Device for automated and serial additive manufacturing of parts on substrate structures

Abstract

Device (1) for the automated and serial additive manufacturing of parts (2) on substrate structures (3) at least comprising: - a manufacturing chamber (4) in which an additive manufacturing process can take place, - at least one secondary chamber (5, 6) which can be connected to the production chamber (4) via a respective lock (7, 8), - a mechanism (9, 16) which is configured to transport substrate structures (3) stored in one of the at least one secondary chambers (5, 6) through the respective lock (7, 8) into the production chamber (4) and / or to transport finished parts (2) from the production chamber (4) through the respective lock (7, 8) into one of the at least one secondary chambers (5, 6), wherein the mechanism (9, 16) is designed such that the substrate structure (3) can be rotated by 180° in the production chamber (4), wherein the rotation of the substrate structure (3) by 180° takes place such that an upper side and a lower side of the substrate structure (3) exchange their position, - wherein a movable suction device (12) is arranged in the production chamber (4), with which a powder arising during additive manufacturing can be sucked off.

Description

[0001] The invention relates to a device for the automated and serial additive manufacturing of parts on substrate structures.

[0002] From DE 10 2004 041 633 A1 a device for producing shaped bodies by layering them from powdered, in particular metallic or ceramic, material is known.

[0003] DE 10 2007 047 326 A1 discloses a device for producing a three-dimensional object. DE 10 2007 018 601 A1 discloses a device for producing three-dimensional objects by successively solidifying layers of a radiation-solidifiable building material. DE 10 2013 223 411 A1 discloses a modular system for producing a three-dimensional object by layer-by-layer application and selective solidification of a powdered building material. DE 10 2015 116 282 A1 discloses a system for producing three-dimensional objects by successively solidifying layers of a radiation-solidifiable building material.DE 10 2016 221 821 A1 discloses a method and a device for the additive manufacturing of a three-dimensional workpiece, in which a thermoplastic material is converted into a liquid phase by heating and selectively applied to locations defined by the shape and dimensions of the workpiece. CN 1 05 170 988 A discloses a method and a device for recovering powder residues on a substrate for additive metal manufacturing. JP 2015 - 196 205 A discloses a blasting device for use in a three-dimensional additive manufacturing device.

[0004] Based on this, it is the object of the present invention to solve or at least alleviate the technical problems existing in connection with the prior art and to provide a further improved device for the automated and serial additive manufacturing of parts from substrate structures.

[0005] This object is achieved by a device according to the features of the independent claim. The measures listed in the dependent claims allow advantageous further developments and improvements of the device.

[0006] A device for automated and serial additive manufacturing of parts on substrate structures according to claim 1 is presented.

[0007] Additive manufacturing takes place primarily in the manufacturing chamber. The additive manufacturing of parts preferably starts from a powder. The powder can, for example, be provided as a layer on a substrate structure within the manufacturing chamber. The powder can then be modified by locally selective action, e.g. with a laser, in such a way that the powder becomes the material of the part to be manufactured. For example, the powder can be locally selectively melted. This allows individual powder particles to bond with one another and thus form the material of the manufactured parts. If this process is repeated for a plurality of layers, the part to be manufactured can be created layer by layer. The excess powder (i.e. the powder that has not been locally selectively acted upon) can be removed at the end of the manufacturing process.For example, additive manufacturing can involve selective laser beam melting, in which the powder is melted with a laser beam.

[0008] There are locks for closing the production chamber and the secondary chambers, which serve to close the production chamber during additive manufacturing.

[0009] The mechanism serves to transport substrate structures and / or finished parts into the production chamber and transport them out of the production chamber again. The mechanism preferably comprises at least one drive and can be controlled independently from outside the device. The mechanism is, in particular, a robot. Particularly preferably, the mechanism is configured and designed to automatically feed substrate structures into the production chamber and remove parts from the production chamber, without requiring operator supervision.

[0010] The device is particularly preferred if the mechanism comprises at least one gripping mechanism. The gripping mechanism is preferably designed in the manner of a gripping robot and preferably comprises at least one gripping arm.

[0011] The at least one gripping mechanism is preferably arranged in the production chamber and configured to transport substrates through a lock between the production chamber and a secondary chamber. Furthermore, the gripping mechanism is preferably designed such that locks of the production chamber can be closed when the gripping mechanism is in a rest position. It is then possible to close the locks of the production chamber for carrying out additive manufacturing. In an extended position, the gripping mechanism extends into at least one secondary chamber and can remove substrate structures and / or deposit parts from the secondary chamber.

