Manufacturing device for the additive manufacturing of a three-dimensional component from a build-up material and method for the additive manufacturing of a three-dimensional component from a build-up material

Abstract

The invention relates to a manufacturing device and a method for the additive manufacturing of a three-dimensional component. The device comprises a movable process chamber that can be moved into release, manufacturing, and maintenance positions, as well as a build platform unit that is positioned within an exchange frame and is vertically movable. A coating unit applies the build material layer by layer, while an irradiation unit selectively hardens it. A protective glass panel is positioned between the irradiation unit and the process chamber, allowing for easy maintenance. Gas-tight connections and flexible handling ensure precise and efficient manufacturing, especially for large-volume components.

Description

[0001] The invention relates to a manufacturing device for the additive manufacturing of a three-dimensional component from a build-up material.

[0002] Such manufacturing devices for the additive manufacturing of a three-dimensional component by layer-by-layer application are generally characterized by locally selective solidification of a build-up material and are fundamentally known from the prior art. For layer-by-layer application, at least one corresponding coating unit is usually provided. For locally selective solidification, at least one corresponding irradiation unit (e.g., comprising at least one laser) is usually provided.

[0003] Furthermore, it is known to construct the three-dimensional component on a construction platform held by a support (construction platform support). Specifically, the component can be constructed within a construction shaft.

[0004] Large-volume components produced using additive manufacturing processes often present challenges, particularly regarding the weight forces generated during the manufacturing process. These forces differ significantly at the beginning and end of a build cycle. At the start of the build, there is very little build material in the build chamber, resulting in low weight forces. Towards the end of the build cycle, however, large quantities of build material are present on the substrate, leading to a considerable increase in weight forces. These fluctuations in weight result from the varying amounts of material throughout the entire manufacturing process.

[0005] The required build material, usually in powder form, is therefore present in large quantities in the build chamber, at least towards the end of the build process. As the build size increases, so does the stress on the manufacturing fixture due to weight forces. These higher weight forces present additional challenges, particularly regarding the stability of the components and the manufacturing fixture itself.

[0006] The larger the build volume, the more pronounced these problems become. The weight of build material within the build chamber can reach quantities of, for example, 400 kg, 1,000 kg, or even 4,000 kg. These large amounts of build material towards the end of the build process often lead to deformation of the components and / or the manufacturing fixture itself, which in turn negatively impacts the quality and dimensional accuracy of the components. Manufacturing fixtures used for large-volume build processes are therefore particularly susceptible to these challenges.

[0007] In the operation of a manufacturing device for the additive manufacturing of a three-dimensional component, it is known from the prior art that the process chamber and the exchange frame are connected to each other in such a way that they have a gas-tight connection. This is done to maintain a protective gas atmosphere or other special environmental conditions within the process chamber throughout the entire manufacturing process. For this purpose, the exchange frame is designed to be movable in the prior art, so that it can be lifted and docked to the bottom of the process chamber from below.

[0008] Extreme precision is required to ensure that the z-axis of the build platform unit remains perfectly aligned at all times. In particular, the z-axis alignment relative to a coating plane must be maintained with very high accuracy throughout the entire build process. Any deviation could lead to deformations or variations in layer thickness, which would compromise the quality of the component.

[0009] The primary objective of the invention is to provide a manufacturing device that exhibits at least reduced deformations of the components and / or the manufacturing device, even when the build volume is large.

[0010] A manufacturing device for the additive manufacturing of a three-dimensional component from a build-up material is proposed. The manufacturing device comprises at least one build platform unit on which the component can be built. At least one build platform unit can be positioned in a process chamber. The manufacturing device includes a coating unit by means of which the build-up material can be applied to the at least one build platform unit in the process chamber, the coating unit being arranged in the process chamber. The manufacturing device includes at least one irradiation unit with which the build-up material can be solidified on the at least one build platform unit, the at least one irradiation unit being arranged above the build platform unit.The manufacturing device further comprises at least one interchangeable frame within which the at least one build platform unit can be positioned, wherein the at least one build platform unit can be moved vertically within the interchangeable frame.

[0011] According to the invention, the process chamber is designed to be movable, so that it can be moved from a manufacturing position to at least one further position, preferably a release, maintenance and / or setup position.

[0012] This represents a significant difference from the prior art, in which the interchangeable frame is designed to be movable in order to dock with the bottom of the process chamber and close it.

[0013] In contrast, with the device according to the invention, the exchange frame can remain in a fixed position while the process chamber itself is moved. In its manufacturing position, the process chamber is sealed at its underside by the exchange frame, preferably in such a way as to create a gas-tight seal. This design offers the advantage that the exchange frame no longer needs to be vertically lifted and precisely positioned to ensure accurate alignment of the z-axis with the coating plane. This reduces potential sources of error that could arise from slight deviations in the positioning of the exchange frame and significantly simplifies the handling and maintenance of the manufacturing device.

[0014] The movable process chamber also facilitates access to the build platform unit and other components of the device, which is particularly advantageous in release, maintenance or setup situations.

