Manufacturing system and process for the additive manufacturing of a component within a build area of ​​a powder bed

Abstract

Manufacturing system (1) for the additive manufacturing of a component within a build area (4) of a powder bed, comprising - a build space (5) in which the powder bed (6) can be formed, and - a coating unit (16) with a coating element (18, 18', 18'', 26) for forming a flat powder bed surface (20), - wherein the coating unit (16) is arranged and designed to adjust the position of the coating element (18, 18', 18'', 26) without operator intervention, such that the powder bed surface (20) of the build area (4) can be formed independently of a defect (34) of the coating element (18, 18', 18'', 26), - characterized in that the manufacturing system comprises a conditioning unit (28) that can be brought into contact with a working side of the coating element (18, 18', 18'', 26) and which is arranged and designed to reduce or eliminate the defect of the coating element (18, 18', 18'', 26).

Description

[0001] The invention relates to a manufacturing system and a method for the additive manufacturing of a component within a build area of ​​a powder bed.

[0002] Manufacturing systems for the additive production of a component within a build area of ​​a powder bed are generally known. The underlying process can be, for example, selective laser melting, also known as laser powder bed fusion (LPBF), electron beam melting, or binder jetting.

[0003] The material to be processed is applied in powder form as a thin layer within a build chamber on a base plate, which is usually retractable. The powdered material can be locally melted using radiation, such as laser radiation, electron beams, or heating radiation, and forms a solid layer after solidification. The powdered material can also be locally bonded. The base plate is then lowered by the thickness of one layer, and more powder is applied, which is also melted.

[0004] This powder application is typically achieved by distributing the powder. The powder is, for example, supplied within the build chamber and then evenly distributed in the process plane by a coating element. This coating element can be, for example, a steel, rubber, or ceramic blade, or a brush, particularly one made of carbon fiber. High-quality components can only be manufactured with a powder bed surface that is as homogeneous as possible.

[0005] Friction between the powder material and the layer-depositing element, as well as partial protrusions from the powder bed (e.g., raised areas of the joined material caused by the selective melting process), lead to both wear and process-impairing damage to the powder-depositing elements. This damage typically worsens over the course of the layer-by-layer iterative manufacturing process.

[0006] Wear and the risk of damage increase continuously with increasing component height. However, damage can already be present initially, for example during setup or when applying the first layer of powder to a build platform.

[0007] Wear and any damage that may occur typically lead to uneven coating application and, consequently, unstable process conditions. This results in inhomogeneous material properties and quality losses of the manufactured component across its height. Damage to the powder-applying elements may necessitate a manual replacement of the coating element, requiring an interruption of the process.

[0008] Premature termination of individual components or even the entire construction process due to insufficient component quality would be unavoidable. The lack of recording and monitoring of the changing state of the layer-applying element during the ongoing process, which affects the quality and reproducibility of the layer application, presents further challenges.

[0009] Furthermore, another disadvantage of existing manufacturing systems is that the quality of the manufactured components depends significantly on the expertise and experience of the operator.

[0010] Powder bed fusion manufacturing processes are also characterized by long cycle times. One goal of using such manufacturing systems is to produce components overnight, thus eliminating personnel costs during this time. However, without personnel, there is no way to manually monitor the process overnight. Consequently, a defect in the coating elements may not be detected until the following day. By then, it is usually no longer possible to rectify the defect, rendering the manufactured component(s) of a build job scrap.

[0011] DE 10 2020 211 637 A1 discloses a coating system for an additive manufacturing system. US 2020 / 0 376 762 A1 discloses a coating system for additive manufacturing. DE 20 2018 003 678 U1 discloses a coating device for a device for the additive manufacturing of a three-dimensional object. CN 1 11 016 172 A discloses a belt-like, flexible powder distribution scraper. Reference is also made to the disclosures in DE 10 2006 056 422 B3, DE 10 2009 024 334 A1, and US 2012 / 0 266 815 A1.

[0012] Industry demands the use of highly reliable manufacturing systems to additively produce high-quality components economically. The cost-effectiveness of such systems, in particular, presents a challenge compared to conventional manufacturing processes such as milling or turning. Furthermore, industry aims to enable the use of these systems regardless of the operator's expertise or experience.

