpiece.

[0062] We further describe a system comprising a device according to one or more exemplary implementations as described herein and a modular system according to one or more exemplary implementations as described herein.

[0063] In some examples, the base module and / or one or more substrate modules include one or more sealable openings for receiving one or more modular elements, wherein, depending on the state of the three-dimensional workpiece produced by the additive manufacturing method (e.g., build height), one or more modular elements can be raised to provide support for the material and / or constraint of the material and / or support for one or more substrate modules. Adjusting the height of the modular elements allows for a reduction in the amount of material required to produce the three-dimensional workpiece, as the modular elements can be raised according to the production height of the three-dimensional workpiece.

[0064] In some examples, the modular system includes a first base module and a second base module, wherein the first base module includes a base module protrusion and the second base module includes a base module recess, the shape of which is adapted to mate with the base module protrusion for temporarily securing the first and second base modules to each other. This advantageously allows for the provision of a larger area on which three-dimensional workpieces can be produced.

[0065] We further describe a method for producing a three-dimensional workpiece using additive manufacturing technology, the method comprising: providing a modular system according to one of the examples above; arranging one or more substrate modules at one or more locations on a base module according to the location of material processing based on the shape of the three-dimensional workpiece to be produced; providing material on the one or more substrate modules, particularly using a process chamber or device according to one of the examples described herein; and processing the material using additive manufacturing technology to produce the three-dimensional workpiece.

[0066] In some examples, the method further includes providing one or more modular elements on one or more of (i) one or more first elements of a base module and (ii) one or more substrate modules to: support material when material is provided on one or more substrate modules, and / or confine material to a region on one or more substrate modules when material is provided on one or more substrate modules, and / or support said substrate modules for subsequent reception of material by the substrate modules.

[0067] In some examples, the method further involves placing the modular element on top of previously arranged modular elements, based on the increase in the build height of the three-dimensional workpiece produced by additive layer manufacturing technology.

[0068] In some examples, the method further includes providing displacement material within a predetermined volume constrained by the modular system before providing the material used to produce the three-dimensional workpiece. This can further enable a reduction in the amount of material required to produce the three-dimensional workpiece.

[0069] We further describe a safety control device for use with a process chamber according to one of the described examples, wherein the process chamber includes a curing device, wherein the safety control device includes: a sensor adapted to sense the state of the process chamber and / or the housing on which the process chamber is disposed, and a control unit adapted to control the curing device, wherein the control unit is coupled to the sensor, and wherein the control unit is adapted to prevent the release of radiation and / or particles (when the curing device includes a particle source) originating from the curing device, and / or adapted to shut down the curing device when the sensor senses that the state meets predetermined conditions. Therefore, the safety control device advantageously enables the reduction or elimination of any hazards to personnel that may originate from radiation and / or particles released from the curing device.

[0070] In some examples, the predetermined conditions include that the opening of the process chamber is not covered (e.g., not covered by a carrier). When the opening of the process chamber is not covered, it prevents the curing device from releasing radiation and / or allows the curing device to be shut down.

[0071] In some examples, the uncovering of the opening of the process chamber includes: lifting the process chamber from a carrier (e.g., lifting from a carrier on which additive layer construction techniques are used to process material to produce a three-dimensional workpiece, and / or lifting from one or more components or parts of a modular system according to exemplary implementations as described herein) and / or changing the orientation of the process chamber relative to the carrier. Thus, changing the orientation of the process chamber relative to the carrier may involve tilting the process chamber.

[0072] In some examples, the sensors include accelerometers. Accelerometers can be used to determine when the orientation of the process chamber changes relative to the carrier.

[0073] In some examples, the sensor includes a pressure sensor adapted to sense pressure changes within a housing in which process chambers are arranged, wherein predetermined conditions include pressure changes. Specifically, a pressure decrease within the housing can be determined, which may be caused by the housing being open, preventing the curing apparatus from releasing radiation, and / or allowing the curing apparatus to be shut down. Additionally or alternatively, an increase in pressure within the housing can be determined, which may be caused by the housing being closed, and where the opening of the process chamber is not covered when gas is introduced into the housing, for example, by a gas introduction unit of the process chamber. When the pressure within the housing increases, it prevents the curing apparatus from releasing radiation and / or particles, and / or allows the curing apparatus to be shut down.

[0074] In some examples, the safety control device further includes a door switch coupled to a control unit, wherein the door switch is adapted to detect when a door of the housing containing the process chamber is opened, and wherein predetermined conditions include the door being open. Thus, whenever personnel attempt to enter the housing, the curing unit can be prevented from releasing radiation and / or particles, and / or the curing unit can be shut off.

[0075] In some examples, the control unit can be coupled to a robotic device operating within the housing. Specifically, the control unit can be coupled to a movement unit as described above, wherein the control unit is adapted to control or influence the movement or mobility of the robotic device, particularly the movement or mobility of the movement unit, when a door switch detects that the housing door is open. Influencing the mobility of the robotic device may include: reducing the maximum speed at which the robotic device can move, and / or preventing the robotic device from moving to certain locations that, due to the physical size of the robotic device, are theoretically reachable. Therefore, contact between the robotic device and personnel entering the housing can be prevented.

[0076] In some examples, the sensor includes a distance sensor adapted to determine the distance between the process chamber and the carrier, wherein predetermined conditions include exceeding a minimum distance between the process chamber and the carrier, and when the minimum distance is exceeded, the control unit prevents the release of radiation and / or particles originating from the curing apparatus and / or shuts down the curing apparatus. This further enhances the safety of any personnel who can access the housing, in which the process chamber operates.

[0077] In some examples, the safety control device further includes a processing unit adapted to determine when radiation can leave a volume confined by the process chamber based on the reflection of radiation (and / or particles) originating from the curing apparatus away from the carrier, wherein predetermined conditions include the ability of the radiation to leave the volume. This further enhances the safety of any personnel who can access the housing, within which the process chamber operates.

[0078] In some examples, the sensors are arranged on the process chamber. This can be particularly advantageous for determining the state of the process chamber. In particular, in examples where the sensors include distance sensors, the distance between the process chamber and the carrier can be determined precisely.

[0079] We further describe a positioning system, specifically, wherein, according to one or more of the described examples, the positioning system is included in or coupled to a device as described herein, wherein the positioning system includes: one or more positioning units adapted to be arranged at a defined location in an edge region of a carrier; and one or more measuring sensors adapted to be arranged on a process chamber and / or at a defined location relative to the process chamber (e.g., on a moving unit for moving the process chamber); wherein the position of the process chamber can be determined and / or corrected by the positioning system based on signals from the one or more measuring sensors. In some examples, the shapes of the positioning units and the measuring sensors are adapted to accommodate each other. Therefore, the positioning system enables precise determination of the position of the process chamber, thereby enabling precise determination of the location where material for producing a three-dimensional workpiece is supplied to the carrier and / or the location where the material is cured. This can be particularly advantageous, for example, when it may be necessary to compensate for temperature fluctuations or other erroneous process parameters during the production of a three-dimensional workpiece.

[0080] In some examples, the positioning system can be used to determine and / or correct the position of multiple process chambers.

[0081] In some examples, the positioning unit comprises three plates, each arranged perpendicular to the other two plates to form an arrangement with two open sides and an open top, wherein the position of the process chamber can be determined and / or corrected based on one or more measuring sensors on the respective plates of the positioning unit. This makes it possible to determine and / or correct the position of the process chamber in all three dimensions.

[0082] In some examples, the positioning system is configured to determine the tilt of the process chamber relative to the carrier based on three measuring sensors that contact the respective plates of the positioning unit. This allows the orientation of the process chamber to be determined and / or corrected. Thus, in some examples, the position of the process chamber on the positioning unit, such as its position on the wall of the positioning unit, can be determined by the measuring sensors contacting the positioning unit. Additionally or alternatively, six measuring sensors may be used in particular to determine the tilt of the process chamber relative to the carrier.

[0083] Thus, based on some examples, contact can involve tactile contact.

[0084] In some examples, one or more positioning units can be raised in a direction perpendicular to the carrier. This can be particularly advantageous because one or more of the positioning units can be raised or lowered depending on the production status of the three-dimensional workpiece, such as the build height of the three-dimensional workpiece.

[0085] In some examples, once the position of the process chamber is determined and / or corrected, the process chamber is adapted to perform a generally circular movement in a plane parallel to the carrier, from the positioning unit to a predetermined position where material is supplied by the material supply unit and / or processed by the curing device. This generally circular movement from the positioning unit to the predetermined position allows for very precise movement, and thus allows for very precise determination of the position where material is supplied by the material supply unit and / or processed by the curing device.

[0086] In some examples, the positioning unit includes a light source adapted to generate one or more light beams for a reference line and / or reference plane, which serve as a reference for the position and / or orientation of the process chamber; and wherein the one or more sensors include one or more photodetectors, particularly laser radiation detectors; wherein the position and / or orientation of the process chamber relative to the reference line and / or reference plane can be determined and / or corrected by the positioning system based on the photodetectors detecting the one or more light beams. In an exemplary implementation using one or more laser radiation detectors, effects caused by the laser can be detected.

[0087] Thus, one or more photodetectors can be configured to detect position in one or two dimensions (depending on the shape of the device and component, and in particular on the shape of one or more process chambers).

[0088] Therefore, the device advantageously enables the definition of a reference coordinate system for one or more process chambers and / or one or more manipulators (e.g., robots) to which one or more process chambers can be coupled, thereby improving the positioning accuracy of the process chambers. This may be particularly advantageous in exemplary implementations including process chambers as described herein, as the supply and / or curing of materials (and / or replacement materials, etc.) for producing three-dimensional workpieces can be performed with higher positional accuracy. This further ensures little or no irregularity in the supply and / or curing of materials during additive layer manufacturing processes. Additionally or alternatively, the increased positioning accuracy based on a well-defined reference coordinate system can further enable modules of a modular system to be positioned more precisely in the desired locations. Additionally or alternatively, the increased positioning accuracy based on a well-defined reference coordinate system can also improve the determination of when the aforementioned predetermined conditions are met for the use of safety controls to prevent the release of radiation and / or particles from the curing device and / or to shut down the curing device. Additionally or alternatively, according to exemplary implementations as described herein, the increased positioning accuracy based on a well-defined reference coordinate system can work collaboratively with the positioning system.

[0089] In some examples, the device is adapted to change the position and / or orientation of the process chamber relative to a reference line and / or reference plane based on the determination, using a moving unit that moves the process chamber. This allows for improved positioning accuracy of the process chamber, particularly when supplying and / or curing materials used in the production of three-dimensional workpieces.

[0090] In some examples, the apparatus is adapted to perform coordinate transformations associated with the curing device based on the determination, for producing three-dimensional workpieces via an additive layer construction method. This allows for precise determination of the position and / or orientation of the process chamber. Consequently, the coordinates of the scanning beam (radiation beam and / or particle beam) on the material layer can be adjusted, and the material layer can be processed via the additive layer construction method to produce the three-dimensional workpiece. Thus, the curing device can be accommodated by considering that the curing device may be tilted in space relative to a carrier or component of, for example, a modular system, thereby allowing for adjustable exposure of the material layer using the curing device. Error correction can be performed in a scanner used to scan the beam of the curing device on the surface of the material layer.

[0091] In some examples, the light source includes a laser source for generating a linear laser beam profile. Therefore, in particular, the device may include a polygon scanner adapted to generate reference lines and / or reference planes from the linear laser beam profile. A precise reference coordinate system can thus be defined using the laser source.

[0092] In some examples, the apparatus includes multiple process chambers, wherein the apparatus is adapted to generate beams for multiple reference planes. Thus, each process chamber can be associated with a corresponding reference coordinate system, enabling high-precision determination of the position and / or orientation of each process chamber. Therefore, the number of process chambers may be the same as or different from the number of reference planes.

[0093] In some examples, the light source and / or one or more photodetectors are movable in three dimensions. This can be particularly advantageous to change the position of the reference coordinate system, for example, according to the manufacturing state (e.g., build height) for producing a three-dimensional workpiece. Depending on the shape of the equipment and / or components (particularly process chambers and / or moving units), it is preferable that the light source and one or more photodetectors are movable for the flexibility of the equipment.

[0094] In some examples, when multiple photodetectors are arranged on or coupled to a housing, the position and / or orientation of the process chamber relative to one or more reference lines is determined based on the reflection of one or more light beams from the process chamber toward the photodetectors. By using, for example, two or more beam source-detector combinations, the relative displacement of the beams on the detectors can be compared with the tilt of the process chamber (e.g., the processing chamber) along the xy-axis and the distance from the process chamber to the detectors, thereby enabling high-precision determination of the position and / or orientation of the process chamber.