[0015] The release position of the process chamber is a specific position in which the process chamber is preferably moved upwards to allow sufficient access. This position preferably allows the exchange frame, including the build platform unit, to be moved from the production position to the setup position of a setup station (described in the next paragraph). The release position ensures that the exchange frame can be moved safely without interference or collision with the process chamber. This position is particularly important for changing build platform units or removing finished components and significantly increases the flexibility of the manufacturing device.

[0016] A setup station is preferably an integral part of the manufacturing device and serves as a separate area located outside the process chamber. The setup station allows the exchange frame, including the build platform unit, to be picked up after a build process is completed. This enables tasks such as removing the finished component, installing a new build platform unit, or performing maintenance on the build platform unit. By positioning the exchange frame in the setup station, the build process can continue uninterrupted, as a second build platform unit can be used in the process chamber. Operation with only one exchange frame is also possible. The exchange frame, including the build platform unit, can therefore be positioned either in the process chamber and / or in the setup station, significantly increasing the flexibility and efficiency of the manufacturing device.

[0017] In the manufacturing position, the process chamber is preferably mounted on the construction shaft and gas-tightly connected to it via the interchangeable frame. This ensures that a closed and controlled environment is maintained throughout the entire construction process, in which the supply of protective gas and other process-critical parameters can be kept constant.

[0018] By placing the process chamber onto the build shaft, it can be ensured that no leaks occur that could impair the manufacturing process. This connection is preferably designed so that the exchange frame on the underside of the process chamber seals the chamber in its manufacturing position, guaranteeing stable and precise positioning. In this way, it can be ensured that the z-axis of the build process and the coating plane remain precisely maintained throughout the entire build process, which is particularly crucial for the production of complex and large-volume components.

[0019] By placing the process chamber on the construction shaft or by connecting the process chamber to the construction shaft, a gas-tight connection is created, enabling the construction process to be carried out in a shielded atmosphere without interrupting media such as inert gas or laser fibers. At the same time, the length compensation provides the necessary clearance to allow these connections to operate flexibly and without impairment despite the movement of the process chamber.

[0020] Within the scope of this invention, a manufacturing device for the additive manufacturing of a three-dimensional component from a build-up material is understood to be a device that serves to build up a component layer by layer from a suitable material. This device enables the targeted application and solidification of the material to create a three-dimensional object.

[0021] In the context of this invention, a build platform unit is understood to be a device component on which the three-dimensional component is built during the manufacturing process. This unit serves as a support for the component and is designed to withstand the mechanical loads encountered during manufacturing.

[0022] In the context of this invention, a process chamber is understood to be an enclosed space in which additive manufacturing takes place. The process chamber provides a controlled environment necessary to carry out the manufacturing processes, such as the application and solidification of the material, under optimal conditions.

[0023] In the context of this invention, a coating unit is understood to be a device that serves to apply the build material preferably uniformly to the build platform unit within the process chamber. This unit is arranged within the process chamber such that it can perform the material application precisely and in a controlled manner.

[0024] In the context of this invention, an irradiation unit is understood to be a device that selectively hardens the build material on the build platform unit by targeted local irradiation, e.g., using a laser. This unit is arranged above the build platform unit to harden the material layer by layer, thus enabling the assembly of the component. Selective hardening by means of the irradiation unit refers in particular to methods in which the irradiation unit focuses its irradiation on individual areas. Preferably, this includes irradiation and, optionally, scanning with laser beams from one or a plurality of lasers or laser diodes.

[0025] In the context of this invention, a "changeable frame" is understood to be a device that enables the positioning of the build platform unit. The changeable frame serves to hold the build platform unit stably and simultaneously allows vertical movement within the build shaft in order to lower the component under construction.

[0026] Preferably, the manufacturing device is additionally equipped with a length compensation mechanism to compensate for the offset of various components caused by the lowering of the process chamber. This length compensation particularly affects critical components of the process chamber, such as the shielding gas supply, the laser fiber, and other media lines that are either moved along with the process chamber during its movement or are subjected to mechanical stresses during the process chamber movement.

[0027] Raising the process chamber to a release, maintenance, or setup position can cause changes in the length and position of the connected lines and components. To ensure that these connections are not under stress or damaged, the length compensation is preferably designed to react flexibly to the changed position of the process chamber and guarantee the functionality of the affected components, at least during the build process.

[0028] In particular, the protective gas supply, which is used for operating the process chamber under controlled conditions, and the laser fiber, which is required for the selective solidification of the build material, are preferably guided by the length compensation in such a way that a safe and precise supply is ensured throughout the entire build process.

[0029] In a preferred embodiment, the manufacturing device comprises a coupling device designed for the preferably positive-locking connection of the exchange frame to the process chamber in the manufacturing position. This coupling device serves to securely and stably connect the exchange frame and the process chamber in the manufacturing position, ensuring precise alignment and / or a gas-tight connection between the two components.

[0030] The coupling device is preferably designed for a positive-locking connection, meaning that the connection is made by precisely interlocking elements on the underside of the process chamber and the top of the exchange frame. This ensures that the process chamber sits immovably on the exchange frame in the manufacturing position, enabling precise positioning along the z-axis.

