Device and method for the additive manufacturing of a three-dimensional object

Abstract

The invention relates to a device and a method for the additive manufacturing of a three-dimensional object made of a powder build material, the device and method making it possible for the supply of build material and the distribution of the build material by means of the application means and / or the removal of reaction by-products to be synchronised. Preferably, the action means is also synchronised with the supply and removal processes. This optimises the machining process in terms of time and location as well as process robustness.

Description

[0001] TITLE

[0002] DEVICE AND METHOD FOR ADDITIVE MANUFACTURING OF A THREE-DIMENSIONAL OBJECT

[0003] TECHNICAL FIELD

[0004] The present invention relates to a device and a method for the additive manufacturing of a three-dimensional object, in particular according to L-PBF (Laser Powder Bed Fusion) technology.

[0005] STATE OF THE ART

[0006] Devices for the additive manufacturing of physical objects from digital data sets are known. Additive manufacturing processes are used to produce a three-dimensional object. In some additive manufacturing processes, the building or starting material is liquid. In other processes, free-flowing bulk material, preferably powdered starting material, is applied layer by layer to a build platform, also called a build plate, in the form of a powder bed, and individual areas of the powder bed are solidified. This process is also called powder bed melting. The material in the powder bed is usually called the substrate material. The starting material is also called the building material. The object to be manufactured is also called the component.

[0007] Such 3D printing processes using powder-bed melting techniques are well known. They generally use powdered starting material and work with a powder bed. The powder can be a metal or a plastic.

[0008] In L-PBF technology, the powder material is melted in a build chamber with the help of a laser. If plastic powder is used, the build chamber and the plastic powder are usually heated to just below the melting point, so that the laser only needs to contribute the remaining energy to process the powder. If metal powder is used, it is usually melted using the laser. The build chamber can also be heated, but it usually does not need to be heated. It is generally filled with an inert gas, also called a protective gas, to prevent oxidation of the metal powder and the molten pool. Nitrogen or argon is usually used for this purpose. The metal powder is melted, i.e. converted from a solid to a liquid state.

[0009] Devices for the additive manufacturing of a three-dimensional object from a powdered building material usually have:

[0010] M1) a process chamber in which the three-dimensional object is gradually formed;

[0011] M2) a feeding means for feeding the powdered build material into the process chamber;

[0012] M3) an application means for applying a powder layer comprising the powdered build material to a target surface in a build area of ​​the successively formed three-dimensional object in the process chamber;

[0013] M4) an impact means for selectively applying energy to selected reaction areas of the applied powder layer in order to fuse the powdered building material in these selected reaction areas, wherein the selected reaction areas correspond to a cross-section of the three-dimensional object to be formed within the powder layer; and

[0014] M5) a laxative for removing reaction by-products, especially volatile reaction by-products

[0015] The supply means forms a powder feed. The application means preferably comprises a coating mechanism. The impact means typically comprises an energy source, preferably a laser. The removal means preferably comprises at least one suction unit. The build area is also called the process area.

[0016] Processes for the additive manufacturing of a three-dimensional object from a powdered building material typically include the following steps:

[0017] 51) Feeding a powdered build material into a process chamber;

[0018] 52) Applying a powder layer comprising the powdered build material to a target surface in a build area or process area of ​​the gradually formed article in the process chamber;

[0019] 53) selectively applying energy to selected reaction areas of the powder layer, which correspond to a cross-section of the object to be formed within the powder layer, in order to fuse the powdered building material in the selected areas; and

[0020] S4) removing reaction by-products from the powder layer, wherein steps S1) to S3) are carried out repeatedly to gradually build up the article layer by layer.

[0021] In many cases, additively manufactured objects are components that are incorporated into systems containing other components, such as devices or machines. Therefore, these additively manufactured components must meet high structural quality requirements, particularly their strength and homogeneity. Furthermore, they must exhibit good dimensional accuracy, meaning that deviations from the specified and desired geometries of the respective component must be as small as possible.

