Additive manufacturing using removable building modules
By using removable building blocks and particle beam providing modules in additive manufacturing equipment to form a vacuum chamber design, the problem of excessive cooling time in building tanks in additive manufacturing is solved, and more efficient cooling and vacuum environment maintenance is achieved.
Patent Information
- Application Number
- CN202380078896.2
- Authority / Receiving Office
- CN · China
- Patent Type
- Applications(China)
- Current Assignee / Owner
- Priority Date
- 2022-11-14
- Filing Date
- 2023-11-08
- Publication Date
- 2025-06-20
AI Technical Summary
In additive manufacturing, the construction tank integrated into the vacuum chamber causes excessive cooling time due to vacuum isolation.
A device including a particle beam providing module and a removable building module is designed to automatically remove from the building tank by the cover of the removable building module, forming a vacuum chamber so that the wall of the building tank becomes a barrier part of the vacuum chamber, thereby maintaining the vacuum and accelerating cooling.
In this way, the cooling time of the build tank is reduced, the efficiency of additive manufacturing is improved, and the vacuum environment in the build tank is maintained.
Smart Images
Figure CN120187547A_ABST
Abstract
Description
Technical Field
[0001] The present disclosure generally relates to additive manufacturing using removable building blocks. Background Art
[0002] In additive manufacturing using a particle beam (such as electron beam powder bed fusion (E-PBF)), a vacuum is required to prevent the particle beam from being deflected by hitting molecules on its way towards the build piece. Typically, the vacuum chamber in an additive manufacturing device contains a particle beam source and a build tank so that the entire system remains under vacuum.
[0003] Problems of the Prior Art
[0004] When the build tank is integrated into the vacuum chamber, the vacuum will isolate the build tank, so it takes a long time to cool the completed build piece.
[0005] Therefore, an improved device and method for additive manufacturing are needed. Summary of the Invention
[0006] The claimed device for additive manufacturing solves the above problems. The device preferably includes a particle beam providing module and a removable build module. The removable build module preferably includes: a build tank including walls; at least one powder supply tank; and a recoating device arranged to recoat the build tank with powder from at least one powder supply tank. When the removable build module is attached to the particle beam providing module in the device, the particle beam providing module and the removable build module preferably jointly form a vacuum chamber such that the walls of the build tank form a barrier portion of the vacuum chamber. The lid of the removable build module preferably forms part of the particle beam providing module and is arranged to automatically be removed from the removable build module when the removable build module is removed from the device to facilitate access to the build tank.
[0007] The above problems are further solved by the claimed method for additive manufacturing, which uses a device comprising a particle beam providing module and a removable build module, the removable build module comprising a build tank (the build tank comprising walls), at least one powder supply tank, and a recoating device. The method preferably comprises: arranging a lid of the removable build module to form part of the particle beam providing module, and when the removable build module is removed from the device, the lid is automatically removed from the removable build module to facilitate access to the build tank; filling at least one powder supply tank in the removable build module with powder; attaching the removable build module to the particle beam providing module such that they together form a vacuum chamber in the device, wherein the walls of the build tank form a barrier part of the vacuum chamber; applying a vacuum pressure to the removable build module and the particle beam providing module; creating a powder bed in the build tank using the recoating device and powder from at least one powder supply tank; continuously forming a build piece in the build tank on successive layers of the powder bed using selective particle beam powder bed melting while continuously recoating the build tank using the recoating device; removing the removable build module from the particle beam providing module; and removing the build piece from the build tank.
[0008] This improves the cooling of the build tank because the build tank is not surrounded by a vacuum and thus not vacuum-insulated. Additionally, as long as the particle beam providing module and the removable build module are connected, a vacuum is maintained in the build tank because the walls of the build tank form a barrier part of the vacuum chamber formed in common with the particle beam providing module. The definition that the walls of the build tank form a barrier part of the vacuum chamber should be understood as the walls of the build tank being a vacuum barrier because the walls of the build tank are airtight and thus air cannot enter the vacuum chamber formed by the build tank and the particle beam providing module.