[0095] We further describe an apparatus for producing three-dimensional workpieces, the apparatus comprising: a carrier adapted to receive material for producing the three-dimensional workpiece; and a plurality of mobile production units, particularly, each mobile production unit comprising a process chamber according to one or more exemplary implementations as described herein, wherein a first mobile production unit includes a curing device adapted to produce a cured material layer on the carrier to produce a workpiece by an additive layer construction method, wherein a second and / or a third and / or a fourth mobile production unit includes a material supply unit adapted to supply material to the carrier and / or the curing device, wherein the second and / or the third mobile production unit... One or more of the second and / or fourth mobile production units include a gas supply system adapted to supply a protective gas to an area irradiated by the curing apparatus, and wherein the second, third, and fourth mobile production units include a layer deposition mechanism for forming the supplied material into a material layer on top of the carrier; wherein the second, third, and fourth mobile production units do not include the curing apparatus; wherein the apparatus further includes a plurality of mobile units, each mobile unit being adapted to move a respective corresponding mobile production unit relative to the carrier so that the mobile production unit is positioned relative to different sections of the carrier.

[0096] Therefore, the aforementioned equipment can be used to achieve efficiency, particularly during the additive manufacturing of large workpieces, while maintaining a sufficient level of quality / accuracy. Thus, the equipment can be combined with exemplary implementations of one or more process chambers, the equipment including process chambers in which one or more sensors are included in the equipment, modular system, safety devices, safety control devices, and the equipment specifically including a light source and one or more photodetectors, as well as a positioning system as described herein. This enables higher efficiency and accuracy when producing three-dimensional workpieces using additive manufacturing technology.

[0097] In some examples, the device further includes: a sensing unit adapted to generate sensor signals relating to the relative arrangement of the mobile production unit and the carrier; and a control unit configured to provide at least one fine positioning function, in addition to positioning the mobile production unit via the moving unit, to compensate for offsets in the desired relative arrangement of the mobile production unit and the carrier based on the sensor signals generated by the sensing unit. This enables higher efficiency and accuracy when producing three-dimensional workpieces using additive manufacturing techniques.

[0098] In some examples, the device may be configured (e.g., by one or more robots) to place and / or remove components of a modular system according to exemplary implementations as described herein.

[0099] Any one or more exemplary implementations of the process chambers, equipment, modular systems, methods, safety devices, safety control devices, positioning systems, and devices used for producing and / or producing three-dimensional workpieces described herein may be combined in any combination.

[0100] Furthermore, in any one or more exemplary implementations of the process chambers, equipment, modular systems, methods, safety devices, safety control devices, positioning systems, and equipment used for producing and / or producing three-dimensional workpieces as described herein, multiple mobile production units (particularly process chambers) can be implemented and / or used, whereby different mobile production units can operate at different levels (i.e., on different material layers, particularly at different heights) and / or on different carriers. Thus, in particular, depending on the three-dimensional workpiece production state based on its shape, different material supplies and / or curing processes can occur simultaneously or continuously. Additionally or alternatively, multiple three-dimensional workpieces can be prepared simultaneously.

[0101] Exemplary implementations, as described herein and particularly as described above, are provided in which the use of multiple mobile production units can further improve efficiency in producing one or more three-dimensional workpieces.

[0102] It should be noted that any references to a carrier listed throughout this disclosure, wherein when describing any example of a process chamber, apparatus, system, method, etc. used in the production of a three-dimensional workpiece and / or in the production of a three-dimensional workpiece, the carrier is referred to, for example, as a reference plane or generally as a reference height and / or reference position, the carrier may also refer to a reference object that generally refers to a basic reference plane, alternatively or additionally, the reference object may be defined to the carrier by a base plate (module) and / or other components and modules of the modular system, and / or by the material to be processed in the production of the three-dimensional workpiece (e.g., a powder material layer, the height of which may be taken into account, since the height of the powder material layer may vary during the additive layer manufacturing process).

[0103] It should also be noted that any references to process chambers listed in the full text of this disclosure may also refer to moving production cells, and vice versa.

[0104] It should also be noted that, in the exemplary implementation described herein, the safety device and the safety control device may be integrated into a single device. Attached Figure Description

[0105] These and other aspects of the invention will now be described further by way of example only with reference to the accompanying drawings, wherein the same reference numerals denote the same parts, and in the drawings: Figures 1a to 1c A schematic cross-sectional side view of a process chamber according to some exemplary implementations as described herein is shown; Figure 2 A schematic cross-sectional side view of a process chamber according to some exemplary implementations as described herein is shown; Figure 3 A schematic cross-sectional side view of a process chamber according to some exemplary implementations as described herein is shown; Figure 4 A schematic cross-sectional top view of a powder annular chamber according to some exemplary implementations as described herein is shown; Figure 5 A schematic cross-sectional top view of a process chamber according to some exemplary implementations as described herein is shown; Figures 6a to 6c A schematic cross-sectional side view of a process chamber according to some exemplary implementations as described herein is shown; Figure 7 A perspective view showing schematic illustrations of modules according to some exemplary implementations as described herein; Figure 8 A perspective view illustrating a schematic diagram of a substrate mounting module according to some exemplary implementations as described herein; Figure 9 A perspective view showing a schematic illustration of a base module according to some exemplary implementations as described herein; Figure 10 A perspective view showing a schematic illustration of a displacement module according to some exemplary implementations as described herein; Figure 11 A perspective view showing a schematic illustration of a support module according to some exemplary implementations as described herein; Figure 12 A schematic diagram illustrating the structure of a baseboard module according to some exemplary implementations as described herein; Figure 13 A schematic illustration shows the arrangement of a substrate mounting module according to some exemplary implementations as described herein; Figure 14 A schematic diagram illustrating the arrangement of process steps according to some exemplary implementations as described herein; Figure 15 A schematic illustration of a positioning module during the manufacturing process is shown, according to some exemplary implementations as described herein; Figure 16 A schematic diagram illustrating the arrangement of displacement modules according to some exemplary implementations as described herein; Figure 17 A schematic diagram of an arrangement related to another process step, according to some exemplary implementations as described herein, is shown. Figure 18 A schematic diagram of an arrangement related to another process step, according to some exemplary implementations as described herein, is shown. Figure 19 A flowchart is shown illustrating a method according to some exemplary implementations as described herein; Figure 20 Schematic illustrations of security settings based on some exemplary implementations as described herein are shown; Figure 21 A schematic diagram illustrating another security setting based on some exemplary implementations as described herein is shown; Figure 22 A schematic diagram illustrating another security setting based on some exemplary implementations as described herein is shown; Figure 23 A cross-sectional side view of a schematic illustration of a positioning system according to some exemplary implementations as described herein is shown; Figure 24 A top view illustrating a schematic diagram of a positioning system according to some exemplary implementations as described herein; Figure 25 A schematic illustration is shown of a system for generating a reference plane for position determination, according to some exemplary implementations as described herein; Figure 26 A schematic illustration shows the arrangement of a reference plane according to some exemplary implementations as described herein; Figure 27a and Figure 27b A schematic diagram illustrating the arrangement of reference lines according to some exemplary implementations as described herein; Figure 28 A top view illustrating a schematic diagram of a device according to some exemplary implementations as described herein; and Figure 29 A cross-sectional side view of a schematic illustration of a device according to some exemplary implementations as described herein is shown. Detailed Implementation

[0106] According to some aspects of this disclosure, therein is a process chamber that can be used to produce three-dimensional workpieces by an additive layer construction method.

[0107] Typically, systems and apparatuses for producing, particularly metal parts and assemblies, using additive manufacturing methods have been limited to date because the size of the process chamber must take into account the size of the parts and assemblies to be produced. Methods exist in which process chamber-based facilities can be moved via linear kinematics, thus enabling the production of fairly large assemblies. Examples of different implementations described herein illustrate such methods and the concept of using different kinds of kinematics to move the process chamber. Exemplary implementations of process chambers described herein are particularly useful when the process chamber is arranged on an industrial robot or other space-flexible handling equipment.

[0108] The exemplary implementations of this disclosure provide solutions for the design of mobile process chambers, for example, used in mobile kinematics. The exemplary implementations described herein can be used in one or more of powder coating, process gas flow, inert gas protection, process gas filtration, and spray particle removal. Omnidirectional coating can be enabled.

[0109] In particular, process chambers according to exemplary implementations as described herein can be used to perform selective laser melting and / or laser powder bed melting processes. Process chambers can provide solutions to a variety of problems, which will be described in further detail below.

[0110] Figures 1a to 1cA schematic cross-sectional side view of different configurations 100, 110, 120 of the process chamber 1 according to some exemplary implementations as described herein is shown. Thus, the shape of the process chamber 1 can vary among configurations 100, 110, and 120.

[0111] The process chamber 1 is typically circular. Circularity is preferred, especially for omnidirectional coating. The structure is typically bell-shaped, and in this example, it is positioned on the powder bed 4 at a defined distance.

[0112] In this example, the beam source 2 is positioned on top of the process chamber 1. In this example, the beam may be a (melting or) melting laser beam 5, which is guided onto the powder bed 4 to process the powder layer deposited on the working surface of the carrier 3.

[0113] If available Figures 1a to 1c As can be seen in the diagram, the optical arrangement can vary between different configurations 100, 110, and 120. As can be seen from the different configurations 100, 110, and 120, the beam deflection unit of the laser beam 5 and / or the beam source 2 can typically be arranged perpendicular to the working surface on the process chamber, or can be laterally offset and / or can be installed at a defined angle.

[0114] Figure 2 A schematic cross-sectional side view of a process chamber 1 according to some exemplary implementations as described herein is shown. Figure 2 The details of the depicted process chamber can be applied to Figures 1a to 1c Any general shape of the process chamber shown.

[0115] For process chamber 1, a single-wall or multi-wall structure can be provided. In the case of a multi-wall design, the partition walls can form cavities between the walls.

[0116] In this example, cavity 44 is formed between intermediate wall 40 and inner wall 42.

[0117] In some examples, the gas extraction unit 7 is disposed between the outer wall 46 and the intermediate wall 40, and the gas extraction unit 7 can remove protective gas from the interior of the process chamber 1.

[0118] In this example, a circumferential powder column 6 is formed between the intermediate wall 40 and the inner wall 42 by introducing powder material from each side.

[0119] Another wall 15 can be used for the supply and discharge of process gases (e.g., protective gases). This additional wall may be located on the inside, as indicated by the dashed line.

[0120] exist Figure 2An exemplary coating mechanism is illustrated. A layer deposition lip / brush / blade 11, embedded in the bottom of the process chamber, smooths the powder bed by moving the process chamber relative to the powder bed. In this example, the minimal distance between the powder column 6 and the coating device (layer deposition lip / brush / blade 11) prevents unintentional leakage of metal powder. The numerous contact points between powder particles create a clamping effect within this narrow gap, preventing unintentional leakage of powder from the cavity 44. The clamped powder also serves as a seal to prevent gas leakage from the process chamber.

[0121] In this example, a sealing lip 12, a process gas introduction unit 9, and a process gas extraction unit 10 may be provided. Additionally, a particle collector 14 may be provided, which can be used to collect, for example, oxide particles 13, which will be described in further detail below.

[0122] In this example, reference numeral 8 indicates the position where the laser beam 5 melts the powder material to produce a three-dimensional workpiece.

[0123] Figure 3 A schematic cross-sectional side view of a process chamber 1 according to some exemplary implementations as described herein is shown. Figure 3 Depicting Figure 2 The enlarged portion of the process chamber is shown. Various functions enable the protection / sealing of process gases (e.g., protective gases) within the process chamber.

[0124] In this example, the sealing lip 12 and the coating geometry (layer deposition lip / brush / blade 11) form multiple gas vortex regions (19 and 20), which can be used to reduce process gases leaking from the inside of the process chamber into the external environment. This allows the gas inside the chamber or bell-shaped structure to be particularly pure.

[0125] Between the coating geometry (layer deposition lip / brush / blade 11) and the first sealing lip 12, a first vortex region is formed by the process gas and sealed relative to the outside by adjacent powder columns 6. Remaining process gas may have traveled through the powder particles and impacted the sealing lip again. In this example, behind the sealing lip, there is a valve / sintering insert / other suction outlet 18, which allows residual process gas to be suctioned by a defined negative pressure.

[0126] In this example, the outer sealing lip forms a final vortex region 20, which prevents excessive gas from being drawn from the environment through the suction outlet 18. The vortex region can slow the airflow to such an extent that only a significantly reduced gas volume flow can occur between these regions.

[0127] In this example, a screen 21 and a gas filtration unit 16 are provided, which will be described in further detail below. Reference numeral 17 indicates the location where powdered material can be deposited onto the carrier from the end portion (in this example, the cavity).

[0128] Figure 4 A schematic cross-sectional top view of a powder annular chamber 400 according to some exemplary implementations as described herein is shown. Different methods for supplying and homogenizing powder material are depicted.

[0129] The powder supplied to the partition wall (cavity) of the process chamber can be coaxial with or laterally offset from the central axis of the process chamber (e.g., through...). Figure 4 (As depicted by reference numeral 22 in the attached figure).