[0022] The component properties are significantly influenced by process robustness. Byproducts from a specific area of ​​application can impair this process robustness. The following problems are particularly evident in L-PBF technology:

[0023] • Interaction of flue gases with the energy source, especially with the laser: The interaction of the energy source with the resulting flue gases can absorb laser energy. The laser light can be refracted or defocused. The beam quality can deteriorate, and the laser light can be scattered. These influences lead to energy fluctuations in the effective range, so it cannot be guaranteed that the properties of the additively manufactured object will consistently meet the specified requirements.

[0024] • Condensate deposits on the optics of the agent, on surfaces of the object to be manufactured, on displacement axes and in the powder bed:

[0025] Flue gases condense. These condensates consist of alloy components of the substrate material, i.e., the powdered starting material in the powder bed. If these alloy components settle on an optic, e.g., the laser or deflecting mirrors or lenses, the transfer of energy from the energy source to the point of impact is impaired. If they settle on the device's displacement axes, mobility is reduced, and increased maintenance is required. If these condensates settle on the surface of the object being formed, they lead to incorrect inclusions / oxide inclusions in the component being formed, which in turn impairs the component properties. Deposits in the powder bed can significantly alter the powder quality.If the unsolidified powder is reused in a later manufacturing process, its contamination may lead to a loss of quality in subsequently manufactured items.

[0026] • Weld spatter in the powder bed:

[0027] Weld spatter generated in the area exposed to the agent can be significantly larger than the powdered starting material. If such weld spatter lands in the powder bed, it can lead to process fluctuations in the area exposed to the agent, thus impairing the properties of the object being formed. Furthermore, the surface of the weld spatter is often coated with an oxidation layer. The weld spatter therefore contaminates the powder material being solidified and thus the resulting object. This weld spatter can only be partially removed through a screening process. It therefore contributes significantly to powder aging. This means that the unsolidified powder in the powder bed can only be recycled to a very limited extent.

[0028] Irregularities in the powder bed, i.e., the substrate material, can also cause process variations. The powder bed should therefore preferably have the following properties:

[0029] • Constant layer height

[0030] • Constant layer density

[0031] • Constant particle size distribution

[0032] In addition to process robustness, i.e., consistent quality, productivity is also relevant for cost-effective component manufacturing. Process time, particularly in L-PBF technology, is influenced by the following factors:

[0033] • Exposure parameters: a. Vector distance between the individual laser paths (called hatching) b. Power of the energy source c. Speed ​​of the exposure medium

[0034] • Dead time a) Caused during the application of the powdered build material, ie caused by the coating process b) Caused during the creation of a protective atmosphere, ie during the setup and / or flooding of the process chamber.

[0035] The current state of the art addresses only a portion of these problems. They address shift time reductions, improved local extraction of byproducts, or local powder feed mechanisms.

[0036] For example, EP 3 634 757 A1 discloses a reduction in coating time by simultaneously processing multiple, spatially offset powder layers. A local powder feed is provided. The coater is synchronized with the position of the energy source.

[0037] DE 10 2014 108061 A1 shows a local fume extraction system close to the effective area of ​​the agent. However, the effective area is very small and significantly slows down the very fast movement of the energy beam. Therefore, welding spatter with a high initial velocity can tend to escape from the area and still land in the powder bed.

[0038] EP 3 323 597 B1 discloses a radially arranged fume extraction system close to the working area. This arrangement also aligns the flow profile radially. This can lead to the formation of an area close to the powder bed that is poorly supplied with new shielding gas.

[0039] DE 10 2016 112652 A1 describes a bidirectional shielding gas flow. The supply and extraction of shielding gas at the coater ensures that the shielding gas flow is always directed in the same direction and as low as possible relative to the powder bed. Layer time is reduced by bidirectional coating using a powder reservoir on the coater.

[0040] PRESENTATION OF THE INVENTION

[0041] It is therefore an object of the invention to provide an improved device and a method for the additive manufacturing of a three-dimensional object.

[0042] This object is achieved by a device and a method having the features of claim 1, 2, 3 and claim 16, respectively.