[0013] It is therefore an object of the invention to provide a manufacturing system and a method for the additive manufacturing of a component within a build area of ​​a powder bed, which reduce or eliminate one or more of the aforementioned disadvantages. In particular, it is an object of the invention to provide a solution that enables the additive manufacturing of high-quality components under economical conditions. At a minimum, it is an object of the invention to provide an alternative to existing manufacturing systems.

[0014] This problem is solved by a manufacturing system and a process according to the features of the independent claims. Further advantageous embodiments of these aspects are specified in the respective dependent claims. The features listed individually in the claims and the description can be combined with one another in any technologically meaningful way, and further embodiments of the invention are shown.

[0015] According to a first aspect, the aforementioned problem is solved by a manufacturing system for the additive manufacturing of a component within a build area of ​​a powder bed, comprising a build space in which the powder bed can be formed, and a coating unit with a coating element for forming a flat powder bed surface, wherein the coating unit is arranged and designed to adjust the position of the coating element without operator intervention so that the powder bed surface of the build area can be formed independently of a defect in the coating element.

[0016] The invention is based, among other things, on the understanding that a defect in the coating element can lead to quality defects, particularly in larger components. Furthermore, the invention is based on the understanding that the existing static application of the coating element does not meet the requirements.

[0017] Furthermore, the invention is based on the understanding that any defect in the coating element, if not immediately detected and rectified, has the potential to reduce quality. This necessitates continuous monitoring. However, manual continuous monitoring is not economically viable. The time interval between the occurrence of a defect and a reaction to compensate for it is crucial. A component layer is typically formed within 30 seconds, so any delay between the occurrence of the defect and the reaction to compensate, even if only a few minutes long, generally leads to an irreparable loss of quality.

[0018] The invention provides for an operator-free adjustable position of the coating element, so that wear and / or defects in the coating element have essentially no effect on the powder bed surface of the build area. Consequently, the component can be manufactured within the build area without the defect in the coating element negatively affecting the powder bed surface there.

[0019] The manufacturing system comprises the build chamber in which the powder bed can be formed. This build chamber can, for example, be configured as a chamber, enabling additive manufacturing within a protective gas atmosphere. Furthermore, the build chamber is preferably designed to allow powder to be introduced into it. In particular, the build chamber is designed to allow the formation of the powder bed, for example, by featuring a lowerable table.

[0020] The manufacturing system further comprises the coating unit with the coating element for forming a flat powder bed surface. The coating element is preferably arranged on the coating unit. This arrangement is preferably variably designed. It is particularly preferred that the coating element is movably arranged relative to the coating unit. For example, the coating element can be slid out from the coating unit. Furthermore, it is preferred that the coating element is movably designed orthogonally to a feed direction of the coating element, particularly in the horizontal direction. The coating element can also be adjustable, orientable, and / or calibrated orthogonally to the feed direction.

[0021] The coating element can, for example, be blade-shaped to form the flat powder bed surface. It is particularly preferred that the coating element extends at least over the width of the powder bed, the width preferably being oriented substantially orthogonally to a feed direction of the coating unit and / or the coating element. It is particularly preferred that the coating element has a straight edge to form the flat powder bed surface.

[0022] The coating unit is arranged and designed to allow for operator-free adjustment of the coating element's position, ensuring that the powder bed surface of the build area can be formed independently of any defects in the coating element. This means, in particular, that a defect in the coating element has no impact on the powder bed surface in the area where the component is manufactured. It also means that the powder bed surface is perfectly flat in the area where the powder is exposed, for example, by a laser.

[0023] The build area is specifically the area of ​​the powder bed in which the component is manufactured or built up. Furthermore, the build area can be defined by the area within which the powder is exposed to light. For example, the build area can be delineated from the rest of the powder bed by connecting the outermost and adjacent exposure points. More generally, the build area is the region of the powder bed where any unevenness in the powder bed surface would negatively impact the quality of the component being manufactured.