[0130] The first approach for supplying and homogenizing powder material involves a material supply geometry. In this example, in the case of a coaxial arrangement, but particularly in the case of a transverse arrangement, a powder guiding geometry 23 is disposed between the inner process chamber walls, allowing the powder material to be uniformly distributed along the circumference. These geometries can be cylindrical, triangular, or free-form. Uniform distribution can produce the same powder column height at all points of the powder supply mechanism to achieve the same pressure conditions along all circumferential directions. Furthermore, this ensures that the material can be applied as uniformly as possible in all directions on the plane where it is cured.

[0131] In this example, segments 24 are also provided to provide different materials to the carrier. In this example, powdered materials 25 and 26 are provided to the carrier, which will be described in further detail below.

[0132] like Figure 3 The second method described involves sieve distribution for supplying and homogenizing powder material. This second method can be provided as an alternative to or addition to the first method for supplying and homogenizing powder material. In this example, a circular sieve 21 is arranged above a column of powder within a cavity where powder has accumulated. The sieve can be designed as a perforated sheet, wire mesh, woven piece, grinder, or even a coarse-perforated plate, or other designs using materials such as metal. The sieve also enhances the defined and uniform accumulation of powder within the partition walls (cavities) of the process chamber.

[0133] As described above, according to some examples, different types of materials or different powder materials can be supplied to the carrier through a process chamber. In this example, the cavity of the process chamber containing the powder column can be segmented so that different powder materials can be deposited at defined points on the construction plane / carrier. Segmentation 24 can be carried out in two to four sections (or another number of sections), and in some examples, each section can be filled with different powder materials 25 and 26. In some examples, each section can provide a type of material that is different from the material provided in any other section.

[0134] The process chamber can be designed for omnidirectional coating, and the process airflow can also rotate. Coating can then be performed by moving the process chamber within the configuration plane of the powder bed.

[0135] Therefore, material changes can occur during the coating process as follows: coating is performed by moving only the process chamber so that the powder column of the material to be exposed moves along the direction of movement with the front of the process chamber, and / or by aligning the chamber (by rotation) along the direction of movement of the processing device (i.e., a robotic arm).

[0136] In terms of material pairing, different metallic materials can be used. This allows for the construction of multi-material components / workpieces.

[0137] Regarding filler materials, besides serving the purpose of multi-material construction or as an alternative, one purpose of chamber segmentation can also be to separate the powder as filler material on one hand, and the powder as construction material for producing three-dimensional workpieces / assemblies on the other. The construction material can be applied wherever the powder is to be cured to produce the assembly. In powder bed areas where assembly construction does not occur, other powders, such as coarser-grained metal powders, ceramic powders, glass powders, etc., can be applied. This filler powder does not participate in the curing process but can perform support and insulation functions. The filler powder can be reused. For example, the amount of qualified metal powder required for the construction process can be reduced to lower costs.

[0138] For example, powders of different particle sizes can also be used to process (relatively) small particles 26 in edge areas more precisely and (relatively) large particles 25 in surface areas different from the edge areas more quickly. Large particles 25 can also be used to reduce dust because the greater weight of large particles 25 means that large particles 25 are not easily swirled by flowing gas.

[0139] Figure 5 A schematic diagram 500 of a process chamber according to some exemplary implementations as described herein is shown in cross-sectional top view.

[0140] In this exemplary process chamber, airflow control is provided. In this example, inside the process chamber, both the process gas introduction unit 9 and the process gas extraction unit 10 are located on a circumferential guide (moving mechanism 28). A grooved structure 29 (e.g., a perforated plate) can be circumferentially positioned in front of the process gas introduction unit 9 and the process gas extraction unit 10. In this example, a semi-circular segment 27 covers the perforated plate structure at points where process gas should not escape (at a given point in time). Gas can be introduced or extracted at uncovered points. By rotating these semi-circular segments and the associated process gas introduction unit 9 and process gas extraction unit 10, the direction of the process airflow can be dynamically adjusted. Therefore, during layer deposition and / or curing processes, the process chamber can move in all directions within the powder bed plane while the process airflow can continue to be continuously aligned, for example, in the direction opposite to the external movement of the manipulator used to move the process chamber (especially during curing processes).

[0141] In this example, oxide particles 13 formed during the workpiece manufacturing process, oversized particles, and other solid ejecta from the additive manufacturing process are collected by a particle collector 14 (e.g., a blade plate). The particle collector 14 may be crescent-shaped and horizontally positioned in front of the process gas extraction unit 10. In this example, particles remain on the actual layers on the particle collector for process construction and are configured to tilt the particle collector by pivoting the process chamber after each layer is completed, allowing particles to reach the outside of the powder bed based on their sliding off the particle collector. These particles can then be collected into a designated container.

[0142] In this example, unwanted small particles, fumes, condensates, etc., can be filtered directly from the process gas at the process chamber via a gas filter positioned directly in front of the process gas extraction unit 10 and above the particle collector 14. This filter can be cleaned periodically, or by tilting it along with the particle collector 14; this periodic cleaning is supported by controls based on specifically measured levels of contamination. Temporary backflow or pressure fluctuations of gas outside the powder bed also represent additional or alternative cleaning options for the filter. Opening the process gas extraction unit downwards can be used additionally or alternatively for particle cleaning.

[0143] Reference numeral 30 depicts the area where the powder material layer has been cured.

[0144] Figure 6a A schematic cross-sectional side view of a process chamber 600 according to some exemplary implementations as described herein is shown.

[0145] In this example, the process chamber 600 includes a heating unit 31 (e.g., a radiation heating unit or an irradiation unit). Within the bell-shaped process chamber, the heating unit 31 can be used to heat the powder bed or otherwise influence the material processing area.

[0146] The heating unit can take on different shapes. A preferred shape is a circular shape.

[0147] The heating unit can be coaxially aligned with the process laser to heat or irradiate the material processing area uniformly or in stages.

[0148] The heating unit may include one or more of an infrared emitter, a laser diode, a VCSEL, a UV emitter, an LED, and other types of lasers.

[0149] The heating unit can be freely installed in the process chamber or integrated into the wall.

[0150] The heating unit can be one or more continuous, integrated heat sources, and / or segmented, such as individually controllable heat sources. The heat source can be fixed or movable within the process chamber. For example, this movement within the process chamber can be circular.

[0151] In addition to or as an alternative to radiation variants, one or more induction heating devices may be used.

[0152] In this example, a pipe 32 is provided on the periphery of the process chamber, from the outside to the inside of the process chamber (in this example, bell-shaped), so that values ​​about the process or process conditions can be obtained from the inside of the process chamber using one or more sensors 33 or a sensor system when producing a three-dimensional workpiece.

[0153] The advantages over existing systems are: particularly the application of powder around the entire build area, enabling omnidirectional coating (potentially eliminating the need for a central coater). Furthermore, the multi-walled structure allows for the extraction of process gases, which can be propelled outwards by a slight overpressure within the chamber. This ensures a particularly clean process gas atmosphere. Additionally, multiple small vortex regions designed below the process chamber result in a relatively low leakage rate. Moreover, the rotating gas introduction and extraction unit ensures that the airflow is consistently aligned with the direction of movement of the process chamber. Furthermore, unlike prior art, the particle collector captures waste rather than integrating it into the part to be built. The integrated gas filter eliminates the need for external filters. In particular, radiant heating allows for localized influence on the temperature balance within the chamber and on the powder bed. Finally, the powder distribution geometry ensures uniform circulation of the powder column.

[0154] All of the above enable the efficient production of high-quality 3D workpieces.

[0155] Figure 6b A schematic cross-sectional side view of a process chamber 602 according to some exemplary implementations as described herein is shown. In this example, an annular heating unit 604 is disposed in the bottom portion of the process chamber. The heating unit 604 may be one or more continuous, integral heat sources, and / or segmented, such as individually controllable heat sources. The heating unit may include one or more of an infrared emitter, laser diode, VCSEL, UV emitter, LED, inductive radiation source, and other types of radiation sources and / or particle emission sources. In this example, the heating unit 604 is arranged radially outward from other components, particularly radially outward from the cavity supplying powder (or another material).

[0156] The annular heating unit 604 can be used to heat metal powder for one or more of the following purposes: increasing the temperature level (of the curing unit / device for curing materials) under reduced voltage, drying powder, increasing the adhesion between powder particles (sintering columns) to passivate active powder and / or reducing powder turbulence and flow outside the process chamber, and / or reducing welding fumes or particle flight within the process chamber in the SLM process, and / or reducing the supply material cone for three-dimensional workpiece assembly, because the resulting powder deposition can make the material deposition angle along the three-dimensional workpiece assembly direction steeper.

[0157] Figure 6c A schematic cross-sectional side view of a process chamber 606 according to some exemplary implementations as described herein is shown. Process chamber 606 is generally the same as process chamber 602, whereby process chamber 606 includes two heating units 604, one heating unit located radially outside the cavity for supplying powder (or another material) and the other heating unit located radially inside the cavity for supplying powder (or another material).

[0158] It should be understood that the components of two or all of the process chambers in process chambers 600, 602, and 606 are combinable. The components of each process chamber in process chambers 600, 602, and 606, and any combination thereof, may be combined with one or more components of the process chambers depicted in any or more of the other figures.

[0159] The efficiency of producing three-dimensional workpieces can be further improved by using a modular system according to the exemplary implementation described herein.

[0160] The process chamber can be attached to a robot or robotic arm to perform additive manufacturing processes. In addition, the design can aim to construct large-volume additive components while maintaining maximum possible flexibility in production layout. The following factors should be considered.

[0161] Depending on the construction sequence (e.g., for large components), mobile production units (which may include process chambers) can consume more space. This may require solutions that allow for flexible combinations of installation space to achieve an overall reduction in manufacturing site size.

[0162] Furthermore, in production sequences with large structural volumes, it may be necessary to supply more powder to the process accordingly. To reduce necessary procurement costs and avoid powder aging, a solution that reduces the required powder quantity may be necessary.

[0163] Furthermore, the encapsulation of the process and the use of protective gases in the process can reduce the impact of external negative influences on the process.

[0164] Furthermore, the support volume required for laser beam melting processes can depend on factors such as the shape, orientation, and size of the component to be produced. The amount of support can be reduced through appropriate measures, thereby improving economic efficiency (by saving time and materials).

[0165] The above content forms a starting point for describing the following exemplary implementations, which, in particular according to the aforementioned process chamber, can further improve the production efficiency of three-dimensional workpieces, thereby enhancing the efficiency improvement based on the process chamber. Exemplary implementations include suitable configurations for the modular design of process components, which can be flexibly supplemented, for example, according to the construction schedule. The resulting technical advantages, on the one hand, realize the potential to reduce resource consumption when using mobile production units (including process chambers) (e.g., by using smaller amounts of powder to construct components or reducing support volume), and also improve the efficiency of workpiece production (particularly when certain component parts or modules can be used, thus potentially eliminating the need for material deposition in the corresponding areas filled by the components or modules). On the other hand, the methods described herein enable the design of flexible mounting spaces, which can be designed, for example, according to the shape of the workpiece to be produced.

[0166] In addition to using modular systems for mobile production units, one can also imagine that modular systems can be used in existing manufacturing sites and technologies.

[0167] A process is described in which a flexible installation space arrangement, which depends on the construction order (e.g., the shape and alignment of components), can be used primarily (but not exclusively) for moving production cells.

[0168] Figures 7 to 11 The different modules used in the process of producing three-dimensional workpieces are shown.

[0169] Figure 7Different wall modules 700 with different connection directions are depicted. A sealing body wall module 702, a sealing element wall module 704, a positioning unit wall module with a top side 706 and a bottom side 708, and a clamping unit with a top side 710 and a bottom side 712 are shown.

[0170] Figure 8 A substrate mounting module 800 is depicted. In this example, the substrate mounting module 800 includes a positioning unit substrate mounting 802, a substrate mounting 804, and a clamping unit substrate mounting 806.

[0171] Figure 9 A base (plate) module 900 is depicted. In this example, the base (plate) module 900 includes a clamping unit base plate 902, a positioning unit base plate 904, and a plug connection element 906 (the plug connection element 906 may be closed based on, for example, a form for connecting different base (plate) modules).

[0172] Figure 10 The displacement module 1000 is depicted. In this example, the displacement module 1000 includes a top 1002 of the displacement clamping unit, a top 1004 of the displacement positioning unit, a bottom 1006 of the displacement positioning unit, and a bottom 1008 of the displacement clamping unit.

[0173] Figure 11 Support module 1100 is depicted. In this example, support module 1100 includes substrate mounting module 800 and displacement module 1000.

[0174] The descriptions of the various features and characteristics of the module are presented below using exemplary and preferred process flows. For this purpose, each process step is selected in ascending time order (process time increases as the number in the image increases), and in... Figures 12 to 18 The examples are presented in the text.

[0175] In a preferred implementation, the manufacturing process begins with the arrangement of the base plate modules. These components represent the bottommost parts of the manufacturing process to be performed by the mobile manufacturing / production unit and serve as a spatial separator between the foundation (e.g., hall floor) and the process components (powder, components, etc.) above.