[0043] The device according to the invention for the additive manufacturing of a three-dimensional object from a powdered building material comprises, in a preferred embodiment,

[0044] - a process chamber in which the three-dimensional object can be gradually formed;

[0045] - a feed means for feeding the powdered build material into the process chamber;

[0046] - an application means for applying a powder layer comprising the powdered build material to a target surface in a build area of ​​the object to be gradually formed in the process chamber;

[0047] - an action means for the targeted action of energy (1b) on selected reaction areas of the powder layer in order to melt the powdery building material in the selected reaction areas, wherein the selected reaction areas correspond to a cross-section of the three-dimensional object to be formed within the powder layer and

[0048] - a laxative for removing reaction by-products (8) from the powder layer.

[0049] The application means and the supply means are integrated together in an assembly that can be moved within the process chamber.

[0050] The device is particularly suitable for L-PBF processes, especially for plastic and / or metal.

[0051] The application means preferably comprises a coating mechanism. The build area is also called the process area. The exposure means comprises an energy source, preferably a laser. Preferably, the exposure means further comprises deflecting mirrors for the controlled movement of the laser beam and focusing optics, preferably a plano-field lens. Plano-field lenses are also called F-theta lenses.

[0052] Because the feeder moves together with the application device, dead times between the application of the powder to the build plate and its distribution onto the target surface can be avoided or at least minimized. This optimizes the processing time without slowing it down. Layer time, i.e., the time required to apply the powder to the target surface, can be reduced compared to conventional systems. This increases productivity. Furthermore, weaker and therefore more cost-effective lasers can be used while still maintaining competitive productivity, as coating can be completed more quickly.

[0053] In another embodiment, the application means and the removal means are integrated together in a module that can be moved selectively within the process chamber. Preferably, the removal means extends at least approximately over the entire length of the application means.

[0054] Due to the proximity of the venting agent to the application agent and their combined movement, fumes and welding spatter are extracted before they can cause the problems mentioned above. The appearance of the application agent is less affected by fumes, condensate deposits are minimized or avoided in all areas, and less welding spatter enters the powder bed. Maintenance is minimized, the powder bed is less contaminated, and the powder can therefore be recycled for longer. These advantages reduce production costs. The beneficial effects are increased when the venting agent extends, if possible, over the entire length of the application agent, i.e., it extends, if possible, over the entire length of a squeegee of the application agent.

[0055] In a preferred embodiment, all three means, ie the application means, the supply means and the discharge means, are integrated together in the assembly which can be moved in a targeted manner within the process chamber.

[0056] When all three of the above-mentioned devices are moved together, the aforementioned advantages are combined. Furthermore, a highly compact, integrated design of the entire device is possible. This reduces the device's space requirements while simultaneously optimizing its effectiveness.

[0057] The movable assembly is preferably arranged on a carriage that can be moved in a guided manner. The movement preferably occurs exclusively in the horizontal direction. The target surface is preferably stationary with respect to the horizontal. However, it is preferably adjustable vertically. The adjustment preferably occurs using the same control system that also controls the assembly. This control system preferably coordinates all movements. A protective gas supply means for supplying a protective gas into the construction area is preferably provided. In some embodiments, it is arranged stationary and separate from the movable assembly. In other embodiments, it is integrated into the movable assembly.

[0058] The feed means preferably comprises a powder conveyor for feeding the powder to the application means. The powder conveyor is preferably a conveyor belt or another conveyor line. The conveyor belt or conveyor line is preferably driven, preferably by means of the control system of the assembly.

[0059] The use of a shielding gas reduces oxidation and thus unwanted deposits. If the shielding gas supply is also integrated into the movable assembly, optimal supply and distribution of the shielding gas within the working area is ensured. Another advantage is that less shielding gas is consumed or required. This also reduces operating costs.

[0060] Preferably, the shielding gas supply means contains a shielding gas dosing unit for metered delivery of the shielding gas to the target surface in the build area or process area of ​​the process chamber. The dosing of the shielding gas ensures optimal prevention of oxidation while simultaneously minimizing shielding gas consumption.