[0009] The claimed device for additive manufacturing also solves the above problems. The device preferably comprises a plurality of devices for additive manufacturing, each device comprising a particle beam providing module and a removable build module. The device preferably comprises a central module comprising resources shared by all the devices in the device.
[0010] The above problems are further solved by the claimed method for additive manufacturing, which uses a device comprising a plurality of devices for additive manufacturing, each device comprising a particle beam providing module and a removable build module. The method preferably comprises arranging all the devices in the device to share the resources contained in the central module.
[0011] This makes additive manufacturing more efficient.
[0012] In an embodiment, a lid covers the build tank and at least one powder supply tank such that when the removable build module is removed from the apparatus, the tops of both the build tank and the at least one powder supply tank are open to facilitate refilling of the at least one powder supply tank.
[0013] In an embodiment, the walls of the build tank are arranged to be cooled by a cooling fluid disposed around the walls.
[0014] In an embodiment, the apparatus includes two separate powder supply tanks.
[0015] In an embodiment, the particle beam providing device includes a particle beam source.
[0016] In an embodiment, the particle beam source is an electron beam source.
[0017] The scope of the present invention is defined by the claims, which are incorporated into this section by reference. By considering the following detailed description of one or more embodiments, a more complete understanding of the embodiments of the present invention will be provided to those skilled in the art, as well as additional advantages of implementing the present invention. The accompanying drawings will be briefly described first with reference to the figures. BRIEF DESCRIPTION OF THE DRAWINGS
[0018] Figure 1 and Figure 2 show embodiments of an apparatus for additive manufacturing according to one or more embodiments described herein.
[0019] Figure 3 show details of embodiments of an apparatus for additive manufacturing according to one or more embodiments described herein.
[0020] Figure 4 and 5 show embodiments of a device for additive manufacturing according to one or more embodiments described herein.
[0021] Figure 6 Schematically shows the interior of a device for additive manufacturing according to one or more embodiments described herein.
[0022] Figure 7 Schematically shows an additive manufacturing method according to one or more embodiments described herein.
[0023] The embodiments of the present disclosure and their advantages will be best understood by reference to the following detailed description. It should be understood that like reference numerals are used to identify like elements shown in one or more of the figures. DETAILED DESCRIPTION
[0024] In additive manufacturing using a particle beam, such as electron beam powder bed fusion (E-PBF), a vacuum is required to prevent the particle beam from being deflected by hitting molecules in its path towards the build piece. If the build chamber is integrated into the vacuum chamber, the vacuum will isolate the build chamber, and thus it takes a long time to cool the completed build piece. According to the described concept, the device includes a particle beam providing module and a removable build module, which together form a vacuum chamber such that the walls of the build chamber form a barrier portion of the vacuum chamber. This concept enables the build chamber to be cooled while maintaining a vacuum inside the vacuum chamber.
[0025] Using the removable build module can also avoid any handling of metal powder in the area where additive manufacturing is performed, which is advantageous. The concept further enables the use of a removable build module, where the tops of both the build chamber and the powder supply chamber are open to provide easier access to the build chamber (for removal of the build piece) and the powder supply chamber (for refilling).
[0026] This disclosure generally relates to devices and methods for additive manufacturing. Embodiments of the disclosed solution are presented in more detail in conjunction with the accompanying drawings.
[0027] Figure 1 and Figure 2 An embodiment of a device 100 for additive manufacturing is schematically illustrated. The illustrated device 100 includes: a particle beam providing module 110, which includes a particle beam source 130; and a removable build module 120, which includes a build chamber 140, two powder supply chambers 150, and a recoating device 160, the recoating device 160 being arranged to recoat the build chamber 140 with powder from the powder supply chamber 150. The build chamber 140 includes walls 145 (as Figure 3 and Figure 6 shown), and the walls 145 can be arranged to be cooled by a cooling fluid disposed around the walls 145.