[0176] The arrangement of the plates follows an automatic or manual layout selected by the user, and may, for example, depend on the workpiece to be produced. The advantage of this process is that the base (plate) modules can be placed close to the workpiece contour, thus saving space and allowing for flexible arrangement. This also results in reduced use of powder material for producing the powder bed, and therefore a lower amount of powder exposed, leading to powder aging.

[0177] Figure 12 A schematic diagram of an exemplary structure 1200 of a base (plate) module assembled in an assembly manner is shown.

[0178] In this example, the clamping unit base plate 902 includes a clamping arrangement. In this example, the positioning unit base plate 904 and the plug connection element 906 include a form enclosure.

[0179] Connections between adjacent base (plate) modules can be achieved, for example, through formal closure (i.e., positive locking), force closure, or a combination of different connection technologies (e.g., a combination of formal closure and force closure).

[0180] Figure 12 The preferred square shape of the upper base (plate) module is shown. However, other suitable shapes (e.g., star shapes) are also conceivable, which can be designed, for example, according to the workpiece task and / or available space. In cases where the shape is not square, it may be necessary to at least partially ensure that the base (plate) module and the substrate plate module arranged above the base (plate) module are arranged continuously without gaps, making continuous component structures possible (e.g., between adjacent base plate modules).

[0181] Figure 13 A schematic diagram of the arrangement 1300 of the substrate mounting module is shown.

[0182] The substrate mounting module can be located on the following side (see...) Figure 8 It is connected to the base plate module below, for example by force and form closure connection. In a preferred variant, the base plate module has suitable matings on functional elements running in a right-angled grid for holding and securing the substrate elements located on the base plate module. Figure 12 Examples of these elements as positioning units (e.g., form-closed, i.e., positive locks) and clamping units (e.g., clamping devices) are shown. Any other suitable connection method may be selected.

[0183] It should be noted that the joining / connection technique used in this example can temporarily fix the modules, thus preventing unintentional displacement of the connected modules during the (manufacturing) process, and allowing the modules to be easily separated after the manufacturing process for producing the workpiece.

[0184] In this example, the upper substrate module (see...) Figure 13 Preferably, it also has a square shape. The number and location of the substrate modules preferably follow the workpiece shape and / or the selected initial layer of the construction task.

[0185] Figure 14 A schematic diagram of the arrangement 1400 of the process steps is shown, wherein, in this example, different regions having adjacent substrate modules appear separately from each other, on which workpiece layers can be fabricated separately from each other (at least initially).

[0186] exist Figure 14 The diagram shows powder material 1402, and a cured layer n 1404 is prepared based on powder material 1402.

[0187] As the workpiece is constructed, powder cones can be formed along the layer profile and depending on the powder application. For example, powder can be selectively applied (e.g., by means of a suitable powder application mechanism, such as, as described herein, using a process chamber) to reduce the volume of powder used. This can result in the formation of multiple powder cones (see [link to documentation]). Figure 14 It may be necessary to select the powder application in such a way that the area of ​​powder to be cured does not slip before the powder is exposed (along the cone of the bulk material). This can be ensured by extending the powder application area more strongly beyond the workpiece or layer boundary.

[0188] It may also be necessary to select the layout of the base plate module (see...) Figure 9 This allows the powder material to be completely retained on the base plate module. Thus, the powder material can cover the substrate module (see...). Figure 14 ).

[0189] If the process (starting from the top of the baseplate module) has progressed to the point where the height of the current layer n exceeds the height of the wall modules, displacement modules, and / or support modules, then the aforementioned modules may be considered in the following arrangements (if suitable). In a preferred variant, the positioning of these modules is not pre-planned to avoid imposing any limitations on the radius of action during the layering process of moving the curing and coating (material supply) unit. On the other hand, the arrangement of the baseplate modules may also be dimensionally determined (before material layer supply and processing) to allow the production unit to be arbitrarily positioned above the relevant process area or the substrate module. If the wall modules are arranged before layer construction, this can have the advantage of dense boundaries of the process area (e.g., for introducing protective gas in the clamped "bowl"). Furthermore, combinations of wall modules, displacement modules, and / or support modules positioned before and during the process may also be considered.

[0190] Figure 15 A schematic illustration 1500 of a preferred variant for positioning the module during the manufacturing process is shown.

[0191] In this example, a wall module is added as indicated by arrow 1502. Further indication is given for process region 1504, where powder has been removed.

[0192] In some examples, before applying the illustrated wall and support modules to their intended locations, it may first be necessary to remove powder material at these points (if appropriate) to expose the functional elements beneath the base plate components and to enable, for example, the connection of the wall modules to the corresponding base plate modules. Powder removal and module positioning may also be selectively performed when the construction process for the current layer or production cell is not occurring (e.g., possibly due to workpiece size) to avoid process interruptions and reduce non-production time. Powder removal (e.g., using vacuum suction) and module machining can be performed using suitable robotic arms (e.g., one or more robots).

[0193] After applying the modules mentioned and anticipated for each case, the powder bed in the empty gaps can be filled with powder material, allowing for uniform layer application to the next layer n+1 as well. In some examples, the powder supply required for this can be performed by moving the production unit, or by another robotic arm (e.g., one or more additional robots).

[0194] Figure 16 A schematic diagram of the arrangement 1600 is shown, in which displacement modules are used in particular.

[0195] By using displacement modules, material filling processes may require less powder material, while wall modules can reduce the amount of material cones formed. Using displacement modules makes manufacturing processes more efficient.

[0196] exist Figure 16 The diagram also illustrates a support module used between two previously separate construction areas. In these areas, a shortened support structure can be constructed according to the exemplary construction schedule shown.

[0197] Figure 17 A schematic illustration of an arrangement 1700 associated with another process step, based on some examples as described herein.

[0198] The cured layer n+1 (1702) is depicted. The constructed support structure 1704 (belonging to layer n+1) is also shown.

[0199] This means that it may no longer be necessary to set up support structures based on the substrate plane, thereby reducing unnecessary material consumption and processing time.

[0200] Figure 18 A schematic illustration of an arrangement 1800 related to another process step, based on some examples as described herein, is shown. Then, thus in Figure 17 Following the process steps shown, the next layer n+2 (as provided in the example) can be extended on the support structure to follow the previously defined workpiece or layer shape.

[0201] The layered structure can continue until the next wall module, displacement module, and / or support module, which can be placed on the existing module and the above process can be repeated. In a preferred variant, the same functional elements or connection technologies as those already used on the top of the base plate module can be found on the top of the respective module.

[0202] Depending on the construction progress, subsequent layer structures and module arrangements can be repeated until the last layer has been fully exposed and thus solidified.

[0203] In some examples, this process may need to be supplemented by the fact that above a certain height, shear stress can act on the wall modules (e.g., due to the mass of powder pressing on the wall modules), thus enabling the use of additive reinforcement modules (not shown). In a preferred form, the additive reinforcement modules may be plate-shaped and connected to each other on the upper side of multiple wall modules based on the connection technology described above. Such intermediate plate components may also have corresponding connecting elements on their upper side, allowing the next wall module to be subsequently connected to the top of the intermediate plate component.

[0204] For example, the shape and size of the wall modules, displacement modules, and / or support modules can be adjusted by the construction task or available space. In a construction process, combinations of different sizes can also be envisioned, such as by using displacement modules, to significantly reduce the size and number of gaps in the powder material.

[0205] In addition to the displacement modules described above, bulk materials (e.g., having a "spherical" shape) can also be used to perform the "displacement function." Besides displacement modules, bulk materials can also be used to fill remaining intermediate areas (e.g., where displacement modules cannot be used due to lack of space) and further reduce powder consumption. In some examples, after the manufacturing process, the bulk material can be separated from the powder again, and preferably fed to subsequent processes through a grading process that is much larger than that of the powder material, such as by a sieving process.

[0206] In another variant, the displacement module can also be replaced by a separate solid "rod" (not shown), driven layer by layer along the assembly direction from the substrate and / or base plate module through sealed openings (e.g., through bottom recesses) as the process progresses. These rods can also be used in addition to displacement modules. These rods can also be combined with the aforementioned bulk materials, allowing our processing to eliminate the need for one or more displacement modules.

[0207] The aforementioned modules are particularly advantageous for providing efficient processes for producing three-dimensional workpieces.

[0208] The process is also applicable to other material forming technologies, such as printing.

[0209] Figure 19 A flowchart of method 1900 according to some exemplary implementations as described herein is shown.

[0210] In step S1902, a modular system is provided (according to any of the exemplary implementations described herein).

[0211] In step S1904, based on the shape of the three-dimensional workpiece to be produced and according to the position of the material to be processed, one or more substrate modules are arranged on one or more positions of the base plate module.

[0212] In step S1906, material is provided on one or more substrate modules.

[0213] In step S1908, materials are processed using additive manufacturing technology to produce a three-dimensional workpiece.

[0214] In method 1900, a process step may be used, which is based on Figures 13 to 18 Any one or more arrangements shown, using Figures 7 to 11 One or more modules are shown.

[0215] Thus, in some examples, method 1900 may specifically include the use of a process chamber according to an exemplary implementation as typically described herein.

[0216] Even in SLM systems with large construction sites and no direct machine enclosure, it may be necessary to ensure laser safety or general radiation safety, and to eliminate any danger / hazard posed to humans by the emitted (laser) radiation. However, at the same time, it may be necessary to ensure access to the process space to allow for planned entry into the work area in the event of any malfunction or even as scheduled.

[0217] The exemplary implementation described herein enables the detection of openings (authorized or unauthorized) in structurally shielded process / work areas and / or the detection of changes in the position (and / or orientation) of a process chamber relative to a powder bed, such openings or changes could expose personnel to threats such as free laser radiation (e.g., due to powder bed lifting and / or tilting of the process chamber relative to the process plane). Based on this detection, laser release from one or more lasers could be locked, or the complete shutdown of one or more lasers could be performed.

[0218] The exemplary implementations described herein relate to safety (control) devices for manufacturing systems and sites, wherein process chambers (as described above) are freely movable and there is no structural shielding of the environment, or where structural shielding is required, personnel must be protected to access the interior space, for example, from free laser radiation.

[0219] When the process area is structurally shielded from the environment, such as through a separate space, flexible chamber, or bellows, the internal pressure can be monitored, and one or more lasers can be shut down or laser release can be prevented when a pressure drop occurs when the shield is opened (authorized or unauthorized).

[0220] Figure 20 A schematic diagram illustrating a security setting based on some exemplary implementations as described herein is shown.

[0221] As can be seen, the mobile production unit is arranged on a robotic arm, in this example, on a robotic arm. The entire arrangement is housed within a housing 2002. The internal pressure of the housing 2002 is denoted as p1, which is equal to x. The internal pressure p1 is greater than the external pressure of the housing 2002, which is denoted as p0.

[0222] In this example, Figure 20 The arrow on the lower left side of the diagram above indicates the structural seal within the closed area of ​​housing 2002. Figure 20 The large arrow in the middle section indicates that the casing 2002 is subsequently opened, as shown. Figure 20 As shown in the diagram below. As a result, the pressure p1 decreases, leading to one or both of the following: the laser shuts off and the robotic arm stops moving (or otherwise affects, for example, the degree of movement is limited). The decrease in p1 is due to gas leaving the interior of the housing 2002 and reaching the exterior.

[0223] In addition to or as an alternative to the aforementioned pressure monitoring, a door switch (e.g., a push-button switch and / or a magnetic switch) may be provided, wherein when the switch is activated or another condition of the switch is changed, one or both of the following occur: the laser is turned off and the robotic arm stops moving (or otherwise affects, for example, the degree of movement is restricted).

[0224] As described above, the movement of a robotic arm can be stopped (or otherwise affected, for example, the degree of movement can be limited) depending on the fulfillment of specific conditions. Therefore, the movement of one or more industrial robots can also be coupled to safety (control) devices, thereby, for example, limiting and / or slowing down the movement of one or more robots in space.

[0225] Additionally or alternatively, for example, without structural shielding, the distance between the process chamber (moving production unit) and the powder bed can be monitored by at least one sensor, and the raising and lowering of the process chamber from the powder bed can be detected. One or more lasers can then be shut off to prevent free laser radiation from entering the environment.

[0226] This is Figure 21 It is described in the text. Figure 21A mechanism for preventing laser from entering the environment when a process chamber is tilted is generally illustrated. In this example, the tilt of the process chamber relative to the build layer is detected based on the distance sensors sensing that the distance from one side of the process chamber to the build layer is no longer the same as the distance from the other side of the process chamber to the build layer. Thus, in this example, the sensors are arranged at approximately the same height on opposite sides of the process chamber. It should be understood that, alternatively, the sensors can be arranged at different heights on different sides of the process chamber, and the change in distance from one sensor to the build layer when the process chamber is tilted can be different compared to the change in distance from the other sensor to the build layer, making it possible to detect the tilt of the process chamber. Other possibilities will be apparent to those skilled in the art.