[0061] Preferably, the laxative contains a reaction by-product suction device for suctioning off reaction by-products, especially volatile reaction by-products. Suction is a simple and efficient method of removal. It is preferably controllable, allowing more or less suction to be applied as needed.

[0062] Preferably, the feed means contains a powder dosing unit for metered delivery of the powdered build material to the target surface in the build area or process area of ​​the process chamber. This also optimizes the time required, shortens the production time, and homogenizes the powder bed properties.

[0063] Preferably, the feed means, the discharge means, and the application means can be controlled by a common control unit. This optimizes the interaction of the individual means, shortens processing times, minimizes oxidation, condensate deposits, interactions with the flue gas, and minimizes contamination of the powder bed by welding spatter.

[0064] Even more preferably, the supply means, the discharge means, the application means, and the action means can be controlled by a common control unit. The aforementioned optimizations and minimizations are thereby even more pronounced.

[0065] Preferably, the positioning of the supply means and the discharge means relative to each other is adjustable. Depending on the type and size of the product to be manufactured, an optimized interaction of the supply means and the discharge means can be achieved.

[0066] Preferably, the positioning of the supply means and / or the discharge means relative to the target surface in the construction or processing area is adjustable. Depending on the type and size of the product to be manufactured, an optimized interaction of the supply means and / or the discharge means with the target surface can be achieved.

[0067] The combination of the aforementioned adjustability optimizes the interaction even more.

[0068] Preferably, the energy input through the agent is adjustable. For example, at least one of the following parameters can be adjusted: scanning speed, laser power, beam diameter, and hatching. Another adjustable component is the relative and absolute layer thickness of the applied powder.

[0069] Preferably, the flow rate of the supply means (in particular the powder dispenser) and / or the discharge means is adjustable. The flow rate of the supply means is preferably determined by the dispenser. The flow rate of the discharge means can be varied by the gas supply rate or speed and / or the suction and / or by changing the distance between the supply and discharge.

[0070] In some embodiments, at least one powder container is arranged outside the device or is connected to the supply means in the device, in particular to the dosing unit, via at least one supply line. In other embodiments, the powder container is a component of the device. The powder container is thus preferably associated with the supply means and integrated into the assembly. This enables local storage and supply of the powder to be used.

[0071] The inventive method for the additive manufacturing of a three-dimensional object from a powdered build material can be carried out in particular, but not exclusively, using the device according to the invention. The method comprises at least the following steps: a. feeding a powdered build material into a process chamber; b. applying a powder layer comprising the powdered build material to a target surface in a build region of the object to be gradually formed in the process chamber; c. targeted application of energy to selected reaction regions of the powder layer in order to fuse the powdered build material in the selected regions, wherein the selected reaction regions correspond to a cross-section of the object to be formed within the powder layer, and d. removing reaction by-products from the powder layer; wherein steps b. and c.be carried out repeatedly to gradually build up the object layer by layer.

[0072] According to the method according to the invention, the supply means, the discharge means and the application means are controlled in a synchronized manner by means of a common control unit.

[0073] The construction area forms a process area.

[0074] It should be noted that the numbering of steps a. to d. should not be interpreted as necessarily establishing a sequence of procedural steps.

[0075] The method is particularly suitable for L-PBF processes, but can also be used for other processes.

[0076] The supply means, the discharge means, and the application means are controlled so that they move in synchronization with one another. Depending on the variant of the method, the three means are arranged on different components, which are moved in synchronization with one another but separately. In a preferred variant, however, they are located on a common component, which essentially moves all three means together, whereby they are preferably also moved in synchronization with one another.

[0077] Preferably, the supply means, the removal means, the application means, and the impact means are controlled synchronously by the common control unit. If the impact means is also synchronized with the other means, in particular the deflection mirrors of the laser beam, a spatially and temporally optimized processing of the powder bed can be achieved. For example, the extraction can take place close to the current effective area. If the shielding gas supply means is also synchronized accordingly, the shielding gas supply can also be optimized.

[0078] Preferably, the powdered building material is fed in intermittently or continuously in step a. The controller preferably selects whether the feed is intermittent or continuous.