[0028] As Figure 2 shown, the removable build module 120 can be removed from the device 100. In Figure 1 and Figure 2In the embodiment shown, the particle beam providing module 110 includes a lid 165 for the removable build module 120. Thus, when the removable build module 120 is removed from the device 100, the top of the removable build module 120 is arranged to be open because the lid 165 remains in the device 100 when the removable build module 120 is removed. This allows easy access to the build chamber 140 when the removable build module 120 is removed from the device 100. The lid 165 may only cover the build chamber 140, but preferably, the lid 165 covers both the build chamber 140 and one or more powder supply chambers 150 simultaneously, such that when the removable build module 120 is removed from the device 100, the tops of both the build chamber 140 and the one or more powder supply chambers 150 are open. This enables easy refilling of the one or more powder supply chambers 150.
[0029] When the removable build module 120 is attached to the particle beam providing module 110 in the device 100, the particle beam providing module 110 and the removable build module 120 preferably jointly form a vacuum chamber. Then the device 100 does not need to be enclosed in any external vacuum chamber. In this way, the wall 145 of the build chamber 140 forms a barrier portion of the vacuum chamber jointly formed with the particle beam providing module 110. To enable the build floor of the build chamber 140 to be movable (which is typically desired in additive manufacturing using a build chamber), a vacuum seal against a movable floor, such as a piston, is typically provided at the bottom of the build chamber 140.
[0030] This concept allows the wall 145 of the build chamber 140 to be cooled by a cooling fluid arranged around the wall 145 of the build chamber 140 while additive manufacturing is still in progress. This makes it possible to remove the build from the build chamber 140 immediately after removing the build module 120 from the device 100. As long as the particle beam providing module 110 and the removable build module 120 are connected, a vacuum is maintained in the build chamber 140 because the wall 145 of the build chamber 140 forms a barrier portion of the vacuum chamber jointly formed with the particle beam providing module 110.
[0031] When the build is complete and the build module 120 is removed from the device 100, a new build module 120 is preferably inserted immediately, and a new build is started. This makes the use of the device 100 more efficient. After being removed from the device 100, the build module 120 is preferably taken to a turnaround station. At the turnaround station, the build is removed from the build chamber 140, thereby clearing the build from the build module 120. Then, the build module 120 is prepared for the next build, for example, by refilling one or more powder chambers 150.
[0032] Since the walls 145 of the build tank 140 can be cooled by a cooling fluid while additive manufacturing is still in progress, the build can be removed from the build tank 140 without any additional cooling (either directly or after removing the build module 120 from the apparatus 100 and allowing it to stay in a turnaround station for a period of time). However, in an embodiment, additional cooling of the walls 145 of the build tank 140 is performed in the turnaround station.
[0033] The cooling fluid that can be used to cool the walls 145 of the build tank 140 can be, for example, a coolant, which is arranged to be circulated and cooled by a cooling system 170. Such a cooling system 170 can include, for example, a pump for circulating the coolant and a heat exchanger for cooling the coolant. The coolant can be, for example, water.
[0034] Figure 3 Details of an embodiment of an additive manufacturing apparatus are shown, in which the walls 145 of the build tank 140 are shown. In Figure 3 the embodiment, there is a space around the wall 145. This space is typically enclosed by a container wall 180 ( Figure 3 not shown in Figure 6 but schematically shown in Figure 3 ). The cooling fluid is preferably arranged in the space between the walls 145 of the build tank 140 and the container wall 180. To improve the circulation of the cooling fluid, spiral ridges can be arranged in this space, as
[0035] shown.
[0036] The particle beam source 130 can be any type of particle beam source, such as an electron beam source, for example in the form of an electron gun with the required electron optics and beam control equipment.