[0227] One or more of the aforementioned sensors can monitor distance inductively and / or capacitively and / or based on the runtime of a signal (e.g., an ultrasonic signal).

[0228] One or more of the aforementioned sensors may be located outside and / or inside the process chamber.

[0229] In some examples, the above monitoring can be combined with a position query of one or more deflection units of one or more lasers, which, together with the position of the end effector, can be used to calculate whether laser radiation or reflection can escape at that location.

[0230] Figure 22 An arrangement is shown in which the deflection of the laser beam from the build-up layer determines whether radiation can exit the process chamber. As shown, this functionality can be combined with the aforementioned distance sensor. It can also be used in combination with any one or more safety mechanisms.

[0231] In an example of monitoring internal pressure in a process chamber, this pressure monitoring may be performed based on one or more sensors used to monitor for leaks in areas (e.g., within the housing and / or process chamber), so that the sensor values ​​can be used for safety circuitry.

[0232] Using one or more sensors—a single sensor that detects changes in the distance from the process chamber to the build layer (which can also detect when the process chamber is no longer covered or is typically no longer covered by the build layer)—to monitor the distance / position / orientation of the process chamber enables robotic production of large components without the need for a laser protective enclosure or similar laser safety structure shielding. This saves on the cost of such a housing and allows for greater flexibility in workpiece size. Furthermore, omitting the complete housing over the entire working area significantly simplifies powder removal and further workpiece transport.

[0233] Furthermore, when one or more sensors are used directly in the process chamber in a multi-robot setup, only one or more lasers that are not in the correct position in the process chamber can be selectively turned off, thus limiting productivity to a minimum.

[0234] Assuming that the mobile production cell / process chamber used in the additive manufacturing process described herein can be moved by a robot (e.g., a robotic arm), the equipment enables the production of additive workpieces with large volumes while ensuring a high degree of flexibility in relation to production layout.

[0235] Challenges associated with implementing this concept include ensuring process precision that meets requirements, particularly for laser beam melting. Tolerances can arise for layer-related positioning of currently common layer heights (e.g., 50 μm), robotic arms (e.g., robots), or production cells mounted on them, which can negatively impact production results.

[0236] The exemplary implementations described herein enable the use of a moving production cell to position a robotic arm before or during an additive manufacturing process. In some examples, the initial layer should first be correctly constructed at the correct location in the layer plane and at the correct build height directly above the substrate (carrier) in the process flow. For example, at even distances (e.g., after multiple n layers), the position correction or calibration of the moving production cell may need to be performed again by the positioning system described herein. Such correction or calibration may be required, for example, if compensation for temperature fluctuations or other error variables may be necessary.

[0237] A process for positioning a robotic arm (e.g., a robot) or a mobile production unit mounted thereon is described, thereby enabling positioning to be performed during additive manufacturing processes in some examples. Consequently, tactile measurement systems, which are relatively more cost-effective than optical systems, can take over these position checking and position correction tasks.

[0238] Figure 23 A schematic illustration of a cross-sectional side view of a positioning system 2300 according to some exemplary implementations as described herein is shown.

[0239] In this example, the positioning system 2300 includes a robot 2302, which is coupled to a corresponding mobile production unit 2304. It should be understood that the positioning system can also be used in systems with one or a different number of robots / mobile production units.

[0240] Furthermore, in this example, multiple measurement sensors 2306 are arranged on each mobile production unit 2304. A receiving device 2308 for receiving the measurement sensors 2306 is provided on each mobile production unit 2304.

[0241] In this example, the positioning unit 2310 is arranged at a defined position in the edge region of the carrier (substrate 2316). The positioning direction 2312 associated with each positioning unit 2310 is indicated by a vertical arrow.

[0242] For the purpose of explanation, Figure 23 The paper also depicts powdered material 2314 and different workpiece layers 2318.

[0243] In this example, two moving production cells are shown at time m, located in the process sequence shown before the exposure of the next layer n. Prior to the exposure of layer n, at this point in the manufacturing process, the production cells can move to their respective positioning cells to check the correct absolute positions of the production cells and, if necessary, correct the values ​​of these absolute positions. For this purpose, the positioning cells are arranged on one side of the edge region of the substrate.

[0244] The distribution or number of these positioning units depends, for example, on the ability of the mobile production units to access them. In some examples, it may be necessary to ensure that a robotic arm (e.g., a robot) can reach at least one positioning unit at a given time. However, in some examples, this number can be significantly increased when optimizing the travel paths of the mobile production units. It may also be necessary to consider that the mobile production units do not obstruct each other's travel paths during the positioning process.

[0245] It should be understood that mobile production units cannot undergo the positioning / calibration process simultaneously, but rather at different points in time.

[0246] In this example, the measuring sensors are arranged directly on the production cell along three spatial directions (according to the Cartesian coordinate system) and form a pair of positioning cells.

[0247] Figure 24 A schematic top view of the arrangement of a positioning system 2300 according to some exemplary implementations as described herein is shown.

[0248] exist Figure 24 The diagram also shows the unmanned transport system 2402, the positioning axes 2404 of each robot, and the positioning directions 2406 of the unmanned transport system and the robots.

[0249] If possible Figure 23 and Figure 24As seen in this variant, the positioning units in this example consist of individual plates manufactured with high precision and perpendicular to each other. In this example, the arrangement opens to the top and sides along the layer plane, allowing measuring sensors (mounted on the moving production unit) traveling to one or more positioning units to be positioned. For example, at least one absolute value can be determined by tactile contact (simultaneously or individually) between at least one measuring sensor and the opposite wall of the positioning unit, and position correction can be performed if necessary (e.g., in case of deviation from the correct initial value). In the case of tilt errors in the moving production unit, three measuring sensors arranged along three spatial directions are preferably used to check the tilt setting and correct the tilt setting if necessary.

[0250] Furthermore, it is conceivable that the positioning units can be mounted on high-precision spindles, allowing them to move along the workpiece's construction direction. For example, one or more of these positioning units can move according to the progress of the process used to manufacture the three-dimensional workpiece. This may be preferred, for example, where positional deviations may only be desired along the mounting direction, and if necessary, to correct for positional deviations within the layer in another manner (e.g., by other process components). In some examples, after such positional correction, a robot (e.g., a manipulator) can move in a circular path (starting from the positioning unit) to a defined position to expose the material layer used for supplying and / or curing material to produce the workpiece. In some examples, where the manipulator has a series kinematic structure, for this form of movement, a smaller number of axes may need to move simultaneously, thereby reducing positional errors (e.g., based on tolerances).

[0251] Therefore, the positioning system enables the use of mobile production cells / process chambers, based on the precisely defined position determination and / or correction of the mobile production cell / process chamber (attached to the robotic arm) to supply and / or cure materials with high quality. This allows for more efficient supply and / or curing of materials while maintaining the high quality of the produced workpieces.

[0252] In particular, in multi-material laser beam melting, the use of powder preparation steps (separating mixed powders from the process) performed after the manufacturing process can be largely or completely avoided by using a process that includes the use of a positioning system as described above.

[0253] As described above with respect to the various exemplary implementations, a mobile production unit (e.g., including or integrated with a process chamber) can be moved by a manipulator (e.g., an industrial robot). Thus, the mobile production unit can be attached to an end effector (e.g., the last kinematic component of a robot).

[0254] In addition to optics for beam shaping and deflection, the moving production unit may also include a material (e.g., powder) supply unit. The position of the moving production unit relative to the powder bed surface determines the intensity of the laser radiation on the powder bed and the height of the applied powder layer. Even a deviation of a few μm or a tilt of a few degrees can lead to significant deviations in workpiece quality.

[0255] However, since the robot's absolute positioning accuracy may not be sufficient to maintain the accurate position of the moving production unit relative to the powder bed, in some examples, it may be necessary to use external measuring devices to record and control the position.

[0256] The exemplary implementation described herein can be used to define a reference coordinate system for any number of robots to increase the positioning accuracy of mobile production cells.

[0257] The exemplary implementations described herein are based on generating reference planes and / or lines using, for example, laser radiation. These planes and / or lines are detected by detectors and their relative positions to the moving production unit can be determined. In some examples, this information can be used to correct the position of the moving production unit or the scan field via closed-loop control.

[0258] The following text describes examples of how to generate and use reference planes and lines.

[0259] Figure 25 A schematic illustration is shown of a system 2500 for generating a reference plane for position determination, according to some exemplary implementations as described herein.

[0260] In this example, the reference plane is always parallel to the powder bed surface. In this example, the plane is generated by a laser 2502 with appropriate optics to produce a linear beam profile. Another possible design for generating the reference plane could be to deflect a point-like laser beam into a straight beam using a polygon scanner.

[0261] In this example, laser 2502 generates laser segment 2504, which can be detected by detectors 2508 and 2510, which are arranged on the mobile production unit 2506.

[0262] In this example, the laser beam 2512 is detected by detectors 2508 and 2510 located at a specific height h above the zero horizontal plane 2518 (the material layer to be processed for producing the three-dimensional workpiece can be arranged at this horizontal plane). The focal point 2514 of the laser beam on the detector horizontal plane and the tilt 2516 of the moving production unit 2506 relative to the reference plane are indicated.

[0263] As described above, the height of the reference plane above the powder bed can be changed so that the position of the reference plane can represent the target position of the powder layer.

[0264] In some examples, the relative position of the reference plane and the moving production unit can be continuously detected by a suitable detector at the moving production unit. For example, a CCD chip or a position-sensing side device (PSD) can be used as the detector.

[0265] In some examples, the localization of the moving production cell can be performed in two steps: it can be assumed that the robot's localization accuracy is sufficient to bring the reference plane into the detector's field of view (in some examples, the detection range can be a rectangular surface with, for example, an edge length of about 5-10 mm). If the reference plane is detected, fine localization can be performed using closed-loop control with the relative position between the reference plane and the moving production cell as the control parameter.

[0266] This position can be corrected by moving the chamber and / or by coordinate transformation of the scan field. If the reference plane is detected by more than one detector, the tilt of the moving production unit around the corresponding axis can be calculated, in addition to its position along the z-axis, based on the relative position of the reference plane in the detector's spatial coordinate system (see [link to relevant documentation]). Figure 25 (on the right side).

[0267] In some examples, if more than one motion generation unit is used, it may be necessary to ensure that the acquisition of the reference plane is not interfered with by another motion generation unit.

[0268] Figure 26 A schematic illustration of an arrangement 2600 of reference planes according to some exemplary implementations as described herein is shown. Thus, arrangement 2600 can be used to generate multiple reference planes simultaneously.

[0269] In this example, a first reference plane 2608 and a second reference plane 2610 are generated for the first robot 2602, the second robot 2604, and the third robot 2606. Figure 26 The shadows cast on the reference plane by objects present in each beam are not shown.

[0270] In this example, detector 2508 is positioned at the top (end of the robot) of the mobile production unit.

[0271] Figure 27a and Figure 27b A schematic illustration of the arrangement 2700 of reference lines according to some exemplary implementations as described herein is shown.

[0272] exist Figure 27aIn this configuration, detector 2508 is arranged on mobile production unit 2506, allowing positioning to occur in the xy-plane. Thus, mobile production unit 2506 moves above construction plane 2704 via robot 2702. In this example, linear axis 2708 is defined by bracket 2710, thereby defining reference line 2706.

[0273] exist Figure 27b In this configuration, two or more detectors are arranged along a linear axis and, in this example, receive laser radiation (or other types of radiation) reflected at a fixed angle. As the laser beam strikes a detector, its position, distance, and tilt along the xy-plane can be determined by moving the laser beam's position.

[0274] If possible Figure 27a and Figure 27b As seen in the example shown, the laser beam source used as a reference line can be moved along any combination of xyz axes using a combination of linear axes. Figure 27a and Figure 27b The example illustrates how kinematics enables movement along the xy-plane. Therefore, in some examples, the positioning accuracy of the reference line may need to be sufficiently high, since the focal point 2514 of the laser beam on the detector's horizontal plane can represent the target position.

[0275] exist Figure 27a In this setup, the laser beam source is movably mounted on a linear axis, and the detector is located on a moving production unit. This configuration allows for the determination of positional deviations in the xy-plane.

[0276] As mentioned above, Figure 27b A detector and a laser beam source are shown on a linear axis. In this example, the laser beam is reflected from the moving production unit to the detector at a fixed angle by suitable optical elements. By using two or more beam source-detector combinations, the relative displacement of the beam on the detector can be compared with the tilt of the moving production unit along the xy-axis and the distance from the moving production unit to the detector.

[0277] Any combination of the solutions described in this article can determine the location of a moving production unit.

[0278] Exemplary implementations of systems / devices using one or more reference planes and / or lines are particularly superior to camera-based systems. In camera-based systems, accuracy decreases with increasing distance from the sensor. Therefore, positioning is often not precise enough in camera-based systems. As described herein, exemplary implementations of systems / devices using one or more reference planes and / or lines are also particularly superior to laser-tracker systems, which are relatively expensive and currently require four trackers to accurately determine the robot's position.