[0012] In a preferred embodiment, the mechanism comprises multiple gripping mechanisms. Preferably, each gripping mechanism is assigned to a lock and configured to transport parts or substrate structures through this lock.

[0013] The device is also preferred if the mechanism comprises at least one rail mechanism. In a preferred embodiment, the rail mechanism comprises at least one rail that starts from the production chamber and extends into at least one secondary chamber. The rail is preferably designed such that a lock between the production chamber and the secondary chamber can be closed despite the rail. In further embodiments of the rail mechanism, the rail mechanism can comprise at least one extendable rail, which is retracted when the lock is closed and can extend through the lock in the extended state when the lock is open. Parts and / or substrate structures can be transported along the at least one rail of the rail mechanism.Preferably, at least one gripping mechanism is attached to the rail mechanism, which is configured to grip parts and / or substrate structures.

[0014] The production chamber is preferably sealed in such a way that, for example, a protective gas atmosphere can be created within it. For this purpose, the production chamber can preferably be sealed gas-tight. The production chamber is sealed using the locks described. The protective gas atmosphere can improve the quality of the part to be produced. This is particularly due to the fact that chemical reactions (especially oxidation reactions) can be prevented by the protective gas. In particular, oxidation of the molten powder can be prevented by a protective gas. Process by-products (such as splashes or smoke) can also be removed from the process chamber by a flow of the protective gas. Such process by-products could deposit on the powder and thus reduce the quality of the part to be produced.

[0015] The at least one secondary chamber can serve to store the substrate structures and / or to accommodate the finished parts. Preferably, the device has at least one secondary chamber for each of the two aforementioned purposes.

[0016] The secondary chambers allow the manufacturing process to be automated. A substrate structure can first be removed from a secondary chamber. One or more parts can then be manufactured on this substrate structure in the manufacturing chamber. Finally, the manufactured parts can be deposited in the same secondary chamber or in another secondary chamber.

[0017] The gripping mechanism in particular can facilitate the automation of production.

[0018] The airlocks and the auxiliary chambers can reduce the consumption of inert gas. If the airlocks are closed (e.g. during part production), the inert gas concentration within the production chamber can be set to the level required for the production process. A lower inert gas concentration is sufficient in the auxiliary chambers. By opening one of the airlocks (e.g. to change the substrate structure and / or to deposit a manufactured part), the inert gas concentrations in the production chamber and the corresponding auxiliary chamber equalize. The inert gas concentration in the production chamber drops. If no auxiliary chambers were provided (i.e. if the airlocks connected the production chamber to the environment), the inert gas concentration would drop even further (to almost zero). The production chamber would have to be filled with new inert gas for each production process.Preferably, no more than one lock is open at any time.

[0019] A particularly low protective gas consumption can be achieved in the preferred embodiment of the device in which the production chamber can be closed gas-tight with the locks.

[0020] The locks can, for example, be designed with doors or flaps that can seal a lock opening in a gas-tight manner. In particular, seals are preferably provided that seal a gap between the door or flap and the lock opening.

[0021] In a further preferred embodiment of the device, a first secondary chamber of the at least one secondary chamber has a first outer lock through which substrate structures can be introduced into the first secondary chamber.

[0022] The first secondary chamber is intended for storing the substrate structures. The first outer lock connects the first secondary chamber to the device's environment. When the first outer lock is open, the substrate structures can be introduced into the first secondary chamber. The lock between the first secondary chamber and the production chamber is preferably closed. If multiple substrate structures are introduced into the first secondary chamber, the first outer lock can remain closed throughout multiple production processes. This can reduce the protective gas consumption, as described above.

[0023] For the same reason, a further embodiment of the device is preferred in which a second secondary chamber of the at least one secondary chamber has a second outer lock through which finished parts can be removed from the second secondary chamber.

[0024] The second secondary chamber is designed to hold the finished parts. The reduction in shielding gas consumption is particularly noticeable here when the second outer lock remains closed throughout several production processes.

[0025] The secondary chambers then form double locks, each with a lock between the respective secondary chamber and the production chamber, and with an external lock between the respective secondary chamber and the environment. Such double locks can ensure that there is never a direct connection between the production chamber and the environment.

[0026] It is particularly preferred if the secondary chambers each have extraction devices with which the protective gas can be removed from the secondary chambers before an external lock is opened to the environment. This allows any loss of protective gas to the environment to be almost completely prevented.

[0027] In the embodiment of the device according to the invention, a movable suction device is arranged in the production chamber, with which powder arising during additive manufacturing can be sucked away.