[0024] A flat powder bed surface is to be understood in the sense of a person skilled in the art. Of course, a flat powder bed surface does not mean mathematical flatness, but rather a roughness of the powder bed surface, which is defined in particular by the powder particle size, the statistical distribution of the powder particles within the powder bed surface, and / or the packing density of the powder particles.

[0025] The powder bed surface required for the additive manufacturing of a component is characterized by uniformity and consistency, so that any inhomogeneity, for example caused by a defect in the coating element, degrades such a powder bed surface. For instance, the defect in the coating element could be a notch on the working side of the coating element facing the powder bed surface. Such a notch would result in a correspondingly flawed powder bed surface.

[0026] The position of the coating element must be adjustable without operator intervention. The position of the coating element can refer, for example, to its relative position within the build space and / or its relative position to a mounting unit of the coating unit that holds the coating element. An adjustment without operator intervention is understood to mean, in particular, an adjustment that requires no operator. For example, the position of the coating element must be adjusted automatically.

[0027] The ability to adjust the position of the coating element without operator intervention can be achieved through various measures. As explained in more detail below, this can be accomplished by moving the coating element and then continuing to use it, or by replacing the coating element and inserting a new one, particularly by renewing the coating element.

[0028] As explained in more detail below, the defect can be detected, particularly with a detection device. Alternatively, the defect can also be predicted, for example, based on expected wear, so that the position of the coating element is adjusted at predefined intervals, and in particular, the coating element is replaced. Furthermore, the position of the coating element can be adjusted by an operator of the manufacturing system, for example, by manual input at a control device described below.

[0029] It is particularly preferred that the manufacturing system includes an exposure unit for selectively melting the powder bed. The exposure unit can, for example, be a laser unit or an electron beam unit. Furthermore, the manufacturing system preferably includes a binder unit for applying a binder.

[0030] A preferred embodiment of the manufacturing system is characterized by the fact that the coating unit is arranged and designed in such a way that a defective section of the coating element containing the defect can be guided past the build-up area.

[0031] It is particularly preferred that the defect section can be guided past the build-up area by moving the coating element orthogonally to a feed direction, especially in a horizontal direction. For this purpose, the coating element is preferably movable relative to the coating unit, so that it can, for example, be moved back and forth, especially orthogonally to the feed direction.

[0032] Thus, for example, a defect in a central section of the coating element can be shifted to a lateral area of ​​the powder bed, where, for instance, the build-up area is not located. Therefore, as will be explained in more detail below, the position of the coating element can also be varied depending on the position and size of the build-up area.

[0033] Furthermore, it is preferred that the coating unit is arranged and designed in such a way that the coating element and / or a working section of the coating element is interchangeably arranged on the coating unit.

[0034] Preferably, the defective section of the coating element can be guided past the build-up area, and the coating element is arranged in a replaceable manner. Unmanned replacement of the coating element can be achieved in various ways, as explained in more detail below. A working section of the coating element can be replaceable, for example, by designing the coating element as a strip and / or a coilable unit. Furthermore, the manufacturing system is preferably designed such that, after removing the coating element with the defect, another coating element, preferably one free of defects, can be installed.

[0035] Another preferred embodiment of the manufacturing system comprises a control device configured to control the coating unit in such a way that the position of the coating element is adjusted so that the powder bed surface of the build area is formed independently of the defect of the coating element.

[0036] In particular, the functionality of the coating unit described above can be efficiently implemented through a control device that is, for example, linked to the coating unit via signal technology. This further improves the automation capabilities and thus the operator-free operation of the manufacturing system.

[0037] Another preferred development of the manufacturing system is characterized by the fact that the control device is set up to control the coating unit depending on a position of the build area in such a way that the defect is guided past the build area or the coating element is replaced.

[0038] The position of the build area is usually known, as it is typically defined during component programming. The control device can therefore be provided with information characterizing the build area itself, as well as its position. For example, the control device can receive data representing the build area and / or its position from a work preparation system.