[0037] To make additive manufacturing more efficient, multiple apparatuses 100 can be grouped into a device 200 for additive manufacturing. Such a device 200 can be referred to, for example, as a melting station. Figure 4 and Figure 5 An embodiment of such a device 200 for additive manufacturing is schematically shown, in which four apparatuses 100 are combined together. In addition to being efficient in terms of space and handling of the apparatuses 100, this also allows all the apparatuses 100 in the device 200 to share resources. Figure 4 and Figure 5The device 200 shown in includes a support system in the form of a central module 250, which includes resources shared by the devices 100 in the device 200. Figure 4 and Figure 5 It is shown that the central module 250 is arranged on the side of the device 100, but the central module 250 can be arranged at any position in the device 200, for example, between two devices 100.
[0038] Figure 6 Schematically shows the interior of another embodiment of the device 200 for additive manufacturing, viewed from the top of the build module 120, in which the particle beam supply module 110 is removed in this figure. In this embodiment, four devices 100 are combined together, and the central module 250 is arranged in the middle between two devices 100. The central module 250 can have the same width as the device 100, or a different width. It can be fixedly installed at a certain position in the device 200, or can be moved between different positions. The central module 250 can include resources such as a control computer, a fore-vacuum pump, a central cooling system, a power supply, and / or various electronic devices. If the central cooling system includes means for circulating the cooling fluid (such as a pump) and means for cooling the cooling fluid (such as a heat exchanger), then the device 100 may not need to include any separate cooling system 170. The device 200 preferably includes an interface with each build module 120, where the build module 120 is connected to the resources. Each interface can include, for example, a vacuum interface for fore-vacuum, a cooling fluid interface, and one or more electrical interfaces.
[0039] Figure 6 Shows the wall 145 of the build tank 140, and how the recoating device 160 is arranged to recoat the build tank 140 with powder from two powder supply tanks 150. There can be any number of powder supply tanks 150 in each device 100. The build tank 140 and one or more powder supply tanks 150 can have any shape, such as cylindrical, as Figure 6 shown.
[0040] The device 200 for additive manufacturing includes four build modules 120 and a central module 250, for example, with a width of approximately 2.5 meters. In this case, the width of each build module 120 is approximately 50 centimeters.
[0041] When using the apparatus 200 for additive manufacturing, it is preferred to share a transfer station among the apparatuses 100 in the apparatus 200. A single transfer station can also be shared by multiple different apparatuses 200 for additive manufacturing. Each build module 120 is preferably taken to the transfer station immediately after being removed from the apparatus 200. At the transfer station, the build part is removed from the build tank 140, thereby clearing the build part in the build module 120. Then, the build module 120 is prepared for the next build, for example, by refilling the powder tank 150.
[0042] An additive manufacturing site can include a large number of apparatuses 200 for additive manufacturing. Each apparatus 200 preferably has a service side and an operator side. The operator side is the side from which the build module 120 is removed from the apparatus 200. The apparatuses 200 are preferably positioned such that the service sides face each other to form a service shaft, and the operator sides face one or more transfer stations. This makes the operation of the apparatuses 200 (including the docking and undocking of the build module 120) more efficient.
[0043] Figure 7 A method 700 for additive manufacturing using an apparatus 100 is schematically shown. The apparatus 100 includes a particle beam providing module 110 and a removable build module 120. The removable build module 120 includes a build tank 140. The build tank 140 includes a wall 145, at least one powder supply tank 150, and a recoating device 160. The method 700 can include:
[0044] Step 710: Arrange the lid 165 of the removable build module 120 to form part of the particle beam providing module 110, and when the removable build module 120 is removed from the apparatus 100, the lid 165 is automatically removed from the removable build module 120 to facilitate access to the build tank 140.
[0045] Step 730: Fill the at least one powder supply tank 150 in the removable build module 120 with powder.