[0028] During additive manufacturing, excess powder may remain. This is preferably removed before the finished parts leave the manufacturing chamber. This is advantageous, for example, because the powder cannot contaminate the environment around the device. Such contamination should be avoided in particular if the powder is harmful to health and / or the environment. By removing the powder within the manufacturing chamber, the powder can also be collected and reused if necessary. The movable suction device preferably comprises a hose made of a flexible material, in particular plastic. The powder can be sucked into the hose by means of a negative pressure within the hose. It is particularly preferred that the movable suction device comprises a mechanism that can move the hose automatically. This mechanism can be a robot arm, for example.Through automated movement of the movable suction device, the powder can be extracted without having to open the production chamber. This also allows the powder to be removed consistently for a large number of manufactured parts, which can reduce fluctuations in the quality of the manufactured parts. In particular, automation can also reduce labor costs.

[0029] In a further preferred embodiment of the device, a movable compressed air device is arranged in the manufacturing chamber, with which a powder arising during additive manufacturing can be loosened.

[0030] Excess powder can be difficult to remove, particularly from manufactured parts with fine structures. The suction power of the movable suction device may not be sufficient. The previously described advantages of (automated) powder removal can be further enhanced by loosening the powder. Therefore, the device preferably comprises both the movable suction device and the movable compressed air device. In this case, powder loosened by the movable compressed air device can be directly sucked away by the movable suction device.

[0031] However, it is also possible to provide only the movable compressed air device. In this case, the powder can be removed from the finished parts and collect, for example, on a floor of the production chamber. From there, it can be removed, for example, automatically or manually. In this embodiment, the powder can be loosened using compressed air. The movable compressed air device preferably comprises a hose made of a flexible material, with which compressed air can be directed to the desired location within the production chamber. It is particularly preferred that the movable compressed air device comprises a mechanism that can move the hose automatically. This mechanism can be a robot arm, for example. The automated movement of the movable compressed air device also results in the advantages previously described for the automated movement of the movable suction device.

[0032] In the embodiment of the device according to the invention, the gripping mechanism is designed such that the substrate structure can be rotated by 180° in the production chamber. For this purpose, the mechanism preferably has at least one pivot joint.

[0033] According to the invention, the substrate structure can be rotated by 180° in such a way that the top and bottom of the substrate structure swap positions (i.e., the substrate structure is turned "upside down"). Excess powder can thus fall off the finished parts. The rotation of the substrate structure can be performed in addition to or as an alternative to the previously described options of extracting the powder using the movable suction device and loosening the powder using the movable compressed air device.

[0034] In a further preferred embodiment, the device comprises at least one ultrasound source which is configured to subject the substrate structure to ultrasound excitation.

[0035] Ultrasonic excitation can loosen the powder. This can be particularly advantageous for parts with fine structures. The powder typically adheres particularly strongly to such fine structures. Loosening the powder by applying ultrasonic excitation can be performed in addition to or as an alternative to the previously described options of extracting the powder with the movable suction device, loosening the powder with the movable compressed air device, and rotating the substrate structure.

[0036] In a further preferred embodiment, the device comprises an alignment device with which the position of a substrate structure in the production chamber can be adjusted.

[0037] The alignment device can, for example, be an arrangement of guide plates, grooves, and / or pins that can facilitate positioning of the substrate structure within the production chamber. Corresponding alignment devices are preferably provided on the substrate structures, which interact with the alignment devices of the device in the production chamber to align the substrate structures. Alternatively or additionally, the alignment device can also comprise one or more sensors that can facilitate precise positioning of the substrate structure within the production chamber via computer control (in particular in interaction with the gripping mechanism). The sensors can, for example, comprise optical and / or mechanical sensors.

[0038] The quality of the manufactured parts can depend on the positioning of the substrate structure within the manufacturing chamber. In manual processes, the substrate structure is positioned individually for each manufacturing operation, which can result in variations in the results. In automated and serial production, the quality of the manufactured parts can be improved in this embodiment through repeatability of the positioning of the substrate structure. In particular, variations in the quality of the manufactured parts can be reduced or even eliminated.

[0039] The invention and the technical environment are explained in more detail below with reference to the figure. The figure shows a particularly preferred embodiment, to which the invention is not limited, however. It should be noted that the figure and, in particular, the proportions shown are only schematic. It shows: Fig. 1: a cross-sectional view of a device for automated and serial additive manufacturing of parts on substrate structures, and Fig. 2: a cross-sectional view of an alternative device for automated and serial additive manufacturing of parts on substrate structures.