[0039] If the control device activates the coating unit based on the position of the build area, the position of the coating element can be precisely adjusted without operator intervention. The control device is preferably configured such that, depending on the size and / or position of the build area, the coating element is either exchanged or moved past the build area. This ensures the quality of the manufactured component, avoids rejects, and saves costs.

[0040] Another preferred embodiment of the manufacturing system is characterized by the fact that it includes a detection device for identifying the defect, wherein the control device is coupled to the detection device and the coating unit via a signal connection and is configured to control the coating unit depending on the defect. It is particularly preferred that the coating unit is controlled depending on the position of the defect.

[0041] The detection device can, for example, provide data representing the state of the coating element and / or a defect and / or the defect's position on it. The control device is specifically configured to receive this data. Based on the data representing the defect, the control device controls the coating unit. For this purpose, the control device preferably sends a control signal to the coating unit, the control signal preferably controlling the coating unit in such a way that the defect does not substantially affect the powder bed surface in the build-up area. This ensures that the defect remains outside the build-up area during the formation of the flat powder bed surface.

[0042] Furthermore, it is preferred that the detection device is arranged and configured to detect the defect based on a property of the powder bed surface and / or based on a property of the coating element. It is preferred that the detection device is designed for optical monitoring.

[0043] The properties of the powder bed surface can include, for example, a raised area, a groove, a ridge, an unevenness and / or a waviness, in particular a chatter mark, for example in the feed direction.

[0044] The characteristic of the coating element can generally be an irregularity on a working side of the coating element facing the powder bed. This could, for example, be a notch.

[0045] It is further preferred that the detection device is a line scanner. Alternatively, the detection device can be a light field camera. Line scanners and light field cameras advantageously enable the detection of a property of the powder bed surface.

[0046] Alternatively or additionally, the detection device may include a line scan camera or be configured as such. Furthermore, the detection device may include a light barrier or be configured as a light barrier.

[0047] Another preferred embodiment of the manufacturing system is characterized by the fact that the coating unit is rotatably arranged about an axis of rotation and has an outer circumferential surface on which the coating element is arranged in such a way that the coating element can be replaced without operator intervention by rotating the coating unit about the axis of rotation.

[0048] For example, two or more coating elements can be arranged on the outer circumferential surface, so that by rotating the coating unit one of the coating elements is replaced by another coating element.

[0049] Furthermore, it may be preferred that the coating unit is arranged such that, by rotating the coating unit, the coating element is moved from a working position to an exchange position, and the coating element in the exchange position is replaced by another coating element. For example, the coating unit can be coupled to the coating magazine and the feed unit, which are described in more detail below, in such a way that the coating element is interchangeable.

[0050] The axis of rotation of the coating unit is preferably oriented substantially horizontally. Furthermore, it is preferred that the axis of rotation is oriented substantially orthogonally to a feed direction of the coating unit. It is also preferred that the coating unit is rotatably arranged to lock into position, so that it can be locked in predetermined positions. This ensures that a coating element forming the flat powder bed surface can be positioned in a predetermined location.

[0051] In a further preferred embodiment of the manufacturing system, it is provided that it comprises a coating magazine for storing two or more coating elements and a feeding unit which is arranged and designed to feed one of the two or more coating elements to the coating unit.

[0052] The advantage of a manufacturing system with a coating magazine and a feeding unit is, in particular, that a large number of coating elements can be provided. This allows the manufacturing system to produce or complete component, multiple components, and / or build jobs unattended for extended periods.

[0053] It is preferred that the feeding unit comprises a gripping unit which is arranged and designed to fix a coating element located in the coating magazine and to feed it to the coating unit in such a way that the coating element arranged on the coating unit is pushed out by the gripped coating element.

[0054] Furthermore, the feeding unit and / or the coating unit can have one, two or more driven rollers arranged in such a way that the coating elements are interchangeable.

[0055] In a further preferred embodiment, the coating element is designed in a band shape and is arranged on the coating unit so as to be movable in at least one direction.

[0056] By means of a band-shaped coating element, it can be ensured with minimal effort that this defect is essentially not used to form the powder bed surface within the build-up area. Furthermore, it is preferred that the band-shaped coating element be arranged to be movable in two directions, in particular to be movable back and forth.