[0046] Step 740: Attach the removable build module 120 to the particle beam providing module 110 such that they jointly form a vacuum chamber in the apparatus 100, where the wall 145 of the build tank 140 forms a barrier portion of the vacuum chamber.
[0047] Step 750: Apply a vacuum pressure to the removable build module 120 and the particle beam providing module 110.
[0048] Step 760: Create a powder bed in the build tank 140 using the recoating device 160 and the powder from the at least one powder supply tank 150.
[0049] Step 770: Continuously form a build in build tank 140 using selective particle beam powder bed fusion on successive layers of a powder bed while continuously recoating build tank 140 using recoating device 160.
[0050] Step 780: Remove removable build module 120 from particle beam supply module 110.
[0051] Step 790: Remove the build from build tank 140.
[0052] This enables improved cooling of the build tank because the build tank is not surrounded by a vacuum and thus not thermally insulated by the vacuum. Additionally, as long as the particle beam supply module and the removable build module are connected, a vacuum is maintained in the build tank because the walls of the build tank form a barrier portion of the vacuum chamber formed in common with the particle beam supply module.
[0053] Method 700 may further include at least one of the following:
[0054] Step 720: Arrange cover 165 to cover build tank 140 and at least one powder supply tank 150 such that when removable build module 120 is removed from device 100, the tops of build tank 140 and at least one powder supply tank 150 are open to facilitate refilling of at least one powder supply tank 150.
[0055] Step 775: During the formation of the build, use a cooling fluid arranged around wall 145 to cool wall 145 of build tank 140. This step is preferably carried out simultaneously with step 770.
[0056] The foregoing disclosure is not intended to limit the invention to the precise forms or particular fields of use disclosed. It is contemplated that various alternative embodiments and / or modifications of the invention are possible in light of the present disclosure, whether or not explicitly described or implied herein. Accordingly, the scope of the invention is defined only by the claims.
Claims
1. An apparatus (100) for additive manufacturing, the apparatus (100) comprising a particle beam providing module (110) and a removable building module (120), wherein, The removable building module (120) includes: A build tank (140) that includes a wall (145); At least one powder supply tank (150); and A recoating device (160) that is arranged to recoat the build tank (140) with powder from at least one of the powder supply tanks (150), wherein when the removable building module (120) is attached to the particle beam providing module (110) in the device (100), the particle beam providing module (110) and the removable building module (120) together form a vacuum chamber such that the wall (145) of the build tank (140) forms a barrier portion of the vacuum chamber, and wherein a lid (165) of the removable building module (120) forms part of the particle beam providing module (110) and is arranged to automatically remove from the removable building module (120) when the removable building module (120) is removed from the device (100) to facilitate access to the build tank (140).
2. The apparatus (100) according to claim 1, wherein, The lid (165) covers the build tank (140) and at least one of the powder supply tanks (150) such that when the removable building module (120) is removed from the device (100), the tops of the build tank (140) and at least one of the powder supply tanks (150) are open to facilitate refilling of at least one of the powder supply tanks (150).
3. The apparatus (100) according to claim 1 or 2, wherein, The wall (145) of the build tank (140) is arranged to be cooled by a cooling fluid disposed around the wall (145).
4. The apparatus (100) according to any one of claims 1 to 3, comprising two independent powder supply tanks (150).
5. The apparatus (100) according to any one of claims 1 to 4, wherein, The particle beam providing module (110) includes a particle beam source (130).
6. The apparatus (100) according to claim 5, wherein, The particle beam source (130) is an electron beam source.
7. An apparatus (200) for additive manufacturing, comprising a plurality of apparatuses (100) according to any one of claims 1 to 6.
8. The apparatus (200) according to claim 7, comprising four apparatuses (100) according to any one of claims 1 to 6.
9. The apparatus (200) according to claim 7 or 8, further comprising a central module (250), the central module (250) comprising resources shared by all apparatuses (100) in the apparatus (200).