[0040] Fig. 1 shows a device 1 for the automated and serial additive manufacturing of parts 2 on substrate structures 3. The device 1 comprises a manufacturing chamber 4 in which an additive manufacturing process can take place. The device 1 also comprises a first secondary chamber 5, which is connected to the manufacturing chamber 4 via a first lock 7 and which is configured to store substrate structures 3. Here, three substrate structures 3 are shown in the first secondary chamber 5. The device 1 also comprises a second secondary chamber 6, which is connected to the manufacturing chamber 4 via a second lock 8 and which is configured to receive finished parts 2.In addition, the device 1 comprises a gripping mechanism 9, which is designed to transport substrate structures 3 stored in the first auxiliary chamber 5 through the first lock 7 into the production chamber 4 and / or to transport finished parts 2 from the production chamber 4 through the second lock 8 into the second auxiliary chamber 6. The gripping mechanism 9 is designed such that the substrate structure 3 can be rotated by 180° in the production chamber 4, wherein an axis of rotation of this rotation is horizontal and within the plane of the drawing. Fig. 1 is arranged.

[0041] The first secondary chamber 5 is connected to the environment of the device 1 via a first outer lock 10. Substrate structures 3 can be introduced into the first secondary chamber 5 through the first outer lock 10. The second secondary chamber 6 is connected to the environment of the device 1 via a second outer lock 11. Finished parts 2 can be removed from the second secondary chamber 6 through the second outer lock 11.

[0042] Furthermore, a movable suction device 12 is arranged in the production chamber 4, with which powder generated during additive manufacturing can be sucked away. Additionally, a movable compressed air device 13 is arranged in the production chamber 4, with which powder generated during additive manufacturing can be loosened. Furthermore, device 1 has an ultrasound source 14, which is configured to apply ultrasonic excitation to the substrate structure 3. Furthermore, device 1 has an alignment device 15, with which the position of a substrate structure 3 in the production chamber 4 can be adjusted.

[0043] The Fig.The embodiment shown in Figure 2 comprises, in addition to a gripping mechanism 9, a rail mechanism 16 to which the gripping mechanism 9 is attached. The rail mechanism 16 extends through the first lock 7 and the second lock 8, and the gripping mechanism can be moved along the rail mechanism to remove substrate structures 3 from the first secondary chamber 5 and to deposit parts 2 in the second secondary chamber 6.

Claims

[1] Device (1) for the automated and serial additive manufacturing of parts (2) on substrate structures (3) at least comprising: - a manufacturing chamber (4) in which an additive manufacturing process can take place, - at least one secondary chamber (5, 6) which can be connected to the production chamber (4) via a respective lock (7, 8), - a mechanism (9, 16) which is configured to transport substrate structures (3) stored in one of the at least one secondary chambers (5, 6) through the respective lock (7, 8) into the production chamber (4) and / or to transport finished parts (2) from the production chamber (4) through the respective lock (7, 8) into one of the at least one secondary chambers (5, 6), wherein the mechanism (9, 16) is designed such that the substrate structure (3) can be rotated by 180° in the production chamber (4), wherein the rotation of the substrate structure (3) by 180° takes place such that an upper side and a lower side of the substrate structure (3) exchange their position, - wherein a movable suction device (12) is arranged in the production chamber (4), with which a powder arising during additive manufacturing can be sucked off. [2] Device (1) according to claim 1, wherein the mechanism (9, 16) comprises at least one gripping mechanism (9). [3] Device (1) according to claim 1 or 2, wherein the mechanism (9, 16) comprises at least one rail mechanism (16). [4] Device (1) according to one of the preceding claims, wherein the production chamber (4) can be closed gas-tight with the locks (7, 8). [5] Device (1) according to one of the preceding claims, wherein a first secondary chamber (5) of the at least one secondary chamber (5, 6) has a first outer lock (10) through which substrate structures (3) can be introduced into the first secondary chamber (5). [6] Device (1) according to one of the preceding claims, wherein a second secondary chamber (6) of the at least one secondary chamber (5, 6) has a second outer lock (11) through which finished parts (2) can be removed from the second secondary chamber (6). [7] Device (1) according to one of the preceding claims, wherein a movable compressed air device (13) is arranged in the manufacturing chamber (4), with which a powder arising during additive manufacturing can be loosened. [8] Device (1) according to one of the preceding claims, further comprising at least one ultrasound source (14) which is configured to apply ultrasound excitation to the substrate structure (3). [9] Device (1) according to one of the preceding claims, further comprising an alignment device (15) with which the position of a substrate structure (3) in the manufacturing chamber (4) can be adjusted.

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