[0057] Another preferred embodiment of the manufacturing system is characterized by the fact that the coating element is designed to be coilable, and the coating unit has two separately spaced, rotatably arranged coiling elements for winding and unwinding the coilable coating element.

[0058] The coating element can be continuously renewed using the winding elements. In particular, after a defect in the coating element has been detected, for example by the detection device, the winding elements can rotate and thus wind and unwind the coating element, allowing a section of the coating element without defects to be used for forming the powder bed surface. The winding elements can be designed, for example, as discs, rollers, or drums.

[0059] It is particularly preferred that the control device is configured to control one or both of the winding elements depending on the detection of a defect. One or both of the winding elements are preferably coupled to a drive, for example an electric motor.

[0060] It is further preferred that the manufacturing system includes a conditioning unit that can be brought into contact with a working side of the coating element and that is arranged and configured to reduce or eliminate the defect of the coating element. It is also preferred that the coating element is arranged to be trackable.

[0061] The conditioning unit can be, for example, a cutting element, a grinding unit, a filing unit, a milling unit, and / or a shearing unit. It is particularly preferred that a coating element made of or comprising rubber be machinable by a cutting element. Furthermore, coating elements made of steel or ceramic can be conditioned with a grinding unit so that the defect is reduced or eliminated.

[0062] According to another aspect, the aforementioned task is solved by a method for the additive manufacturing of a component within a build area of ​​a powder bed, comprising the steps: creating a flat powder bed surface with a coating element and unattended adjustment of a position of the coating element such that the powder bed surface of the build area is formed independently of a defect of the coating element.

[0063] This means, in particular, that the defect is located outside the build-up area during the formation of the flat powder bed surface. This can be achieved, for example, by routing the defect alongside the build-up area or by replacing the coating element. Furthermore, the coating element can be reworked or replaced.

[0064] A preferred embodiment of the method provides that the operatorless adjustment of the position of the coating element involves replacing and / or moving the coating element. The movement is performed, in particular, orthogonally to a feed direction of the coating element.

[0065] Another preferred embodiment of the method comprises the step of: detecting a defect in the coating element, in particular based on a property of the powder bed surface and / or a property of the coating element, wherein the position of the coating element is adjusted after the defect has been detected.

[0066] The process and its possible further developments exhibit characteristics or process steps that make them particularly suitable for use in a manufacturing system and its further developments.

[0067] For further advantages, design variants and design details of the other aspects and their possible further training, reference is also made to the previously given description of the corresponding features and further training of the manufacturing system.

[0068] Preferred embodiments are explained by way of example with reference to the accompanying figures. These show: Fig. 1: a schematic, two-dimensional view of an exemplary embodiment of a manufacturing system; Fig. 2: a schematic, two-dimensional view of another exemplary embodiment of a manufacturing system; Fig. 3: a schematic, two-dimensional view of another exemplary embodiment of a manufacturing system; Fig. 4: a schematic, two-dimensional top view of the in Fig. 1. Manufacturing system shown; Fig. 5: a schematic, two-dimensional sectional view of the in Fig. 1 of the manufacturing system shown; Fig. 6: another schematic, two-dimensional sectional view of the in Fig. 1 manufacturing system shown with a compared to Fig. 5 moving coating elements; Fig. 7: a schematic, three-dimensional view of an exemplary embodiment of a coating magazine and a feeding unit; Fig. 8: a schematic, three-dimensional view of an exemplary embodiment of a coating unit; Fig. 9: a schematic, three-dimensional view of another exemplary embodiment of a coating unit; and Fig. 10: a schematic view of an exemplary embodiment of a method.

[0069] In the figures, identical or essentially functionally equivalent or similar elements are designated with the same reference symbols.

[0070] The in the Fig. The manufacturing system 1, 1', 1'' shown in Figures 1-3 is designed for the additive manufacturing of a component 2 within a build area 4 of a powder bed 6. The manufacturing system 1, 1', 1'' comprises a build chamber 5 in which the powder bed 4 is formed. The powder bed 4 comprises the powder 8, which is selectively melted by an exposure unit 24.

