Additive manufacturing by powder fusion with a fixed laser

By using a movable support surface in additive manufacturing, the installation addresses the challenges of complex geometries and surface defects in selective laser melting, achieving improved material quality and surface conditions for large and complex parts.

FR3149526A1Pending Publication Date: 2024-12-13SAFRAN AIRCRAFT ENGINES SAS
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Patent Information

Application Number
FR2023005917
Authority / Receiving Office
FR · FR
Patent Type
Applications
Current Assignee / Owner
Filing Date
2023-06-12
Publication Date
2024-12-13

AI Technical Summary

Technical Problem

Conventional additive manufacturing methods like selective laser melting face challenges in producing parts with complex geometries and unsatisfactory surface conditions, often leading to metallurgical defects, especially for large parts and those requiring significant inclinations, which are incompatible with aeronautical requirements.

Method used

An installation and process where the support surface is movable relative to a fixed frame, allowing the laser to maintain a fixed direction, reducing defects from laser accelerations and decelerations, and enabling the production of large and complex parts with improved surface conditions by aligning the laser with part inclinations.

Benefits of technology

The solution significantly reduces material defects and improves surface quality, enabling the production of large and complex parts with enhanced material properties, particularly suitable for aeronautical applications.

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Abstract

Additive manufacturing by powder fusion with a fixed laser. The invention relates to an installation (1) for the additive manufacturing of a part by powder fusion, the installation (1) comprising a fixed frame (11), a support surface (12) configured to receive the powder and at least one laser emitter (13) configured to emit a laser (14) directed along a first direction (D1) towards the support surface (12), the installation (1) being characterized in that the first direction (D1) is fixed relative to the frame (11) and in that the support surface (12) is movable relative to the frame (11). Figure for the abstract: Fig. 1
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Description

Title of the invention: Additive manufacturing by powder fusion with a fixed laser Technical field

[0001] The present invention relates to additive manufacturing installations and methods. In particular, the present invention relates to the manufacturing of parts by selective laser melting, called "Selective Laser Melting" in English abbreviated "SLM" or "Laser Beam Melting" in English abbreviated "LBM", or by laser powder bed fusion, called "Laser Powder Bed Fusion" in English abbreviated "L-PBF". Prior art

[0002] Conventional manufacturing methods such as machining, casting or forging do not allow for the easy production of parts with complex geometry. This problem is solved by additive manufacturing, which makes it possible to manufacture parts with an optimized shape. In addition, additive manufacturing processes contribute to reducing environmental impact by optimizing the quantity of material produced compared to the quantity of material actually used. Thus, additive manufacturing processes make it possible to actually use up to 80% of the material produced, in particular thanks to the recycling and reuse of powders, compared to an average of 40% for machining processes and an average of 70% for casting processes.

[0003] Common additive manufacturing processes include selective laser melting, also known as "Selective Laser Melting," abbreviated "SLM," or "Laser Beam Melting," abbreviated "LBM," or laser powder bed fusion, also known as "Laser Powder Bed Fusion," abbreviated "L-PBF." This method allows layers of metal powder to be selectively fused in succession to form the desired part. This method is implemented by spreading metal powder to form a powder layer on a support surface, then moving a laser over the metal powder bed to locally fuse and densify the powder layer. When a layer is complete, a new layer of metal powder is spread and refused using the laser.

[0004] However, this method has drawbacks. Indeed, parts produced by such a method regularly have metallurgical defects and unsatisfactory surface conditions. Such anomalies are, for example, often incompatible with aeronautical requirements.

[0005] In addition, the production of large parts, i.e. parts with different dimensions, is a matter of considerable complexity. dimensions greater than 400 mm, remains complex to implement with such a method. Statement of the invention

[0006] It has been found that the anomalies described above could be caused by jerks of the laser due to successive accelerations and decelerations of said laser, and by inaccuracies in the angle of incidence of the laser on the powder bed.

[0007] The present invention aims to remedy the aforementioned drawbacks by proposing an installation and a method for producing parts by laser powder fusion with good material quality and good surface finishes.

[0008] To this end, the invention proposes an installation for the additive manufacturing of a part by powder fusion, the installation comprising a fixed frame, a support surface configured to receive the powder and at least one laser emitter configured to emit a laser directed in a first direction towards the support surface, the installation being characterized in that the first direction is fixed relative to the frame and in that the support surface is movable relative to the frame.

[0009] Thus, by moving the support surface rather than the laser, material defects are greatly limited and the surface condition obtained is improved. Indeed, as the laser(s) remain stationary, the movement speeds are lower and defects due to the accelerations and decelerations of said laser(s) are eliminated.