[0031] Furthermore, the positive-locking coupling preferably ensures that the process chamber is not displaced by external influences or internal vibrations during the manufacturing process. This can significantly increase stability and process reliability, as no readjustments of the chamber are required once the connection has been established. The preferably gas-tight seal, ensured by the coupling device between the process chamber and the exchange frame, also allows for the maintenance of a controlled protective gas atmosphere in the process chamber, which is crucial for the quality of the finished component.

[0032] This embodiment offers the additional advantage that, after completion of the construction process, the process chamber can be easily decoupled and moved into a release, maintenance or setup position without affecting the precision of the connection in the manufacturing position.

[0033] In a further embodiment, the exchange frame and the process chamber are designed such that they form a common gas space in the manufacturing position. In this configuration, the exchange frame and the process chamber are preferably designed and arranged such that, upon reaching the manufacturing position, a continuous and gas-tight connection is created between the two components, thereby establishing a closed gas space.

[0034] The shared gas space ensures a uniform protective gas atmosphere in both the process chamber and the area of ​​the exchange frame. This guarantees that the entire environment in which the build process takes place operates under identical conditions, for example, with regard to temperature, pressure, and gas composition. This is particularly advantageous for preventing material oxidation or undesirable chemical reactions during the build process and maximizing the quality of the component.

[0035] The design of the exchange frame and the process chamber is preferably such that they are connected in the production position in a way that allows for a virtually unimpeded gas flow between the two elements. This can be achieved, for example, by seals or positive-locking elements that ensure a gas-tight connection and thus enable a homogeneous gas space across the entire production area.

[0036] Another advantage of this design is that the protective gas can be used more efficiently, as separate gas spaces for the process chamber and the exchange frame are not required. The shared gas space minimizes gas losses and simplifies the control and monitoring of the protective gas atmosphere. Furthermore, this solution increases process reliability, as continuous control of the gas conditions is ensured throughout the entire build process.

[0037] In another embodiment, the exchange frame is designed to be stationary, so that it does not need to be moved during the production of a three-dimensional component. With this design, the exchange frame can remain in a fixed position during the build process, ensuring that the process chamber and the build platform unit are held stable. This guarantees precise alignment of the z-axis and prevents any movements that could impair the accuracy and quality of the build process.

[0038] It is particularly advantageous that the exchange frame only needs to be stationary during the build process. After completion of the build process, the exchange frame can easily be moved to, for example, the setup position to prepare for the next build process or to the maintenance position for maintenance work. During production, however, the exchange frame can remain in its stable position, ensuring that all relevant components, including the build platform unit, remain precisely aligned.

[0039] In this embodiment, it is irrelevant whether the process chamber or the exchange frame can be moved relative to each other, as long as the fixed position of the exchange frame is ensured during the build process. This offers the flexibility that, after completion of a build process, the various components of the manufacturing device can be moved into release, maintenance, or setup positions without affecting the precision of the build process.

[0040] In a preferred embodiment, the process chamber is designed to be movable, so that it can be moved from its manufacturing position – in which it is placed and preferably gas-tightly connected to the construction shaft – to several other positions. These different positions can facilitate the handling of the manufacturing device and enable release, maintenance, setup, or other activities outside the actual construction process.

[0041] In the manufacturing position, the process chamber is firmly connected to the build shaft, ensuring a stable, preferably gas-tight, environment for the construction of the three-dimensional component. After completion of the build process, however, the process chamber can be moved from this position to other defined positions to, for example, allow easy access to internal components of the device for maintenance or to facilitate the changing of build platforms or materials.

[0042] This flexibility in the process chamber's movement significantly increases the efficiency of the entire production process, as setup and maintenance work can be carried out without extensive disassembly or manual intervention. Furthermore, the mobile process chamber helps reduce downtime between build processes, as it can be quickly and easily moved into the required position to perform necessary tasks.

[0043] This solution improves the modularity of the manufacturing device, as the process chamber can be reliably used in both the manufacturing position and in release, maintenance or setup positions without compromising the precision or integrity of the build process.

[0044] In another embodiment, the coating unit is assigned at least one metering device from which the coating unit can be supplied with the build material continuously or at defined intervals. This metering device serves to precisely meter the build material and supply it to the coating unit in the required quantity and quality to enable the layer-by-layer build-up of the three-dimensional component.

[0045] The coating unit, in combination with the dosing system, ensures that the build-up material is applied evenly and in a controlled manner, thus improving the layer thickness and dimensional accuracy of the manufactured component. It can be adjusted to different quantities and flow rates of the material to meet the specific requirements of each build process.

[0046] By assigning the dosing device to the coating unit, a continuous supply of the build material is enabled throughout the entire construction process, without interruptions or fluctuations in the material supply.

[0047] The manufacturing device can also include several, for example two, dosing units, each assigned to different coating units or build materials. This configuration allows for flexible material feed, which is particularly advantageous when different materials are to be used in a single build process, such as when manufacturing components with different material properties or layer structures.

[0048] Multiple dosing units offer the possibility of precisely dosing different types of materials and supplying them to the corresponding coating units in the required quantities. Each dosing unit can be individually adjusted and controlled to meet the specific requirements of the respective construction process. This solution not only improves the flexibility of the production equipment but also increases efficiency and productivity by enabling seamless material changes between different construction phases.