[0071] The installation space 5 is formed, among other things, by a machine frame 14 and a table 10. The table 10 is coupled to a support unit 12, which allows the table 10 to be lowered. The manufacturing system 1, 1', 1'' further comprises a coating unit 16, which has a first coating element 18, 18', 18" . The in Fig. 2 The manufacturing system 1' shown comprises a coating unit 16 with a total of 8 coating elements, of which the first coating element 18' and a second coating element 26 are referenced as examples.

[0072] The coating unit 16 is movable back and forth in the feed direction V with the coating elements 18, 18', 18", 26. This allows the coating elements 18, 18', 18", 26 to form a flat powder bed surface 20. The powder bed surface 20 is particularly flat because the coating element 18, 18', 18", 26 has a straight edge.

[0073] In order to produce a high-quality component 2, the powder bed surface formed by the coating element 18, 18', 18", 26 must be as flat as possible. However, a flat powder bed surface is generally not possible if the coating element 18, 18', 18", 26 has a groove in the Fig. 4 - 6 shows defect 34.

[0074] Especially from the Fig. 5 and Fig. Figure 6 shows that the defect 34 affects the powder bed surface 20. For example, a groove 44 can be introduced into the powder bed surface by the defect 34. In the Fig. Figure 4 shows the groove 44, where the position of the defect 34 on the coating element 18 causes the groove to extend through the build-up area 4. Therefore, the powder bed surface 20 in the build-up area 4 is not completely flat, and the quality of the manufactured component 2 may be reduced.

[0075] Advantageously, in the manufacturing system 1, 1', 1'', the coating unit 16 is arranged and configured to allow the position of the coating element 18, 18', 18", 26 to be adjusted without operator intervention, such that the powder bed surface 20 of the build area 4 can be formed independently of any defect 34 of the coating element 18, 18', 18", 26. This is demonstrated in the Fig. 4 is achieved by allowing a defect section 32 of the coating element 18, 26, exhibiting the defect 34, to pass by the build-up area 4, namely by setting a lateral offset. This is illustrated by the coating elements 18 shown with dashed lines.

[0076] The coating elements 18 can be displaced in the direction of width B. Thus, the defect 34 and the defect section 32 can also be displaced in the direction of B, so that the defect 34 does not affect the powder bed surface in build-up area 4. The Roman numerals I, II, and III represent different points in time for the movement of the coating unit 16 and the coating element 18. In particular, it is evident that the groove 44' caused by the displaced coating element 18 does not extend through build-up area 4.

[0077] In addition to or as an alternative to bypassing the defect section 32, it is possible to arrange the coating element 18, 18', 18", 26 and / or a working section of the coating element 18, 18', 18", 26 interchangeably on the coating unit 16. An interchangeably arranged coating element 18', 26 is particularly suitable in the Fig. 2 shown.

[0078] The coating unit 16 is rotatably arranged about an axis of rotation and has an outer circumferential surface. A total of eight coating elements 18', 26 are arranged on the outer circumferential surface such that one or more of the coating elements 18', 26 can be replaced without operator intervention by rotating the coating unit 16 about the axis of rotation. The coating unit 16 is movable with a feed direction 22.

[0079] In the Fig. Figure 3 further shows a conditioning unit 28 that can be brought into contact with a working side of the coating element 18". The conditioning unit 28 is specifically arranged and designed to reduce or eliminate the defect 34 of the coating element 18". Furthermore, the coating element 18" is arranged to be tracked.

[0080] The manufacturing system 1, 1', 1'' further comprises a control device 30 which is configured to control the coating unit 16 in such a way that the position of the coating element 18, 18', 18', 26 is set such that the powder bed surface 20 of the build area 4 is formed independently of the defect 34 of the coating element 18, 26.

[0081] The control device 30 is further configured to control the coating unit 16 depending on the position of the build-up area 4 in such a way that the defect 34 is guided past the build-up area.

[0082] The manufacturing system 1, 1', 1" includes a detection device 46 for detecting the defect 34. The detection device 46 can, for example, be a light field camera. The control device 30 is signal-linked to the detection device 46 and the coating unit 16.