[0279] Advantageously, in exemplary implementations of systems / devices using one or more reference planes and / or lines as described herein, the acquisition and control of measurement variables are relatively simple; and the integration of multiple robot systems is also easily achieved compared to other positioning systems.

[0280] Figure 28 A top view of a schematic illustration of a device 2800 according to some exemplary implementations as described herein is shown.

[0281] In this example, device 2800 includes two robots 2302a and 2302b.

[0282] In this example, robot 2302a includes curing unit 2808.

[0283] In this example, robot 2302b includes layer supply unit 2812.

[0284] The robot's positioning axis 2404 is in Figure 28 Described in the text.

[0285] An unmanned transport system 2402 is provided, and a robot 2302b is deployed on the unmanned transport system 2402. A robot 2302a is deployed on a corresponding unmanned transport system. The positioning direction 2406 of the unmanned transport system is indicated.

[0286] In this example, the device 2800 further includes a process gas conduit (or channel) 2810 through which process gas (e.g., protective gas) can be supplied to the construction area to produce a three-dimensional workpiece.

[0287] In this example, Figure 28 The powder layer n (2802), the cured layer n of the workpiece (2804), and the powder layer n+1 (2806) are shown.

[0288] Figure 28Other functional combinations of the different units depicted are possible. For example, the first mobile production unit includes a curing device adapted to produce a cured material layer on a carrier for producing a workpiece by an additive layer construction method; the second and / or third and / or fourth mobile production units include a material supply unit adapted to supply material to the carrier and / or the curing device; wherein the second and / or third and / or fourth mobile production units include a gas supply system adapted to supply a protective gas to the area irradiated by the curing device; and wherein the second and / or third and / or fourth mobile production units include a layer deposition mechanism for forming the supplied material into a material layer on top of the carrier; wherein the second, third, and fourth mobile production units do not include the curing device. Other combinations are also possible.

[0289] Figure 29 A schematic cross-sectional side view of a device 2900 according to some exemplary implementations as described herein is shown.

[0290] In this example, device 2900 includes two robots, each having a first robotic arm 2908 and a second robotic arm 2906.

[0291] In this example, device 2900 further includes particle collector 2910.

[0292] In this example, the first mobile production unit includes a connection module 2912 to connect the robotic arm 2908 to the curing unit 2808a and the layer supply / deposition unit 2812a. In this example, the second mobile production unit includes a connection module 2904 to connect the robotic arm 2906 to the curing unit 2808b and the layer supply / deposition unit 2812b.

[0293] Therefore, curing units 2808a and 2808b can be radiation units.

[0294] exist Figure 29 The diagram also shows a radiation beam 2902, a curing layer, a substrate 2316, a powder material 2314, and a process airflow 2914.

[0295] The following examples are also included in this disclosure and may be incorporated in whole or in part into the embodiments.

[0296] 1. A process chamber for producing three-dimensional workpieces using an additive manufacturing method, the process chamber comprising: A material supply unit includes a generally annular end portion located on a first side of a process chamber. The material supply unit is adapted to supply material via the end portion to a carrier on which the material is processed by the process chamber to produce a three-dimensional workpiece. An opening, located on the first side of the process chamber, is used to process materials supplied to a carrier to produce three-dimensional workpieces. The generally annular end portion surrounds the opening.

[0297] 2. The process chamber according to Clause 1, wherein the material supply unit includes a bell-shaped structure through which material can be supplied to the carrier, and wherein the end portion forms the end of the bell-shaped structure.

[0298] 3. The process chamber according to clause 1 or 2, wherein the process chamber includes a multi-walled structure, and wherein a first cavity is formed between a first wall and a second wall of the multi-walled structure, the first cavity being included in or connected to a material supply unit.

[0299] 4. In particular, the process chamber according to Clause 3, the process chamber for producing three-dimensional workpieces by additive layer construction method, the process chamber including a gas extraction unit and / or a gas introduction unit, wherein a second cavity is formed between a third and a fourth wall of a multi-walled structure, wherein the second cavity is arranged radially outside the first cavity along a direction away from the central portion of the process chamber, and wherein the second cavity is included in the gas extraction unit and / or the gas introduction unit, or the second cavity is coupled to the gas extraction unit and / or the gas introduction unit, the gas extraction unit and / or the gas introduction unit being configured to extract gas from the central portion of the process chamber and / or introduce gas to the central portion of the process chamber.

[0300] 5. The process chamber described in Clause 4 when subordinate to Clause 3, wherein the second wall and the third wall are integral.

[0301] 7. The process chamber according to any one of clauses 3 to 5, wherein a third cavity is formed between the fifth and sixth walls of the multi-walled structure, and wherein process gas is introduced into and / or extracted from the process chamber through the third cavity.

[0302] 7. The process chamber according to any of the foregoing clauses, the process chamber further comprising a curing device adapted to cure the material supplied to the carrier for the production of a three-dimensional workpiece.

[0303] 8. The process chamber according to Clause 7, wherein the curing device is offset from the central axis of the process chamber, wherein the central axis is defined as perpendicular to the plane defined by the opening of the process chamber and passing through the center point of the opening.

[0304] 9. The process chamber according to any of the foregoing clauses, the process chamber further comprising a layer deposition mechanism disposed on a first side of the process chamber and adapted to form the supplied material as a material layer on top of the carrier.

[0305] 10. The process chamber described in Clause 9 when subordinate to Clause 3, wherein the layer deposition mechanism is arranged adjacent to and radially inside the first cavity for controlling the supply of material to the carrier through the first cavity via the layer deposition mechanism.

[0306] 11. The process chamber according to any of the foregoing clauses, the process chamber further comprising a first seal disposed on a first side of the process chamber and between an end portion and an opening, for generating a first gas vortex when the process chamber is in use.

[0307] 12. The process chamber as described in Clause 4 or any of Clauses 5 to 11 when subordinate to Clause 4, the process chamber further includes a second seal disposed on a first side of the process chamber and located radially outside the second cavity.

[0308] 13. The process chamber according to any of the foregoing clauses, the process chamber further comprising a third seal disposed on a first side of the process chamber and located radially outward of the end portion of the material supply unit, for generating a second gas vortex when the process chamber is in use.

[0309] 14. The process chamber according to any of the foregoing clauses, wherein the material supply unit includes a material supply geometry adapted to uniformly distribute the material to be supplied to the carrier in the end portion.

[0310] 15. The process chamber according to any of the foregoing clauses, the process chamber further comprising an annular screen connected to or integrated with the material supply unit, wherein the screen is adapted to uniformly distribute the material to be supplied to the carrier in its end portion.

[0311] 16. The process chamber described in accordance with any one of Clauses 3 or 4 to 15 when subordinate to Clause 3, wherein the first cavity includes segments for supplying different materials to the carrier through different sections of the end portion.

[0312] 17. The process chamber according to Clause 16, wherein, depending on the direction of movement of the process chamber above the carrier, material can be supplied from one of the different segments of the end portion to the carrier.

[0313] 18. The process chamber according to clause 16 or 17, wherein a first material having a first particle size can be supplied to the carrier through a first section of different sections, and a second material having a second particle size can be supplied to the carrier through a second section of different sections, the second particle size being different from the first size, wherein the second section is different from the first section.

[0314] 19. The process chamber according to any of the foregoing clauses, the process chamber further includes: A process gas introduction unit and a process gas extraction unit are arranged opposite to each other on the first side of the process chamber for respectively introducing process gas into the process chamber and extracting process gas from the process chamber. The moving mechanism is suitable for changing the position of the process gas introduction unit and the process gas extraction unit on the first side of the process chamber.

[0315] 20. The process chamber according to Clause 19, the process chamber further comprising a generally circular structure including a recess, wherein the structure is arranged radially inside the process gas introduction unit and the process gas extraction unit, toward the central portion of the process chamber, and wherein the structure including the recess is adapted to guide process gas from the process gas introduction unit to the process gas extraction unit.

[0316] 21. The process chamber according to Clause 2, the process chamber further includes a generally semi-circular section configured to cover a groove at a location that prevents process gases from entering the interior portion of the process chamber.

[0317] 22. The process chamber according to any of the foregoing clauses, the process chamber further comprising a particle collector adapted to collect particles of material supplied to a carrier, but the particles are not included in the three-dimensional workpiece to be produced.

[0318] 23. The process chamber described in Clause 22 when subordinate to any of Clauses 19 to 21, wherein the particle collector is arranged adjacent to and radially inside the process gas extraction unit.

[0319] 24. The process chamber described in any one of Clauses 19 to 21 or Clauses 22 or 23 when subordinate to Clause 19, the process chamber further includes a process gas filter, the process gas filter being (i) arranged adjacent to and radially inside the process gas extraction unit and / or (ii) integral with the process gas extraction unit.

[0320] 25. A process chamber according to any of the foregoing clauses, used for producing a three-dimensional workpiece by an additive manufacturing method, the process chamber including a heating unit arranged (i) within an internal portion of the process chamber and / or (ii) radially inside and / or radially outside an annular end portion of a material supply unit adjacent to or near the annular end portion of the material supply unit. The heating unit is suitable for heating the material supplied to the carrier.

[0321] 26. The process chamber according to Clause 25, wherein the heating unit has a generally circular shape.

[0322] 27. The process chamber according to clause 25 or 26, wherein the heating unit is coaxially aligned with the central axis of the process chamber, wherein the central axis is defined as perpendicular to the plane defined by the opening of the process chamber and passing through the center point of the opening.

[0323] 28. The process chamber according to any one of clauses 25 to 27, wherein the heating unit is movable within the interior portion of the process chamber.

[0324] 29. The process chamber according to any of the foregoing clauses, the process chamber further comprising one or more conduits for arranging one or more sensors around the periphery of the process chamber for obtaining process parameters during the production of a three-dimensional workpiece using the process chamber.

[0325] 30. An apparatus for producing three-dimensional workpieces using an additive layer construction method, the apparatus comprising: A carrier suitable for receiving materials used in the production of three-dimensional workpieces via additive layer construction methods; The process chamber according to any one of the foregoing clauses; and The moving unit is adapted to move the process chamber relative to the carrier so as to position the different sections of the process chamber relative to the carrier.

[0326] 31. The equipment as described in Clause 30, the equipment comprising: The process chamber of Clause 29, and One or more sensors, suitable for sensing the position of the process chamber relative to the carrier. The equipment is suitable for generating sensor signals based on the sensed position of the process chamber relative to the carrier, and The moving unit is suitable for moving the process chamber relative to the carrier based on sensor signals.

[0327] 32. A modular system for use with a process chamber according to any one of clauses 1 to 29 or equipment according to clause 30 or 31, wherein the modular system comprises: A base module, the base module including one or more first elements, the one or more first elements being located on the surface of the base module; One or more substrate modules are configured to receive material to be processed for producing a three-dimensional workpiece by an additive layer construction method on a first surface of the substrate module, wherein the substrate module includes one or more second elements located on a second surface of the substrate module, wherein the first surface is opposite to the second surface, and wherein the shape of the second elements is adapted to mate with the first element of a base module for temporarily fixing the base module and the one or more substrate modules; and One or more modular elements are used to (i) support material when it is received by one or more substrate modules and / or (ii) confine material to a region on one or more substrate modules and / or (iii) support substrate modules, wherein the modular elements include one or more third elements, wherein the shape of the third elements is adapted to mate with the first elements of the base module for temporarily securing one or more modular elements to the base module.

[0328] 33. The modular system according to Clause 32, wherein the base module and / or one or more substrate modules include one or more sealable openings for receiving one or more modular elements, and wherein, depending on the state of the three-dimensional workpiece produced by the additive layer construction method, one or more modular elements are capable of being raised for the support of the material and / or the constraint of the material and / or the support of one or more substrate modules.

[0329] 34. The modular system according to clause 32 or 33, the modular system comprising a first base module and a second base module, wherein the first base module includes a base module protrusion and the second base module includes a base module recess, the shape of the base module recess being adapted to mate with the base module protrusion for temporarily fixing the first base module and the second base module to each other.

[0330] 35. A method for producing a three-dimensional workpiece using additive manufacturing technology, the method comprising: Provide a modular system in accordance with any one of Clauses 32 to 34; Based on the shape of the three-dimensional workpiece to be produced, the material is processed and positioned, and one or more substrate modules are arranged on one or more locations of the base module. Providing material on one or more substrate modules, particularly using a process chamber according to any one of clauses 1 to 29 or the apparatus described in clause 30 or 31; and Materials are processed using additive manufacturing technology to produce three-dimensional workpieces.

[0331] 36. The method according to Clause 35, the method further comprising providing one or more modular elements on one or more of the first elements of the base module and (ii) one or more of the substrate modules to: When materials are provided on one or more substrate modules, support materials, and / or When material is provided on one or more substrate modules, the material is confined to a region on one or more substrate modules, and / or The substrate module is supported for subsequently receiving materials.