[0049] Furthermore, dividing the total amount of build material among several dosing units has a positive static effect on the manufacturing device through weight distribution. In another embodiment, the manufacturing device includes at least one conveying device for the build material. This conveying device is designed to transport the build material from a storage container to the at least one dosing unit. This ensures that the dosing unit is continuously supplied with sufficient build material to carry out the construction process without interruption.

[0050] It is also possible for the device to include multiple conveying units that operate, for example, in parallel or alternately. This arrangement can be particularly advantageous when different types of building materials are used simultaneously or when large quantities of material are required to efficiently support the construction process for large-volume components. Multiple conveying units allow for redundant material supply and offer the flexibility to transport different materials at varying conveying rates.

[0051] The conveying systems can be implemented in various designs, for example as mechanical conveying systems, pneumatic transport systems, or screw conveyors, depending on the type of material used. They ensure that the material reaches the dosing unit in a controlled quantity and while preventing contamination or losses.

[0052] This arrangement ensures efficient material flow from storage to the actual coating unit. This helps guarantee a consistent material supply for the production equipment, even during extended build processes, preventing delays or material shortages.

[0053] In a further embodiment, the at least one dosing device and / or the at least one conveying device are arranged on the process chamber in such a way that they can be moved together with the process chamber between the production position and at least one of the other positions, such as the release, maintenance, or setup position. This embodiment allows for high operational flexibility, since the material supply units are permanently integrated into the process chamber and thus remain immediately ready for operation in any position without the need for additional adjustments or connections.

[0054] Alternatively, the at least one dosing unit and / or the at least one conveying unit can also be decoupled from the process chamber in such a way that they remain stationary while the process chamber is moved between the production position and one of the other positions. In this embodiment, the material supply remains independent of the movement of the process chamber, which allows for a stable and fixed installation of the conveying and dosing units. This variant offers the advantage that the supply units do not need to be moved, which simplifies maintenance and handling of the material supply and ensures a constant connection to the storage container or other stationary components.

[0055] Both variants enable efficient handling of the material supply, either by carrying the supply units with the process chamber or by their stationary arrangement, depending on the specific requirements of the manufacturing processes and maintenance tasks.

[0056] In a further embodiment, the at least one irradiation unit is arranged on the process chamber in such a way that it can be moved together with the process chamber between the production position and at least one of the other positions, such as the release, maintenance, or setup position. This configuration makes it possible to preferably integrate the irradiation unit permanently with the process chamber, so that it remains functional in all positions without the need for additional adjustments or conversions. This simplifies operation, since both the process chamber and the irradiation unit can move as a single unit and operate optimally in the desired position.

[0057] Alternatively, the at least one irradiation unit can be decoupled from the process chamber in such a way that it remains stationary while the process chamber is moved between the production position and one of the other positions. In this embodiment, the irradiation unit remains fixed, regardless of the movement of the process chamber. This variant offers the advantage that the irradiation unit remains stably and precisely positioned and does not need to be moved, which can be particularly advantageous during complex adjustments or calibrations of the irradiation unit.

[0058] Both designs offer flexibility depending on the requirements of the manufacturing process. Carrying the irradiation unit along with the process chamber allows for seamless integration, while the stationary arrangement provides a stable and maintenance-friendly solution.

[0059] In another embodiment, the process chamber is designed to be movable segment by segment, so that individual segments or groups of segments can be moved independently of one another between the production position and at least one other position, such as the release, maintenance, or setup position. This segmented design enables flexible and precise handling of the process chamber, as only specific areas or sections of the chamber can be moved, while other parts can remain in the production position.

[0060] This segmented mobility makes it possible to move specific sections of the process chamber, for example for maintenance or setup work, without having to move the entire process chamber. This can be particularly advantageous when only certain components need to be accessed or adjusted, while the rest of the chamber remains stable in position.

[0061] In another embodiment, the process chamber is designed to be vertically movable, allowing it to be raised and lowered between the production position and at least one other position, such as the release, maintenance, or setup position. This vertical mobility enables flexible positioning of the process chamber to optimally adapt it to different work or maintenance situations.

[0062] In the manufacturing position, the process chamber is in a stable and precise alignment for the build process. Once the build process is complete, the process chamber can be moved to the release, maintenance, or setup position simply by lifting it. This facilitates access to internal components or allows for material changes without having to move the entire fixture horizontally.

[0063] The vertical adjustability of the process chamber offers the advantage of efficient space utilization and allows access to the chamber from different levels. This solution contributes to workflow optimization by enabling quick and easy switching between positions without the need for complex adjustments.

[0064] In an alternative embodiment, the process chamber is designed to be horizontally movable, allowing it to be moved horizontally between the manufacturing position and at least one other position, such as the release, maintenance, or setup position. This horizontal mobility makes it possible to move the process chamber laterally, facilitating access to different areas of the device and making the manufacturing process more efficient.

[0065] In the manufacturing position, the process chamber remains firmly and precisely mounted on the build shaft to carry out the construction process. Once construction is complete, however, the chamber can be moved horizontally to perform tasks such as maintenance or material changes. This horizontal movement allows the process chamber to be positioned as needed without affecting the components or the rest of the setup.