[0083] Furthermore, the control device 30 is configured to control the coating unit depending on the defect 34, in particular depending on the position of the defect 34. This ensures that the powder bed surface 20 of the build-up area 4 can be formed independently of the defect 34 of the coating element 18, 18', 18', 26.

[0084] In the Fig. 5 and Fig. Figure 6 illustrates the displacement of the coating element 18, 18', 18", 26 in the direction of width B. Fig. 5. The powder bed surface 20 of the build-up area 4, namely the area where exposure is carried out by the exposure unit 24, is affected by the defect 34. If this is detected in time, for example in situation I. of the Fig. 4, the coating element 18 can be moved in the direction of width B so that it is in the position of Fig. 6. Consequently, the defect 34 is shifted in the direction of width B and is therefore, in situation II, outside the assembly area 4. Consequently, the defect 34 is not detrimental to the quality of component 2.

[0085] Fig. Figure 7 shows a coating magazine 36 in which a large number of coating elements 18 are stored. The coating elements 18 are fed to the coating unit 16 by means of a feeding unit 38. A defective coating element 18 that needs to be replaced can be disposed of with the disposal unit 48 and is preferably not returned to the magazine.

[0086] In Fig. Figure 8 shows a further embodiment of a coating unit 16. The coating unit 16 has a band-shaped coating element 18, which is arranged within the coating unit 16 so as to be movable in one direction. For this purpose, the coating unit 16 has two spaced-apart, rotatably arranged winding elements 40, 42. The winding elements 40, 42 are coupled to a drive.

[0087] The coating element 18 is wound up by rotating the winding element 42. As a result, the coating element 18 moves towards the lower longitudinal edge of the coating unit 16. This allows, on the one hand, a working section of the coating element to be replaced and, on the other hand, a defective section with a defect can be moved past the build-up area 4.

[0088] The one in Fig. The coating unit 16 shown in Figure 9 exhibits a design essentially analogous to that in Figure 9. Fig. The coating element 18 shown in Figure 8 protrudes from one flat side of the coating unit 16.

[0089] Fig.Figure 10 shows a schematic representation of a process. In step 100, a flat powder bed surface 20 is formed with a coating element 18, 18', 18'', 26. This can also be done several times and, in particular, sequentially with an exposure. In step 102, a defect 34 of the coating element 18, 18', 18'', 26 is detected, in particular based on a property of the powder bed surface 20. In step 104, the position of the coating element 18, 18', 18'', 26 is set automatically such that the powder bed surface 20 of the build area 4 can be formed independently of a defect 34 of the coating element 18, 18', 18'', 26.

[0090] With the manufacturing system 1, 1', 1'' and process described above, the production of high-quality components 2 using an additive manufacturing process is possible. In particular, this high-quality component 2 can also be manufactured economically, since, especially, the position of the coating element 18, 18', 18'', 26 can be adjusted without operator intervention. Thus, either the use of a coating element 18, 18', 18'', 26 with a defect can be avoided, or the defect 34 of the coating element 18, 18', 18'', 26 can be moved into such a position that it has essentially no quality-reducing effect on the component 2 being manufactured. This generally makes the production of larger additively manufactured components 2 possible. REFERENCE MARK 1 Manufacturing system 2 components 4 Construction area 5 Construction space 6 Powder bed 8 powders 10 tables 12 support units 14 machine frame 16 coating units 18 first coating element 20 Powder bed surface 22 Feed direction 24 exposure units 26 second coating element 28 conditioning units 30 Control device 32 Defect section 34 Defect 36 Coating Magazine 38 Feed unit 40 first winding element 42 second winding element 44, 44' groove 46 Detection device 48 disposal units L Construction space length H Installation space height B Construction space width