[0079] Preferably, the removal of reaction by-products in step d. occurs intermittently or continuously. Preferably, the control system selects whether the removal is intermittent or continuous.

[0080] Preferably, the positioning of the delivery and discharge agents is adjusted during the procedure. This increases the spatial and timely coordination of the individual agents.

[0081] Preferably, the positioning of the supply means and / or the discharge means relative to the target surface in the construction area or process area is adjusted during the process. This increases the spatial and timely coordination of the individual means relative to the target surface.

[0082] Preferably, the flow rate of the supply means and / or the discharge means is adjusted during the process.

[0083] Preferably, the respective adjustment of one of the means takes place depending on the setting and / or adjustment of one of the other means.

[0084] By parallelizing the local powder supply, exposure and extraction according to the invention, the slowdown of the process can be compensated and the layer time can be reduced compared to conventional systems

[0085] Synchronized extraction allows the entire construction area to be taken into account.

[0086] A synchronization strategy between exposure, i.e. the agent, and the powder feed as well as the suction is particularly advantageous in order to be able to suction close to the effective area.

[0087] The method and device according to the invention enable process by-products to be extracted close to the active zone, powder to be simultaneously introduced into the active zone, and irradiated synchronously with the energy source. This allows for more efficient removal of process by-products, reduced layer time, minimized fluctuations in powder bed properties, and enables a highly compact, integrated design.

[0088] Preferably, an integrated coating unit is provided, in which at least one extraction unit and / or a powder feed with a corresponding dosing unit is integrated into the layer-forming coating unit. The position of the integrated unit and the movement of the energy beam are coordinated and synchronized.

[0089] Further embodiments are specified in the dependent claims.

[0090] BRIEF DESCRIPTION OF THE DRAWINGS

[0091] Preferred embodiments of the invention are described below with reference to the drawings, which are for illustrative purposes only and are not to be construed as limiting. In the drawings:

[0092] Figure 1 is a partially cutaway perspective schematic representation of the device according to the invention according to a first embodiment,

[0093] Figure 2 is a partially cutaway perspective schematic representation of the device according to Figure 1 with some further details; Figure 3 is a perspective representation of the device according to the invention according to a second embodiment;

[0094] Figure 4 shows a section through part of the device according to Figure 3 in an enlarged view;

[0095] Figure 5 shows part of the device according to Figure 3 and

[0096] Figure 6 shows a further section through a part of the device according to Figure 3.

[0097] DESCRIPTION OF PREFERRED EMBODIMENTS

[0098] The basic principle of the device according to the invention is shown schematically in Figures 1 and 2.

[0099] The device comprises a preferably gas-tight housing 0. A build plate 3, on which the object to be created is produced, is arranged in the housing 0. The build plate 3 is height-adjustable.

[0100] An impact device 1 is arranged on the housing 0, comprising an energy source, preferably a laser, or the supply of at least one laser beam. An energy beam deflection mechanism 1a directs and focuses an energy beam 1b from the impact device 1 onto the building board 3. The energy beam 1b is typically a laser beam. Reference numeral 11 indicates a collimator of an externally arranged laser light source. The collimator 11 forms the exit of the laser beam onto the movable galvo mirrors.

[0101] To deflect the laser beam, motor-driven deflecting mirrors are preferably arranged in the energy beam deflection mechanism 1a. They are not shown in the figures, but are well known in the art. Focusing on the desired plane above the build plate 3 is preferably achieved by means of a plano-field lens 10, also called an F-theta lens, which is preferably arranged between the deflecting mirror and the build plate 3. The area within which a target surface for the focused impingement of the laser beam lies is also called the processing surface. Furthermore, at least one powder container 2 is present in the housing 0, which contains the free-flowing material to be applied, in particular the powder material 20. This is preferably metal powder. In other embodiments, it is plastic. The powder container 2 is preferably a cartridge or a cartridge. The powder material can be seen in Figure 4. Preferably, several powder containers 2 are present.