[0066] The horizontal mobility of the process chamber simplifies access to internal components such as the build platform or the coating unit. This contributes to optimized use of the workspace and improved handling of the device, as the chamber can be easily moved laterally without requiring vertical movements. This solution enables quick and efficient changeovers between different chamber positions, which is particularly advantageous during extensive maintenance or setup operations.

[0067] In a further embodiment, the manufacturing device comprises a lifting unit designed to move the process chamber. The lifting unit preferably enables the process chamber to be moved vertically and / or horizontally between the manufacturing position and at least one other position, such as the release, maintenance, or setup position.

[0068] This lifting unit ensures precise and controlled movement of the process chamber, enabling smooth and safe raising, lowering, and / or lateral movement of the chamber. In the manufacturing position, the lifting unit keeps the process chamber stable in the desired position. After the manufacturing process is complete, the lifting unit is used to move the process chamber to the respective release, maintenance, or setup position.

[0069] Integrating the lifting unit offers the advantage of automating and precisely controlling the process chamber's movement, thus improving both operation and the safety of the manufacturing device. This solution allows for flexible adaptation of the process chamber to various tasks and significantly increases efficiency during maintenance or setup operations.

[0070] Hybrid forms of vertical and horizontal movement of the process chamber are also conceivable.

[0071] In one embodiment, the process chamber is designed to be tiltable, inclined, and / or rotatable between the production position and one of the other positions. The hybrid forms and / or the tiltable, inclined, and / or rotatable process chamber can be used specifically for different positions or to enable more complex movements. Thus, the process chamber can not only be moved vertically or horizontally between the production position and another position, such as the maintenance or setup position, but can also be inclined or tilted at a specific angle or rotated around an axis.

[0072] The rotatable process chamber allows it to be rotated, for example, around a vertical or horizontal axis, as needed. This feature can be particularly advantageous when certain areas of the chamber need to be made more accessible, such as during maintenance work on hard-to-reach components or when adjusting the chamber orientation for specific manufacturing requirements. The rotatability significantly increases the flexibility of the process chamber, as it can be operated or machined in different orientations without requiring complete disassembly.

[0073] These extended movement options offer the advantage that the process chamber can be flexibly adapted to the specific requirements of the construction process or maintenance. Tilting or tilting allows complex work processes to be made more efficient, for example, by improving access to certain areas of the process chamber. For special construction projects or maintenance tasks requiring specific angles, these hybrid forms can be used to position the process chamber precisely and in multiple planes.

[0074] Furthermore, these more complex movements offer the possibility of bringing the process chamber into intermediate positions that would not be accessible with purely vertical or horizontal movements.

[0075] In a further embodiment, the manufacturing device comprises guide elements along which the process chamber can be moved between the manufacturing position and at least one of the other positions, such as the release, maintenance, or setup position. These guide elements ensure precise movement of the process chamber and enable its secure positioning.

[0076] In the simplest case, these guide elements are guide rails along which the process chamber moves linearly. Guide rails are a robust and proven solution that ensures precise alignment of the chamber and prevents unwanted deviations. They allow movement in vertical, horizontal, or combined directions, depending on the requirements of the construction process or maintenance.

[0077] Alternatively, other guide elements can be used. One option is guide rollers, which enable low-friction movement along a fixed path and are particularly suitable for lighter constructions. Guide profiles represent another alternative, where the guide rails have more complex cross-sections to offer additional stability and precision in movement.

[0078] Furthermore, guide carriages could be used that not only allow linear movements but also support tilting or tilting functions by sliding on rails or axles. For larger travel distances, telescopic guides are a good option, enabling extended mobility over long distances without making the entire guide structure bulky.

[0079] All these guide elements ensure that the process chamber can be moved safely and in a controlled manner, and guarantee precise and stable movement of the chamber during the construction process or during maintenance work.

[0080] In a further embodiment, the manufacturing device comprises compensating elements and / or sealing elements between the process chamber and stationary components. These elements serve to compensate for movements of the process chamber during the manufacturing process and simultaneously maintain the necessary connections, in particular gas-tight connections, between the non-moving and moving parts of the device.

[0081] The compensating elements primarily ensure that movements of the process chamber, which occur during relocation between the production position and other positions such as the release, maintenance, or setup position, are precisely compensated. This prevents mechanical stresses or misalignments that could lead to malfunctions or deviations in the construction process.

[0082] The sealing elements preferably ensure that a secure and gas-tight connection to the stationary components of the device is maintained despite the movement of the process chamber. The tightness of the connections is particularly important when maintaining a protective gas atmosphere or other controlled environments within the process chamber. The sealing elements preferably adapt to the movements of the chamber and prevent leaks or pressure losses, even when the process chamber is moved.

[0083] It is still possible for a single element to combine the properties of both a compensating element and a sealing element. Such a combined element can compensate for movements of the process chamber while simultaneously ensuring a gas-tight connection. This solution simplifies the design and reduces the number of components, thereby facilitating maintenance and minimizing potential sources of error.

[0084] In another embodiment, the compensating and / or sealing elements of the manufacturing device are formed from the group consisting of compensators, flexible connecting lines, flexible connecting elements, and telescopic compensating and / or guiding elements. These elements serve to compensate for the movements of the process chamber during the process between the manufacturing position and other positions, while simultaneously ensuring gas-tight connections between stationary and moving parts.