Claims

[1] Manufacturing system (1) for the additive production of a component within a build-up area (4) of a powder bed, comprising - a construction space (5) in which the powder bed (6) can be formed, and - a coating unit (16) with a coating element (18, 18', 18'', 26) for forming a flat powder bed surface (20), - wherein the coating unit (16) is arranged and designed to adjust a position of the coating element (18, 18', 18'', 26) without the need for an operator in such a way that the powder bed surface (20) of the build-up area (4) can be formed independently of a defect (34) of the coating element (18, 18', 18'', 26), - characterized by in that the production system comprises a conditioning unit (28) which can be brought into contact with a working side of the coating element (18, 18', 18'', 26) and which is arranged and designed to reduce or eliminate the defect of the coating element (18, 18', 18'', 26). [2] Manufacturing system (1) according to claim 1, wherein the coating unit (16) is arranged and designed such that - a defect section (32) of the coating element (18, 18', 18'', 26) having the defect can be guided past the build-up area (4), and / or - the coating element (18, 18', 18'', 26) and / or a working section of the coating element (18, 18', 18'', 26) is arranged interchangeably on the coating unit (16). [3] Manufacturing system (1) according to one of the preceding claims, comprising - a control device (30) which is configured to control the coating unit (16) in such a way that the position of the coating element (18, 18', 18'', 26) is adjusted in such a way that the powder bed surface (20) of the build-up area (4) is formed independently of the defect in the coating element (18, 18', 18'', 26). [4] Manufacturing system (1) according to the preceding claim 3, wherein - the control device (30) is configured to control the coating unit (16) as a function of a position of the build-up area (4) in such a way that the defect is guided past the build-up area or the coating element (18, 18', 18'', 26) is replaced. [5] Manufacturing system (1) according to one of the preceding claims 3-4, comprising - a detection device (46) for detecting the defect, - wherein the control device (30) is signal-coupled to the detection device and the coating unit (16) and is configured to control the coating unit (16) depending on the defect. [6] Manufacturing system (1) according to the preceding claim 5, wherein - the detection device (46) is arranged and designed to detect the defect based on a property of the powder bed surface (20) and / or based on a property of the coating element (18, 18', 18'', 26). [7] Manufacturing system (1) according to one of the preceding claims 5-6, wherein - the detection device (46) is or comprises a line scanner and / or a light field camera. [8] Manufacturing system (1) according to one of the preceding claims, wherein the coating unit (16) is arranged to be rotatable about a rotation axis and has an outer circumferential surface on which the coating element is arranged such that the coating element can be replaced without operator intervention by rotating the coating unit (16) about the rotation axis. [9] Manufacturing system (1) according to one of the preceding claims, comprising - a coating magazine (36) for storing two or more coating elements (18, 18', 18'', 26), and - a feed unit (38) arranged and designed to feed one of the two or more coating elements to the coating unit (16). [10] Manufacturing system (1) according to one of the preceding claims, wherein - the coating element (18, 18', 18'', 26) is band-shaped and is arranged on the coating unit (16) so as to be movable in at least one direction. [11] Manufacturing system (1) according to one of the preceding claims, wherein - the coating element (18, 18', 18'', 26) is designed to be windable, and - the coating unit (16) has two spaced-apart, rotationally movable winding elements (40, 42) for winding and unwinding the windable coating element (18, 18', 18'', 26). [12] Method for the additive manufacturing of a component within a build-up area (4) of a powder bed (6) of a manufacturing system according to one of the preceding claims 1-11, comprising the steps: - producing a flat powder bed surface (20) with a coating element, and - operator-free adjustment of a position of the coating element (18, 18', 18'', 26) such that the powder bed surface (20) of the build-up area (4) is formed independently of a defect in the coating element (18, 18', 18'', 26), - characterized by Reducing or eliminating the defect with a conditioning unit (28) of the manufacturing system that can be brought into contact with a working side of the coating element (18, 18', 18'', 26). [13] Method according to the preceding claim 12, wherein - the operator-free adjustment of the position of the coating element (18, 18', 18'', 26) is an exchange and / or a movement of the coating element (18, 18', 18'', 26). [14] Method according to one of the preceding claims 12-13, comprising the step: - detecting a defect in the coating element (18, 18', 18'', 26), wherein the position of the coating element (18, 18', 18'', 26) is adjusted after the defect has been detected.

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