[0332] 37. The method according to clause 35 or 36, the method further comprising: arranging the modular element on top of a previously arranged modular element in accordance with an increase in the build height of the three-dimensional workpiece produced by additive layer manufacturing technology.

[0333] 38. The method according to any one of clauses 35 to 37, the method further comprising: providing replacement material in a predetermined volume limited by a modular system prior to providing material for producing a three-dimensional workpiece.

[0334] 39. A safety device for use with a process chamber according to clause 7 or 8, wherein the safety device comprises: Sensors suitable for sensing the state of process chambers and / or housings containing process chambers, and Control unit, the control unit is suitable for controlling the curing device. The control unit is connected to the sensor, and The control unit is adapted to prevent the release of radiation and / or particles originating from the curing device, and / or to shut down the curing device when a sensor senses that a predetermined condition is met.

[0335] 40. The safety device according to Clause 39, wherein the predetermined condition includes that the opening of the process chamber is not covered.

[0336] 41. The safety device according to Clause 40, wherein the opening of the process chamber is not covered includes: the process chamber being raised and / or the orientation of the process chamber relative to the carrier being changed.

[0337] 42. The safety device according to any one of clauses 39 to 41, wherein the sensor includes an accelerometer.

[0338] 43. The safety device according to any one of clauses 39 to 42, wherein the sensor includes a pressure sensor adapted to sense pressure changes in a housing in which a process chamber is arranged, and wherein the predetermined conditions include pressure changes.

[0339] 44. The safety device according to any one of clauses 39 to 43, the safety device further comprising a door switch, the door switch being coupled to the control unit. The door switch is suitable for detecting when a door of a housing containing a process chamber is opened, and the predetermined conditions include the door being opened.

[0340] 45. The safety device according to Clause 44, wherein the control unit is capable of being coupled to a robotic device operating within the housing, and in particular, the control unit is capable of being coupled to a mobile unit as described in Clause 30 or 31, wherein the control unit is adapted to control or influence the movement or mobility of the robotic device, particularly the movement or mobility of the mobile unit, when a door switch detects that the door of the housing is open.

[0341] 46. ​​The safety device according to any one of Clauses 39 to 45, wherein the sensor includes a distance sensor adapted to determine the distance between the process chamber and the carrier, and wherein the predetermined condition includes exceeding a minimum distance between the process chamber and the carrier, and when the minimum distance between the process chamber and the carrier is exceeded, the control unit prevents the release of radiation and / or particles originating from the curing apparatus and / or shuts down the curing apparatus.

[0342] 47. The safety device according to any one of clauses 39 to 46, the safety device further comprising a processing unit adapted to determine when radiation can leave a volume limited by a process chamber based on radiation reflection from the curing apparatus leaving the carrier, and wherein predetermined conditions include radiation being able to leave the volume.

[0343] 48. The safety device according to any one of clauses 39 to 47, wherein the sensor is arranged on the process chamber.

[0344] 49. A positioning system for determining and / or correcting the position of a moving production unit, particularly for determining and / or correcting the positioning system of a process chamber relative to a carrier according to any one of claims 1 to 29, the positioning system being adapted to receive material processed by the moving production unit, wherein the positioning system comprises: One or more positioning units, wherein the one or more positioning units are adapted to be arranged at a defined location in the edge region of the carrier and / or at a location at a predetermined distance from the carrier; and One or more measuring sensors, which are adapted to be arranged on a moving production unit and / or at a defined position relative to the moving production unit; The positioning unit and the measuring sensor are shaped to accommodate each other. The location of the mobile production unit can be determined and / or corrected by a positioning system based on measurement sensors placed on the mobile production unit and received at the positioning unit located at the defined position.

[0345] 50. The positioning system according to Clause 49, wherein the positioning unit comprises three plates, each plate being arranged perpendicular to the other two plates to form an arrangement having two open sides and an open top, and wherein the position of the moving production unit can be determined and / or corrected based on one or more measuring sensors that contact the respective one or more plates of the positioning unit.

[0346] 51. The positioning system according to clause 49 or 50, wherein the positioning system is configured to determine the tilt of the moving production unit relative to the carrier based on three measuring sensors that contact each corresponding plate of the positioning unit.

[0347] 52. The positioning system according to any one of clauses 49 to 51, wherein one or more positioning units are capable of rising in a direction perpendicular to the carrier.

[0348] 53. A system comprising: The positioning system pursuant to any one of Clauses 49 to 52; and The mobile production unit includes a curing device; Once the position of the mobile production unit is determined and / or corrected, the mobile production unit is adapted to perform a generally circular movement in a plane parallel to the carrier, moving from the positioning unit to a predetermined position, where material is supplied by the mobile production unit and / or processed by the curing device.

[0349] 54. A system comprising: A mobile production unit, which in particular includes a process chamber according to any one of clauses 1 to 29, is suitable for producing three-dimensional workpieces by an additive manufacturing method. A moving unit, which is connected to a moving production unit and is adapted to move the moving production unit; A light source, suitable for generating one or more light beams for a reference line and / or reference plane, the reference line and / or reference plane serving as a reference for the position and / or orientation of a moving production unit; and One or more photodetectors, particularly laser radiation detectors, are arranged in (i) a mobile production unit and / or (ii) a housing in which the mobile production unit is arranged or are connected to (i) the mobile production unit and / or (ii) the housing in which the mobile production unit is arranged; Among them, the photodetector is suitable for detecting one or more light beams, and The system is suitable for determining the position and / or orientation of a moving production unit relative to a reference line and / or reference plane based on a photodetector that detects one or more light beams.

[0350] 55. The system according to Clause 54, wherein the system is adapted to change the position and / or orientation of the mobile production unit relative to a reference line and / or reference plane based on the determination, using a mobile unit that moves the mobile production unit.

[0351] 56. The system according to clause 54 or 55, wherein the system is adapted to perform coordinate transformations associated with the curing apparatus based on the determination for producing three-dimensional workpieces by an additive layer construction method.

[0352] 57. The system according to any one of clauses 54 to 56, wherein the light source includes a laser light source for generating a linear laser beam profile.

[0353] 58. The system according to Clause 57, further comprising a polygon scanner adapted to generate reference lines and / or reference planes from a linear laser beam profile.

[0354] 59. The system according to any one of clauses 54 to 58, the system comprising a plurality of mobile production units, wherein the system is adapted to generate beams for a plurality of reference planes.

[0355] 60. The system according to any one of clauses 54 to 59, wherein the light source and / or one or more photodetectors are movable in three dimensions.

[0356] 61. The system according to any one of Clauses 54 to 60, wherein, when a plurality of photodetectors are arranged on or coupled to a housing, the position and / or orientation of the mobile production unit relative to one or more reference lines is determined based on the reflection of one or more light beams from the mobile production unit toward the photodetectors.

[0357] 62. An apparatus for producing three-dimensional workpieces, the apparatus comprising: A carrier, suitable for receiving materials used in the production of three-dimensional workpieces; Multiple mobile production units, in particular, each mobile production unit includes a process chamber according to any one of clauses 1 to 29. The first mobile production unit includes a curing device adapted to produce a cured material layer on a carrier for producing workpieces via an additive layer construction method. The second and / or third and / or fourth mobile production units include a material supply unit adapted to supply materials to the carrier and / or curing device. The second and / or third and / or fourth mobile production units include a gas supply system adapted to supply a protective gas to the area irradiated by the curing device. The second mobile production unit and / or the third mobile production unit and / or the fourth mobile production unit include a layer deposition mechanism for forming the supplied material into a material layer located on top of the carrier. The second, third, and fourth mobile production units do not include the curing device. The equipment further includes: Multiple moving units, wherein each moving unit is adapted to move its respective corresponding moving production unit relative to a carrier so that the moving production unit is positioned relative to different sections of the carrier.

[0358] 63. The equipment as described in Clause 62, the equipment further comprising: Sensing units, adapted to generate sensor signals related to the relative arrangement of mobile production units and carriers; and The control unit is configured to provide at least one fine positioning function, in addition to positioning the mobile production unit via the moving unit, to compensate for the offset relative to the desired arrangement of the mobile production unit and the carrier based on sensor signals generated by the sensing unit.

[0359] Undoubtedly, those skilled in the art will conceive of many other effective alternatives. It should be understood that the invention is not limited to the described embodiments and exemplary implementations, but includes modifications that will be obvious to those skilled in the art and fall within the scope of the appended claims.

Claims

1. An apparatus for producing a three-dimensional workpiece by an additive layer construction method, the apparatus comprising: A carrier adapted to receive material for producing the three-dimensional workpiece; A material supply unit, adapted to supply material to the carrier and / or to a prior material layer located on top of the carrier. A layer deposition mechanism for forming supplied material as a material layer on top of the carrier and / or as a material layer on top of a previous material layer on the carrier. A curing apparatus adapted to cure material supplied to the carrier and / or to cure material supplied to a previous material layer located on top of the carrier, in order to produce the three-dimensional workpiece. A gas supply unit, adapted to supply protective gas to areas of the material layer cured by the curing apparatus. The process chamber includes the gas supply unit and the curing device. A moving unit, the moving unit being adapted to move the process chamber relative to the carrier, and A positioning system adapted to determine the position of the process chamber relative to the carrier. The process chamber further includes one or more of the following: An airflow device adapted to generate an airflow over the surface of a region of a material layer cured by the curing device. A heating unit, adapted to heat a material supplied to the carrier, and A safety device or part thereof, said safety device or part thereof adapted to prevent process emissions from being released into the vicinity of the process chamber during operation of said equipment. Wherein, at least one of the airflow device, the heating unit, and the safety device or a portion thereof in the process chamber is adapted to operate independently of the movement direction of the process chamber; The positioning system includes: One or more positioning units, said one or more positioning units being adapted to be arranged at a defined location in the edge region of the carrier and / or at a location within a predetermined distance from the carrier; and One or more measuring sensors, the one or more measuring sensors being adapted to be arranged on the process chamber and / or arranged at a defined position relative to the process chamber; The position of the process chamber can be determined and / or corrected by the positioning system based on one or more signals from one or more of the measurement sensors.

2. The device according to claim 1, wherein The positioning unit includes a light source adapted to generate one or more light beams for a reference line and / or a reference plane, the reference line and / or reference plane serving as a reference for the position and / or orientation of the process chamber; as well as Wherein, the one or more sensors include one or more photodetectors; The photodetector is adapted to detect the one or more light beams, and The position and / or orientation of the process chamber relative to the reference line and / or the reference plane can be determined and / or corrected by the positioning system based on the photodetector that detects the one or more light beams; The device includes multiple process chambers and is adapted to generate beams for multiple reference planes.

3. The apparatus according to claim 1, wherein the process chamber further comprises a material supply unit; The material supply unit comprises an end portion, which is located at a first side of the process chamber, wherein The material supply unit is adapted to supply material to the carrier via the end portion, on which the material is processed by the process chamber to produce the three-dimensional workpiece. An opening is located on a first side of the process chamber, the process chamber being used to process material supplied to the carrier to produce the three-dimensional workpiece. The end portion surrounds the opening.

4. The apparatus of claim 3, wherein, The material supply unit includes a bell-shaped structure through which material can be supplied to the carrier, wherein the end portion forms the end of the bell-shaped structure.

5. The device according to claim 3, wherein, The process chamber includes a multi-walled structure, wherein a first cavity is formed between a first wall and a second wall of the multi-walled structure, the first cavity being included in or connected to the material supply unit.

6. The apparatus according to claim 5, wherein the apparatus is used to produce a three-dimensional workpiece by an additive layer construction method, the process chamber comprising a gas extraction unit and / or a gas introduction unit, wherein, A second cavity is formed between the third and fourth walls of the multi-walled structure, wherein the second cavity is arranged radially outward from the first cavity along a direction away from the central portion of the process chamber, and wherein the second cavity is included in the gas extraction unit and / or the gas introduction unit, or the second cavity is coupled to the gas extraction unit and / or the gas introduction unit, the gas extraction unit and / or the gas introduction unit being configured to extract gas from the central portion of the process chamber and / or introduce gas to the central portion of the process chamber.

7. The apparatus of claim 6, wherein, The second wall and the third wall are integral.

8. The apparatus of claim 5, wherein, A third cavity is formed between the fifth and sixth walls of the multi-walled structure, wherein process gas is introduced into the process chamber and / or extracted from the process chamber through the third cavity.

9. The apparatus of claim 8, wherein, The curing device is offset from the central axis of the process chamber, wherein the central axis is defined as being perpendicular to the plane defined by the opening of the process chamber and passing through the center point of the opening.

10. The apparatus of claim 1 or 2, wherein, The layer deposition mechanism is arranged on the first side of the process chamber and is adapted to form the supplied material as a material layer on top of the carrier.

11. The apparatus of claim 5, wherein, The layer deposition mechanism is arranged adjacent to and radially inside the first cavity to control the supply of material to the carrier through the first cavity.