[0085] The compensating and / or sealing elements are preferably designed to allow targeted coupling and decoupling between the process chamber and the stationary components. During the process chamber's movement into the release, maintenance, or setup position, the elements can flexibly adapt to the new position without causing mechanical stress or leakage in the connections. In particular, the connection can be completely decoupled if necessary, for example, by means of quick-release mechanical locks, allowing for rapid and straightforward disconnection of the process chamber from stationary lines or supply units.

[0086] In the manufacturing position, the compensating and / or sealing elements reconnect the process chamber to the stationary components, creating a gas-tight and mechanically stable connection. This design enables a safe and precise supply of protective gas, laser radiation, or other process media to the process chamber without any disruption from movement. The combination of coupling and uncoupling mechanisms and the flexibility of the elements ensures high process reliability and significantly simplifies maintenance and setup procedures.

[0087] In this context, compensators are components that can compensate for movements or expansions of the process chamber due to temperature fluctuations or mechanical forces. They ensure that no mechanical stresses are transferred to the connections and that the process chamber remains precise in its function during movement.

[0088] Flexible connecting lines and fittings enable the process chamber to be supplied with media such as gases, lasers, or other essential process fluids even during movement. These flexible lines adapt to the chamber's movements without any interruptions in connection or leakage. They provide flexibility and ensure that all supply lines to the process chamber remain continuous and stable.

[0089] Telescopic compensating and / or guiding elements ensure that the process chamber is precisely controlled and stably guided, even over larger travel distances. These telescopic elements can adapt to the chamber's position, compensating for movements while simultaneously ensuring precise guidance. They contribute to maintaining the chamber's exact positioning regardless of the direction of movement.

[0090] This combination of compensators, flexible lines and telescopic guide elements ensures that the connections between stationary and moving components of the manufacturing device remain stable and gas-tight even during the process of the process chamber.

[0091] The present invention relates to a method for the additive manufacturing of a three-dimensional component from a build-up material using a manufacturing device specifically designed for large-volume and precise manufacturing processes.

[0092] The process begins with the provision of a manufacturing device comprising at least one build platform unit on which the component is built during the manufacturing process. The build platform unit is arranged within a mounting frame that enables its precise positioning and absorbs the mechanical loads during the manufacturing process. The build platform unit is then positioned in a process chamber, which is moved into a manufacturing position. In the manufacturing position, the mounting frame seals the bottom of the process chamber gas-tight to ensure a controlled environment for the manufacturing process.

[0093] The process further involves the layer-by-layer application of the build material onto the build platform unit. This is done using a coating unit located within the process chamber. The build material is applied in precise layers to create the foundation for additive manufacturing. After each layer is applied, the material is selectively solidified using an irradiation unit positioned above the build platform unit. This is typically achieved through targeted irradiation with laser beams or another suitable radiation source to fuse the build material at defined locations and create the desired layer structure of the component.

[0094] After completion of the build process, the process chamber is moved from the build position to at least one other position, such as a release, maintenance, or setup position. This procedure allows improved access to the internal components of the device, including the build platform unit, the coating unit, or the irradiation unit. In the release, maintenance, or setup position, the build platform unit can be removed from the exchange frame to remove the finished component or to insert a new build platform unit for the next build process.

[0095] The inventive method offers several advantages. By sealing the process chamber gas-tight in the manufacturing position, a controlled protective gas atmosphere is ensured within the process chamber, which significantly improves the quality of the manufactured component. Furthermore, the process chamber's position between the manufacturing position and at least one other position allows for simple and efficient maintenance of the device without the need for complex disassembly. This significantly increases the flexibility and productivity of the manufacturing device.

[0096] This process is particularly suitable for the additive manufacturing of large-volume components where precise manufacturing conditions and ease of handling the process chamber are crucial. The combination of layer-by-layer material deposition, selective solidification, and the ability to move the process chamber flexibly results in a high degree of process control and efficiency. The process is preferably carried out using a manufacturing device of the type described. This device comprises a movable process chamber that can be moved between a manufacturing position and at least one other position, such as a release, maintenance, or setup position.The combination of a build platform unit precisely positioned within an exchange frame, a coating unit for layer-by-layer material application, and an irradiation unit for selective material solidification ensures optimal conditions for additive manufacturing. In particular, the gas-tight connection between the process chamber and the exchange frame in the manufacturing position enables a controlled atmosphere, while the process chamber's mobility ensures flexible and efficient handling of the fixture throughout the entire manufacturing process.

[0097] Further advantages and aspects of the invention will become apparent from the claims and from the following description of preferred embodiments of the invention, which are explained below with reference to the schematic figures. Fig. Figure 1 shows a first embodiment of a manufacturing device according to the invention in a cutaway side view shortly before the process chamber is in the manufacturing position. Fig. Figure 2 shows the manufacturing device Fig. 1 with the process chamber in the manufacturing position Fig. Figure 3 shows the manufacturing device during a construction process. Fig. Figure 4 shows the manufacturing device after completion of a construction process. Fig. Figure 5 shows the manufacturing device with the process chamber in the release position. Fig. Figure 6 shows a manufacturing device according to the invention with the interchangeable frame in a setup position. Fig. Figure 7 shows a second embodiment of a manufacturing device according to the invention in a cutaway side view shortly before the process chamber is in the manufacturing position.