10. An apparatus (200) for additive manufacturing, comprising a plurality of apparatuses (100) for additive manufacturing, each apparatus (100) comprising a particle beam providing module (110) and a removable building module (120), wherein, The device (200) further includes a central module (250) that includes resources shared by all of the devices (100) in the device (200).
11. The apparatus (200) according to claim 10, wherein, When the removable building module (120) is attached to the particle beam providing module (110), the particle beam providing module (110) and the removable building module (120) together form a vacuum chamber.
12. The apparatus (200) according to claim 10 or 11, wherein, The lid (165) of the removable building module (120) forms part of the particle beam providing module (110) and is arranged to automatically remove from the removable building module (120) when the removable building module (120) is removed from the device (100).
13. The apparatus (200) according to any one of claims 10 to 12, wherein, The particle beam providing device (110) includes a particle beam source (130).
14. The apparatus (200) according to claim 13, wherein, The particle beam source (130) is an electron beam source.
15. The device (200) according to any one of claims 10 to 14, wherein, The removable building module (120) includes: A build tank (140) that includes a wall (145); At least one powder supply tank (150); and A recoating device (160) that is arranged to recoat the build tank (140) with powder from at least one of the powder supply tanks (150), Wherein, when the removable building module (120) is disposed in the device (100), the particle beam providing module (110) and the removable building module (120) together form a vacuum chamber such that the wall (145) of the build tank (140) forms a barrier portion of the vacuum chamber.
16. The device (200) according to claim 15, wherein, The wall (145) of the build tank (140) is arranged to be cooled by a cooling fluid disposed around the wall (145).
17. The device (200) according to claim 15 or 16, comprising two independent powder supply tanks (150).
18. A method (700) of additive manufacturing using a device (100) comprising a particle beam providing module (110) and a removable build module (120), the removable build module (120) comprising a build tank (140) comprising a wall (145), at least one powder supply tank (150) and a recoating device (160), the method (700) comprising: The lid (165) of the removable building module (120) is arranged (710) to form part of the particle beam providing module (110), and when the removable building module (120) is removed from the device (100), the lid (165) is automatically removed from the removable building module (120) to facilitate access to the build tank (140); Fill (730) powder into at least one of the powder supply tanks (150) in the removable building module (120); Attach (740) the removable building module (120) to the particle beam providing module (110) such that they together form a vacuum chamber in the device (100), wherein the wall (145) of the build tank (140) forms a barrier portion of the vacuum chamber; Apply (750) a vacuum pressure to the removable building module (120) and the particle beam providing module (110); Create (760) a powder bed in the build tank (140) using the recoating device (160) and powder from at least one of the powder supply tanks (150); Form (770) a workpiece continuously in the build tank (140) using selective particle beam powder bed melting on successive layers of the powder bed while continuously recoating the build tank (140) using the recoating device (160); Remove (780) the removable building module (120) from the particle beam providing module (110); and Remove (790) the workpiece from the build tank (140).
19. The method (700) according to claim 18, further comprising arranging (720) the lid (165) to cover the build tank (140) and at least one of the powder supply tanks (150) such that when the removable build module (120) is removed from the device (100), the tops of the build tank (140) and at least one of the powder supply tanks (150) are open to facilitate refilling of at least one of the powder supply tanks (150).
20. The method (700) according to claim 18 or 19, further comprising cooling (775) the wall (145) of the build tank (140) using a cooling fluid arranged around the wall (145) during the process of forming the build.
21. A method (700) for additive manufacturing, using an apparatus (200) comprising a plurality of devices (100) for additive manufacturing, each device (100) comprising a particle beam providing module (110) and a removable build module (120), the method comprising arranging all the devices (100) in the apparatus (200) to share resources contained in a central module (250).
22. The method (700) for additive manufacturing according to claim 21, further comprising arranging the particle beam providing module (110) and the removable build module (120) to jointly form a vacuum chamber when the removable build module (120) is attached to the particle beam providing module (110).