12. The apparatus of claim 3, further comprising a first seal disposed on a first side of the process chamber and between the end portion and the opening, for generating a first gas vortex when the process chamber is used.

13. The apparatus of claim 6, further comprising a second seal disposed on a first side of the process chamber and located radially outward of the second cavity.

14. The apparatus of claim 3, further comprising a third seal disposed on a first side of the process chamber and radially outward of the end portion of the material supply unit for generating a second gas vortex when the process chamber is used.

15. The apparatus of claim 3, wherein, The material supply unit includes a material supply geometry adapted to uniformly distribute the material to be supplied to the carrier in the end portion of the material supply unit.

16. The apparatus of claim 3, further comprising an annular screen, the annular screen being connected to or integrated with the material supply unit, wherein, The screen is adapted to uniformly distribute the material to be supplied to the carrier in the end portion of the material supply unit.

17. The apparatus of claim 5, wherein, The first cavity includes segments for supplying different materials to the carrier through different sections of the end portion.

18. The apparatus of claim 17, wherein, Depending on the direction of movement of the process chamber above the carrier, material can be supplied from one of the different sections of the end portion to the carrier.

19. The apparatus of claim 17, wherein, A first material having a first particle size can be supplied to the carrier through a first segment of the different sections, and a second material having a second particle size can be supplied to the carrier through a second segment of the different sections, wherein the second particle size is different from the first particle size, and the second segment is different from the first segment.

20. The apparatus of claim 1 or 2, wherein, When the process chamber includes the airflow device, the airflow device is arranged on a first side of the process chamber and includes a process gas introduction unit and a process gas extraction unit. The process gas introduction unit and the process gas extraction unit are arranged opposite to each other for introducing process gas into the process chamber and extracting process gas from the process chamber, respectively. The device further includes a moving mechanism adapted to change the position of the process gas introduction unit and the process gas extraction unit on the first side of the process chamber.

21. The apparatus of claim 20, further comprising a circular structure comprising a groove, wherein, The structure is arranged radially inside the process gas introduction unit and the process gas extraction unit, toward the central portion of the process chamber, and wherein the structure including the groove is adapted to guide process gas from the process gas introduction unit to the process gas extraction unit.

22. The apparatus of claim 21, further comprising a semi-circular section configured to cover the groove at a location preventing process gases from entering the interior portion of the process chamber.

23. The apparatus of claim 20, further comprising a particle collector adapted to collect particles of material supplied to the carrier, but the particles are not included in the three-dimensional workpiece to be produced.

24. The apparatus of claim 23, wherein, The particle collector is arranged adjacent to the process gas extraction unit and located radially inside the process gas extraction unit.

25. The apparatus of claim 20, further comprising a process gas filter, the process gas filter (i) being arranged adjacent to and radially inside the process gas extraction unit and / or (ii) being integral with the process gas extraction unit.

26. The apparatus of claim 3, wherein, When the process chamber includes the heating unit, the heating unit is arranged such that (i) it is located within the interior portion of the process chamber and / or (ii) it is located radially inside the end portion of the material supply unit and / or radially outside the end portion of the material supply unit, adjacent to or near the end portion of the material supply unit.

27. The apparatus of claim 1 or 2, wherein, When the process chamber includes the heating unit, the heating unit has a circular shape.

28. The apparatus of claim 3, wherein, When the process chamber includes the heating unit, the heating unit is coaxially aligned with the central axis of the process chamber, wherein the central axis is defined as being perpendicular to the plane defined by the opening of the process chamber and passing through the center point of the opening.

29. The apparatus of claim 1 or 2, wherein, When the process chamber includes the heating unit, the heating unit is movable within the interior portion of the process chamber.

30. The apparatus of claim 1 or 2, further comprising one or more conduits for arranging one or more sensors around the periphery of the process chamber to obtain process parameters during the production of the three-dimensional workpiece using the process chamber.

31. The device according to claim 30, wherein the device comprises: The one or more sensors are adapted to sense the position of the process chamber relative to the carrier. The device is adapted to generate sensor signals based on the sensed position of the process chamber relative to the carrier, and The moving unit is adapted to move the process chamber relative to the carrier based on the sensor signal.

32. The apparatus of claim 1 or 2, further comprising a safety control device for use with the process chamber, wherein, The safety control device includes: Sensors, the sensors being adapted to sense the state of the process chamber and / or the housing on which the process chamber is disposed, and A control unit, adapted to control the curing device. The control unit is connected to the sensor, and The control unit is adapted to prevent the release of radiation and / or particles originating from the curing device, and / or to shut down the curing device when the sensor senses that a predetermined condition is met.

33. The device according to claim 32, wherein, The predetermined condition includes that the opening of the process chamber is not covered.

34. The apparatus of claim 33, wherein, The fact that the opening of the process chamber is not covered includes situations where the process chamber is raised and / or the orientation of the process chamber relative to the carrier is changed.

35. The apparatus of claim 32, wherein, The sensor includes an accelerometer.

36. The apparatus of claim 32, wherein, The sensor includes a pressure sensor adapted to sense pressure changes in a housing in which the process chamber is arranged, wherein the predetermined conditions include the pressure changes.

37. The device of claim 32, further comprising a door switch connected to the control unit. wherein, The door switch is adapted to detect when a door of the housing containing the process chamber is opened, and wherein the predetermined condition includes the door being opened.

38. The apparatus of claim 37, wherein, The control unit is capable of being coupled to a robotic device operating within the housing, wherein the control unit is adapted to control or influence the movement or mobility of the robotic device when the door switch detects that the door of the housing is open.

39. The apparatus of claim 32, wherein, The sensor includes a distance sensor adapted to determine the distance between the process chamber and the carrier, wherein the predetermined condition includes exceeding a minimum distance between the process chamber and the carrier, and when the minimum distance between the process chamber and the carrier is exceeded, the control unit prevents the release of radiation and / or particles originating from the curing apparatus and / or shuts down the curing apparatus.

40. The apparatus of claim 32, further comprising a processing unit adapted to determine when radiation is able to exit a volume confined by the process chamber based on reflection of radiation originating from the solidification device off the carrier, and wherein, The predetermined conditions include the ability of radiation to leave the volume.

41. The apparatus of claim 32, wherein, The sensor is arranged on the process chamber.

42. The apparatus of claim 1, wherein, The shapes of the positioning unit and the measuring sensor are adapted to fit together.

43. The apparatus of claim 1 or 42, wherein, The positioning unit includes three plates, each plate arranged perpendicular to the other two plates to form an arrangement with two open sides and an open top, and wherein the position of the process chamber can be determined and / or corrected based on one or more of the measuring sensors on the corresponding one or more plates of the positioning unit.

44. The apparatus of claim 1 or 42, wherein the apparatus is configured to determine the tilt of the process chamber relative to the carrier based on three measuring sensors that contact each corresponding plate of the positioning unit.

45. The apparatus of claim 1 or 42, wherein, The one or more positioning units can be raised in a direction perpendicular to the carrier.

46. The apparatus of claim 1 or 42, wherein, Once the position of the process chamber is determined and / or corrected, the process chamber is adapted to perform circular movement in a plane parallel to the carrier, moving from the positioning unit to a predetermined position where material is supplied by the material supply unit and / or processed by the curing device.

47. The apparatus of claim 2, wherein, The device is adapted to change the position and / or orientation of the process chamber relative to the reference line and / or the reference plane based on the position and / or orientation of the process chamber relative to the reference line and / or the reference plane determined by the positioning system, based on the moving unit that moves the process chamber.

48. The apparatus of claim 2 or 47, wherein, The device is adapted to perform coordinate transformations associated with the curing apparatus based on the position and / or orientation of the process chamber relative to the reference line and / or the reference plane, as determined by the positioning system, for producing the three-dimensional workpiece by the additive layer construction method.

49. The device according to claim 2 or 47, wherein, The light source includes a laser light source, which is used to generate a linear laser beam profile.

50. The apparatus of claim 49, further comprising a polygon scanner adapted to generate the reference line and / or the reference plane from the linear laser beam profile.

51. The device according to claim 2 or 47, wherein, The light source and / or one or more photodetectors are capable of moving in three dimensions.

52. The device according to claim 2 or 47, wherein, When the plurality of photodetectors are arranged on or connected to the housing in which the process chamber is arranged, the position and / or orientation of the process chamber relative to one or more of the reference lines are determined based on the reflection of the one or more light beams from the process chamber toward the photodetectors.

53. The device according to claim 2, wherein, The one or more sensors include one or more laser radiation detectors.

54. The device according to claim 3, wherein, The end portion is ring-shaped.

55. The device according to claim 38, wherein, The control unit can be connected to the mobile unit.

56. The device according to claim 38, wherein, The control unit is adapted to control or influence the movement or movement capability of the moving unit when the door switch detects that the door of the housing is open.

57. An apparatus for producing three-dimensional workpieces, the apparatus comprising: A carrier adapted to receive material for producing the three-dimensional workpiece; Multiple mobile production units, including a first mobile production unit, a second mobile production unit, a third mobile production unit, and a fourth mobile production unit. The first mobile production unit includes a process chamber, which in turn includes a curing device adapted to produce a cured material layer on the carrier for producing the workpiece via an additive layer construction method. The second mobile production unit and / or the third mobile production unit and / or the fourth mobile production unit include a material supply unit adapted to supply materials to the carrier and / or the curing device. The second mobile production unit and / or the third mobile production unit and / or the fourth mobile production unit include a gas supply system adapted to supply a protective gas to the area irradiated by the curing device. The second mobile production unit and / or the third mobile production unit and / or the fourth mobile production unit include a layer deposition mechanism for forming the supplied material into a material layer located on top of the carrier; Wherein, one or more of the second mobile production unit, the third mobile production unit, and the fourth mobile production unit do not include the curing device; The device further includes: Multiple moving units, wherein each moving unit is adapted to move a corresponding moving production unit relative to the carrier so that the moving production unit is positioned relative to different sections of the carrier.

58. The apparatus of claim 57, further comprising: A sensing unit adapted to generate sensor signals relating to the relative arrangement of the mobile production unit and the carrier; as well as A control unit configured to, in addition to positioning the mobile production unit via the moving unit, provide at least one fine positioning function to compensate for offsets relative to the desired arrangement of the mobile production unit and the carrier based on sensor signals generated by the sensing unit.

59. A modular system for use with the device according to any one of claims 1 to 58, wherein, The modular system includes: A base module, the base module including one or more first elements, the one or more first elements being located on the surface of the base module; One or more substrate modules are configured to receive material to be processed for producing a three-dimensional workpiece by an additive layer construction method on a first surface of the substrate module, wherein the substrate module includes one or more second elements located on a second surface of the substrate module, wherein the first surface is opposite to the second surface, and wherein the shape of the second elements is adapted to mate with the first element of the base module for temporarily fixing the base module to the one or more substrate modules; and One or more modular elements are used for (i) supporting material when it is received by the one or more substrate modules and / or (ii) confining the material in a region on the one or more substrate modules and / or (iii) supporting the substrate modules, wherein the modular elements include one or more third elements, wherein the shape of the third elements is adapted to mate with the first elements of the base module for temporarily securing the one or more modular elements to the base module.

60. The modular system according to claim 59, wherein, The base module and / or the one or more substrate modules include one or more sealable openings for receiving the one or more modular elements, and wherein, depending on the state of the three-dimensional workpiece produced by the additive layer construction method, the one or more modular elements can be raised for the support of the material and / or the constraint of the material and / or the support of the one or more substrate modules.

61. The modular system according to claim 59 or 60, wherein, The base module of the modular system includes a first base module and a second base module. The first base module includes a base module protrusion, and the second base module includes a base module groove. The shape of the base module groove is adapted to cooperate with the base module protrusion for temporarily fixing the first base module and the second base module to each other.

62. A method for producing a three-dimensional workpiece using additive manufacturing technology, the method comprising: Provide a modular system according to any one of claims 59 to 61; The one or more substrate modules are arranged on one or more locations of the base module according to the material processing position based on the shape of the three-dimensional workpiece to be produced; Material is provided on the one or more substrate modules; as well as The material is processed using the additive manufacturing technology to produce the three-dimensional workpiece.

63. The method of claim 62, further comprising providing the one or more modular elements on (i) one or more of the one or more first elements of the base module and (ii) one or more of the one or more substrate modules to: When material is provided on one or more substrate modules, support material, and / or When material is provided on one or more substrate modules, the material is confined to a region on one or more substrate modules, and / or The substrate module is supported for subsequently receiving materials by the substrate module.

64. The method according to claim 62 or 63, wherein the method further comprises: As the build height of the three-dimensional workpiece produced by the additive manufacturing technology increases, the modular element is arranged on top of the previously arranged modular element.

65. The method according to claim 62 or 63, wherein the method further comprises: Before providing the material for producing the three-dimensional workpiece, a replacement material is provided in a predetermined volume limited by the modular system.

66. The method according to claim 62, wherein, The method includes using the apparatus according to any one of claims 1 to 31 to provide material on the one or more substrate modules.

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