[0098] Fig. Figure 1 shows an embodiment of a manufacturing device 100 according to the invention for the additive manufacturing of a three-dimensional component 200 from a powdered build-up material 58. The manufacturing device 100 has a base 20 and a process chamber 10 arranged above it. The process chamber 10 is designed to be vertically movable along guide elements 12 and can be displaced along the guide elements 12 by a lifting unit 16 on each side. This linear movement is stabilized by compensating elements 14 to compensate for mechanical stresses. In the closed state, an interior space 40 is enclosed between the base 20 and the process chamber 10. The interior space 40 is sealed gas-tight by several coupling devices 22a, 22b, which are arranged between the process chamber 10 and the base 20. These coupling devices 22a, 22b ensure a gas-tight seal of the interior space 40 against the external atmosphere.

[0099] The Fig. Figure 1 shows the manufacturing device 100 in a position shortly before complete closure, where the process chamber 10 is not yet fully positioned on the base 20 in the manufacturing position. In this embodiment, the base 20 has a build platform unit 34 on which the component 200 is built. The build platform unit 34 is vertically movable within a build shaft 30 inside a changeover frame 32. Above the build platform unit 34 is a coating unit 50, which serves to apply the build material 58 in thin layers to the build platform unit 34. The build platform unit 34 is oriented such that its upper surface is at the level of the coating level 62. The applied build material 58 is solidified on the coating level 62 by two irradiation units 60a, 60b, which are arranged above the build platform unit 34.

[0100] In this embodiment, the irradiation units 60a, 60b are mounted on the process chamber 10 so that they move along the guide elements 12 together with the process chamber 10. To transport the build-up material 58 to the coating unit 50, two metering devices 52a, 52b are provided, each connected to a reservoir 54a, 54b in which the build-up material 58 is stored. Each metering device 52a, 52b is supplied with the build-up material 58 from its respective reservoir 54a, 54b by a conveying device 56a, 56b and delivers it to the coating unit 50 via a connection (not shown).

[0101] Fig. Figure 2 shows the manufacturing device 100. Fig. 1 in a fully closed position, with the process chamber 10 completely placed on the base 20. In this state, the coupling device 22a, 22b seals the interior 40 gas-tight from the outside atmosphere. The manufacturing device 100 is in this position ready to build the component 200 on the build platform unit 34. Layer by layer, build material 58 is applied to the build platform unit 34 by the coating unit 50 and solidified by the irradiation units 60a, 60b in the respective irradiation areas 64a, 64b. Once a layer has solidified, the build platform unit 34 is moved downwards in the build shaft 30 to make room for the next layer of build material 58, which is then applied and solidified.

[0102] Fig. Figure 3 shows the manufacturing device 100 during the production of a component 200. It can be seen that the coating unit 50 is in a different position at this moment.

[0103] Fig. Figure 4 shows the manufacturing device 100 after complete production of component 200. Component 200 is surrounded by unconsolidated build material 58.

[0104] Fig. Figure 5 shows the manufacturing device 100 in a release position in which the process chamber 10 has been moved.

[0105] Fig. Figure 6 shows the manufacturing device 100 with the exchange frame 32 in a setup position for removing the manufactured component 200. The unconsolidated build material 58 has already been removed, and the build platform unit 34 has been moved upwards to release the component 200. The component 200 was moved into this setup position through an opening (not shown here), which is designed for the safe and ergonomic removal of the component. This opening allows for efficient handling of the component without affecting the other components of the device.

[0106] Fig. Figure 7 shows a variant of the manufacturing device 110 in which the irradiation units 60a, 60b and the dosing devices 52a, 52b are decoupled from the process chamber 10. In this case, the irradiation units 60a, 60b and dosing devices 52a, 52b are mounted on a stationary platform 70 and are not moved along with the process chamber 10. The components mounted on the platform 70 are connected to the process chamber 10 via flexible compensating elements 72. For clarity, only the upper part of the manufacturing device 100 is shown in this illustration. The lower part, in particular the base 20, the build shaft 30, and the exchange frame 32, can preferably be arranged as shown in the Fig. 1, Fig. 2, Fig. 3, Fig. 4, Fig. 5 to Fig. 6. These components ensure the stability and precise alignment of the process chamber 10 during the manufacturing and setup process.

[0107] Fig. Figure 7 further shows that a protective glass 68 is arranged between the irradiation unit 60a, 60b and the process chamber 10. These protective glasses 68 serve to protect the irradiation units 60a, 60b from contaminants such as particles of the build material 58 or other process residues.

[0108] The protective glasses 68 are positioned so that the laser beam or another beam from the irradiation unit can enter the process chamber 10 unhindered and selectively solidify the build-up material 58. They are preferably made of heat- and radiation-resistant material to withstand the stresses during the manufacturing process.