[0102] Furthermore, a feed means 5 is provided for supplying the powder material 20. The feed means 5 preferably comprises valves 50 for selectively opening the powder containers 2. In other embodiments, the valves 50 are part of the powder containers. The feed means 5 further comprises a powder conveyor 51 for conveying the powder removed from the powder container 2. The powder conveyor 50 is preferably a conveyor belt that extends below the outlets of the powder containers 2 along the powder containers 2, which are preferably arranged in a row. Other arrangements of the powder containers 2 relative to one another are possible.

[0103] The feed means 5 further comprises at least one, preferably precisely one, dosing unit 52 for the metered supply of the powder material. Such dosing units are well known in the art. The powder conveyor 51 extends to the dosing unit 52, which is preferably located below the powder conveyor 51, so that the powder falls into the dosing unit 52 by gravity.

[0104] An application device 7 applies the metered, dispensed powder material to the building board 3. It typically comprises a coating unit, also known as a layering unit, which distributes the powder layer by layer on the powder bed. It typically comprises or consists of at least one doctor blade. This is also known in the prior art and need not be explained in detail here.

[0105] Preferably, the squeegee is arranged in the immediate vicinity of the outlet of the dosing unit 52 in order to distribute the powder falling or dispensed from the dosing unit 52 onto the building plate 3.

[0106] The device further comprises a removal means 6 for removing reaction by-products, in particular volatile reaction by-products. The removal means 6 is preferably a suction device. Its suction opening 60 preferably extends across the entire width of the application means 7, in particular the doctor blade. The suction opening 60 can be formed by several distributed openings or a single opening.

[0107] The supply means 5, the discharge means 6, and also the application means 7 are preferably mounted together on the same assembly. Preferably, one or more powder containers 2 are also part of this assembly.

[0108] The assembly can be moved in a controlled manner relative to the building plate 3. For this purpose, axes 4 are preferably provided for guidance, which are arranged on a base plate 30 of the device. The displacement preferably takes place by means of a carriage 53 and at least one motor, which is not shown here. The carriage 53 is preferably displaceable along the axes 4 by means of rollers 54. In the figures, the axes 4 are not shown continuously, so that the rollers can be seen in Figures 3 and 5. Other types of translational movement of the assembly are possible and known to those skilled in the art. In some embodiments, only a translational movement is carried out, in others also a rotational movement or a pivoting movement.

[0109] The actuating means 1 is preferably arranged in a stationary manner. However, the deflection mechanism 1a, in particular the deflection of the deflecting mirrors, is preferably synchronized with the movement of the assembly via a control system of the device.

[0110] The individual means, which are integrated into the assembly, can preferably be moved relative to one another, whereby this movement is also preferably synchronized by the controller. The synchronization preferably occurs with respect to the build plate 3, more precisely with respect to the target surface in the area of ​​the build plate 3.

[0111] The device works as follows:

[0112] Powder is dispensed from the powder container 2 into the area of ​​the build plate 3 by means of the feed means 5 and distributed in the form of a layer on the work plate or build plate 3 by the application means 7, in particular the squeegee. By exposure to the at least one energy beam 1b in the work area on the build plate 3, this layer is melted and solidified. The build plate 3 is then lowered by this layer height and repositioned. The next layer is then applied. The new layer is bonded to the lower layer by further exposure. By exposure to the energy beam 1b, at least one geometric object can thus be additively built up layer by layer.

[0113] The deflection mechanism 1a positions the point of intervention of the laser beam in the desired effective area or on the target surface on the construction plate 3.

[0114] The process preferably takes place in a protective atmosphere. A protective gas is preferably used for this purpose. This is explained in more detail below using Figures 3 to 5.

[0115] Thanks to the use of a movable assembly, process byproducts 8, such as flue gases, can be extracted close to the active zone by means of the extraction means 6, and powder can be simultaneously fed into the active zone by means of the supply means 5 and the layer-forming application means 7, and irradiated in synchronization with the energy beam 1b. Thus, process byproducts 8 are more efficiently removed, the layer time is reduced, fluctuations in the powder bed properties are minimized, and a highly compact, integrated structure is enabled. The position of the integrated assembly, i.e., the unit, and the movement of the energy beam 1b are preferably coordinated and synchronized.

[0116] Figures 3 to 5 illustrate an embodiment of the device according to the invention in more detail. The housing 0 is shown transparent to show the components arranged therein.

[0117] In comparison to the embodiment according to Figures 1 and 2, the protective gas supply means 9 is now also shown. It can also be arranged on the assembly and moved together with the other means 5, 6, 7. Preferably, however, it is arranged at the end of the movable assembly opposite the build plate 3. That is, it is arranged opposite the removal means 6. The arrows in Figures 3 to 5 show the protective gas flow 90, which thus flows flatly over the build plate 3. The protective gas flow 90 is also called the flow path. The effective area is thus flowed over by the protective gas flow in order to remove process by-products. Preferably, the supply opening of the protective gas supply means 9 also extends across the entire width of the build plate 3, that is, it preferably has the same width as the removal means 6. It can also have just one opening or several openings arranged in a distributed manner.Figures 3 to 5 also show a suction line 61 of the laxative 6.

[0118] Furthermore, the powder bed 21 on the building plate 3 is clearly visible, as is the powder 20 supplied from one of the powder containers 2. The reaction by-products 8 are shown as smoke in Figure 5.

[0119] In this embodiment, several powder containers 2 are provided, arranged one behind the other in the device and integrated into the same assembly together with the other means 5, 6, 7. The assembly can be automatically moved along the axes 4. The corresponding motor is operated via the controller, which synchronizes this movement with the movement of the deflection mirrors for the laser beam 1b. The synchronization further includes, if necessary and mechanically provided, the movements of the dosing device, powder conveyor, and the valves in the feed means 5, the movement of the doctor blade of the application means 7, and the power of the discharge means 6.

[0120] The device and method according to the invention enable synchronization of the supply of building material and the distribution of the building material by means of the application means and / or the removal of reaction by-products. Preferably, the application means is also synchronized with the supply and removal. This optimizes the processing process in terms of time and location, as well as process robustness.

[0121] LIST OF REFERENCE SYMBOLS

[0122] Dosing unit housing,

[0123] Powder conveying)

[0124] Influencing agent 50 valve

[0125] (Energy source, laser) 51 Powder feeder a Energy beam 52 Dosing unit

[0126] Deflection mechanism 53 Carriage 0 Lens 54 Roller 1 Collimator / laser output b Energy, energy beam 6 Laxative (suction agent)

[0127] (Laser beam) 60 suction opening

[0128] 61 Suction line

[0129] Powder container (cartridge, cartridge) 7 Application means0 Powder (coating unit,1 powder bed layering forming unit)

[0130] Building plate 8 Reaction byproducts0 Base plate (volatile byproducts)

[0131] Axis (coater axis) 9 protective gas supply means

[0132] 90 Shielding gas flow

[0133] Feeding means (powder feed, powder

Claims

PATENT CLAIMS 1. Device for the additive manufacturing of a three-dimensional object from a powdered building material, wherein the device comprises: - a process chamber in which the three-dimensional object can be gradually formed; - a feeder (5) for feeding the powdered building material into the process chamber; - an application means (7) for applying a powder layer comprising the powdered building material to a target surface in a building area of ​​the object to be formed gradually in the process chamber; - a means (1a) for selectively applying energy (1b) to selected reaction areas of the powder layer in order to fuse the powdered building material in the selected reaction areas, wherein the selected reaction areas correspond to a cross-section of the three-dimensional object to be formed within the powder layer; - a removal agent (6) for removing reaction by-products (8) from the powder layer, characterized in that the application agent (7) and the supply agent (5) are jointly integrated in an assembly that can be moved in a targeted manner within the process chamber.