[0109] For maintenance purposes, the protective glasses 68 can be removed and cleaned or replaced as needed. This contributes to maintaining the beam quality and the long-term operational reliability of the irradiation units 60a, 60b. In the illustrated embodiment, the protective glasses 658 are designed so that they can be removed from their holder with minimal effort to simplify the maintenance process. Reference symbol list 100, 110 Manufacturing device 10th Trial Chamber 12 Guide element 14 Compensating element 16 lifting units 20 base 22a, 22b Coupling device 30 construction shaft 32 interchangeable frames 34 Construction platform unit 40 Interior 50 coating units 52a, 52b Dosing device 54a, 54b Stock 56a, 56b Funding institution 58 Assembly material 60a, 60b Irradiation unit 62 Coating level 64a, 64b Irradiation area 70 platform 72 Compensating element 200 components

Claims

A manufacturing device for the additive manufacturing of a three-dimensional component from a build material, wherein the manufacturing device comprises at least one build platform unit on which the component can be built, and wherein the at least one build platform unit can be positioned in a process chamber during manufacturing, and wherein the manufacturing device comprises a coating unit by means of which the build material can be applied to the at least one build platform unit in the process chamber, and wherein the coating unit is arranged in the process chamber, and wherein the manufacturing device comprises at least one irradiation unit with which the build material can be solidified on the at least one build platform unit, and wherein the at least one irradiation unit is arranged above the build platform unit, and wherein the manufacturing device comprises at least one exchange frame.within which the at least one build platform unit can be positioned, and wherein the at least one build platform unit is vertically movable within the exchange frame, characterized in that the process chamber is designed to be movable, so that it can be moved from a production position to at least one further position, preferably a release, maintenance and / or setup position, and that the process chamber is closed at its underside in its production position by the exchange frame. Manufacturing device according to claim 1, characterized in that the manufacturing device comprises a coupling device for the preferably positive locking connection of the exchange frame with the process chamber in the manufacturing position. Manufacturing device according to one of claims 1 or 2, characterized in that the exchange frame and the process chamber are designed such that they form a common gas space in the manufacturing position. Manufacturing device according to one of the preceding claims, characterized in that the interchangeable frame is designed to be stationary, so that it does not have to be moved during the manufacture of a three-dimensional component. Manufacturing device according to one of the preceding claims, characterized in that the coating unit is assigned at least one metering device from which the coating unit can be supplied with the build-up material. Manufacturing device according to claim 5, characterized in that the manufacturing device comprises at least one conveying device for the assembly material, from which the assembly material can be conveyed from a supply to the at least one metering device. Manufacturing device according to one of claims 5 or 6, characterized in that the at least one dosing device and / or the at least one conveying device are arranged on the process chamber in such a way that they can be moved together with the process chamber between the production position and the release, maintenance or setup position, or that the at least one dosing device and / or the at least one conveying device are decoupled from the process chamber in such a way that they are stationary when the process chamber is moved between the production position and one of the further positions. Manufacturing device according to one of the preceding claims, characterized in that the at least one irradiation unit is arranged on the process chamber in such a way that it can be moved together with the process chamber between the manufacturing position and one of the further positions, or that the at least one irradiation unit is decoupled from the process chamber in such a way that it is stationary when the process chamber is moved between the manufacturing position and one of the further positions. Manufacturing device according to one of the preceding claims, characterized in that the process chamber is designed to be vertically movable between the manufacturing position and one of the further positions, so that it can be raised and lowered, and / or that the process chamber and / or the exchange frame is designed to be horizontally and / or vertically movable between the manufacturing position and one of the further positions. Manufacturing device according to one of the preceding claims, characterized in that the manufacturing device comprises a lifting unit configured to move the process chamber. Manufacturing device according to one of the preceding claims 1 to 10, characterized in that the process chamber is designed to be tiltable and / or inclinable and / or rotatable between the manufacturing position and one of the further positions. Manufacturing device according to one of the preceding claims, characterized in that the manufacturing device comprises guide elements along which the process chamber can be moved. Manufacturing device according to one of the preceding claims, characterized in that the manufacturing device comprises compensating elements and / or sealing elements between the process chamber and stationary components to compensate for movements and to maintain connections, in particular gas-tight connections, between non-moving and moving parts during the process. Manufacturing device according to claim 13, characterized in that the compensating elements and / or sealing elements are formed from the group consisting of compensators, flexible connecting lines, flexible connecting elements and telescopic compensating and / or guiding elements. A method for the additive manufacturing of a three-dimensional component from a build material, comprising the steps of: • Providing a manufacturing device with at least one build platform unit positioned within a swap frame and on which the three-dimensional component can be built; • Positioning the at least one build platform unit within a process chamber, which is moved into a manufacturing position; • Gas-tight sealing of the process chamber by the swap frame at its underside in the manufacturing position; • Layer-by-layer application of the build material onto the at least one build platform unit by means of a coating unit arranged in the process chamber; • Selective solidification of the applied build material on the at least one build platform unit by means of at least one irradiation unit arranged above the build platform unit;• Moving the process chamber from the manufacturing position to at least one further position, preferably a release, maintenance and / or setup position, after completion of the build process; • Providing the build platform unit in the further position for the release of the exchange frame, maintenance or setup work, including the replacement of the build platform unit or the removal of the manufactured component.;

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