2. Device for the additive manufacturing of a three-dimensional object from a powdered building material, wherein the device comprises: - a process chamber in which the three-dimensional object can be gradually formed; - a feeder (5) for feeding the powdered building material into the process chamber; - an application means (7) for applying a powder layer comprising the powdered building material to a target surface in a building area of ​​the object to be formed gradually in the process chamber; - an action means (1a) for selectively applying energy (1b) to selected reaction areas of the powder layer in order to fuse the powdered building material in the selected reaction areas, wherein the selected reaction areas correspond to a cross-section of the three-dimensional object to be formed within the powder layer; - a laxative (6) for removing reaction by-products (8) from the powder layer, characterized in that the application agent (7) and the laxative (6) are integrated together in an assembly that can be moved in a targeted manner within the process chamber.

3. Device according to one of claims 1 or 2, wherein the application means (7), the supply means (5) and the discharge means (6) are jointly integrated in the assembly which can be moved in a targeted manner within the process chamber.

4. Device according to one of claims 1 to 3, wherein the feed means (5) comprises a powder feeder (51) for feeding the powder to the application means (7).

5. Device according to one of claims 1 to 4, wherein the protective gas supply means comprises a protective gas metering unit for metering the protective gas onto the target surface in the construction area of ​​the process chamber.

6. Device according to any one of claims 1 to 5, wherein the laxative (6) comprises a reaction by-product extraction agent for extraction of reaction by-products (8).

7. Device according to one of claims 1 to 6, wherein the feed means (5) comprises a powder metering unit for metering the powdered building material onto the target surface in the build area of ​​the process chamber.

8. Device according to one of claims 1 to 7, wherein the supply means, the removal means (6) and the application means (7) can be controlled by a common control unit.

9. Device according to one of claims 1 to 8, wherein the supply means, the removal means (6), the application means (7) and the action means (1a) can be controlled by a common control unit.

10. Device according to any one of claims 1 to 9, wherein the positioning of the supply means (5) and the discharge means (6) is adjustable relative to each other.

11. Device according to one of claims 1 to 10, wherein the positioning of the feed means (5) and / or the discharge means (6) relative to the target surface in the construction area is adjustable.

12. Device according to one of claims 1 to 11, wherein the energy input to the selected reaction areas is adjustable by the action medium (1a).

13. Device according to one of claims 1 to 12, wherein the throughput of the supply means (5) and / or the discharge means (6) is adjustable.

14. Device according to any one of claims 1 to 13, wherein it has at least one powder container (2).

15. Device according to claim 14, wherein the powder container(s) (2) is associated with the feed means (5) and is integrated into the assembly.

16. A method for the additive manufacturing of a three-dimensional object from a powdered building material, in particular using a device according to any one of claims 1 to 15, wherein the method comprises the following steps: a. feeding a powdered building material into a process chamber; b. applying a powder layer comprising the powdered building material to a target surface in a build area of ​​the object to be formed gradually in the process chamber; c. selectively applying energy to selected reaction areas of the powder layer to fuse the powdered building material in the selected areas, wherein the selected reaction areas correspond to a cross-section of the object to be formed within the powder layer; and d. removing reaction by-products (8) from the powder layer; wherein steps b. and c.repeated processes are used to gradually build up the object layer by layer, characterized by this. that the supply agent (5), the laxative agent (6) and the application agent (7) are controlled synchronously by means of a common control unit.

17. Method according to claim 16, wherein the supply means (5), the removal means (6), the application means (7) and the action means (1a) are synchronously controlled, in particular moved, by means of the common control unit.

18. Method according to claim 16 or 17, wherein the supply of the powdered building material in step a. is intermittent or continuous.

19. Method according to any one of claims 16 to 18, wherein the removal of reaction by-products (8) in step d. is carried out intermittently or continuously 20. Method according to any one of claims 16 to 19, wherein the positioning of the feed means (5) and the discharge means (6) is adjusted during the method.

21. Method according to any one of claims 16 to 20, wherein the positioning of the feed means (5) and / or the discharge means (6) relative to the target surface in the construction area is adjusted during the method.

22. Method according to any one of claims 16 to 21, wherein the flow rate of the feed agent (5) and / or the discharge agent (6) is adjusted during the method.

23. Method according to one of claims 16 to 22, wherein the respective adjustment of one of the means (5, 6, 7, 1a) is carried out depending on the setting and / or adjustment of another of the means (5, 6, 7, 1a).

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