[0010] Furthermore, the installation as described makes it possible to produce parts of larger dimensions than the installations of the prior art with a mobile laser. By using several lasers, the present installation also makes it possible to produce several parts simultaneously.

[0011] According to a particular embodiment of the invention, the support surface is movable in the first direction.

[0012] Thus, such mobility makes it easier to deposit the different layers of powder on the support surface.

[0013] According to another particular embodiment of the invention, the support surface is movable at least in a second direction and a third intersecting direction belonging to the same mobility plane, the first direction being intersecting said mobility plane.

[0014] Thus, the laser(s) can easily reach the majority of the support surface, even when the latter is large.

[0015] The second direction and the third direction may be perpendicular. The first direction may be perpendicular to the plane of mobility.

[0016] According to another particular embodiment of the invention, the support surface is movable in rotation around the third direction.

[0017] Such rotational mobility makes it possible to produce parts having significant inclinations relative to the support surface, for example parts whose small angle between one of the surfaces of the part and the support surface is less than 40°, or even less than 30°, during manufacture by powder fusion using a laser. Indeed, this mobility makes it possible to align the laser with the inclination of the part to be produced. The material quality and the surface condition of the part are also greatly improved.

[0018] According to another particular embodiment of the invention, the support surface is movable in rotation around an axis perpendicular to said support surface.

[0019] According to another particular embodiment of the invention, the powder is a metallic powder.

[0020] The invention also relates to a method of manufacturing a part by additive manufacturing by powder fusion, the method comprising:

[0021] - the deposition of one or more layers of powder on a support surface of an ins installation, said installation further comprising a fixed frame, and

[0022] - the emission by at least one laser emitter of a laser directed towards the powder layer after the deposition of each layer of powder so as to locally fuse the powder to obtain a layer of the part to be manufactured,

[0023] said method being characterized in that the emitted laser is emitted in a fixed direction relative to the frame during the emission of said laser and in that the support surface is mobile during the emission of the laser.

[0024] Such a method allows the same advantages as those linked to the invention, in particular concerning the improvement of the material quality and the surface condition. Such a method also makes it possible to manufacture large parts, and / or to facilitate the simultaneous manufacture of several parts.

[0025] According to a particular embodiment of the method of the invention, the laser is directed in a first direction towards the layer of powder, the support surface being movable in said first direction.

[0026] Thus, such mobility makes it easier to deposit the different layers of powder on the support surface.

[0027] According to another particular embodiment of the method of the invention, the laser is directed in a first direction towards the layer of powder, the support surface being movable at least in second and third intersecting directions belonging to the same mobility plane, the first direction being intersecting said mobility plane.

[0028] Thus, the laser(s) can easily reach the majority of the support surface, even when the latter is large.

[0029] According to another particular embodiment of the method of the invention, the surface of support is movable in rotation around the third direction.

[0030] Such rotational mobility makes it possible to produce parts having significant inclinations relative to the support surface, for example parts whose small angle between one of the surfaces of the part and the support surface is less than 40°, or even less than 30°, during manufacture by powder fusion using a laser. Indeed, this mobility makes it possible to align the laser with the inclination of the part to be produced. The material quality and the surface condition of the part are also greatly improved.

[0031] According to another particular embodiment of the method of the invention, the support surface is movable in rotation around an axis perpendicular to said support surface.

[0032] According to another particular embodiment of the method of the invention, the powder is a metal powder. Brief description of the drawings

[0033] [Fig.l] [Fig.l] is a schematic perspective representation of an installation according to a particular embodiment of the invention.

[0034] [Fig.2] [Fig.2] is a schematic perspective representation of the installation of [Fig.l] in operation.

[0035] [Fig.3] [Fig.3] is a cross-sectional representation along a plane including the laser of the installation of figures 1 and 2 in operation.

[0036] [Fig.4] [Fig.4] is a schematic perspective representation of an ins tallation according to another particular embodiment of the invention. Description of the embodiments

[0037] The present invention applies generally to the additive manufacturing of parts by powder fusion using a laser. For example, manufacturing by selective laser fusion, also called "Selective Laser Melting", abbreviated "SLM", or "Laser Beam Melting", abbreviated "LBM", or by laser powder bed fusion, called "Laser Powder Bed Fusion" in English abbreviated "L-PBF", as indicated above, is known.

[0038] [Fig. 1] schematically illustrates an example of installation 1 according to the invention. Installation 1 comprises a frame 11. Frame 11 is conventionally fixed relative to the ground. The reference frame of installation 1 is defined by an abscissa axis X, an ordinate axis Y and a coordinate axis Z. Conventionally, these three axes X, Y and Z are perpendicular to each other. Conventionally, the coordinate axis Z extends in the direction of the acceleration of gravity.

[0039] The installation 1 further comprises at least one support surface 12 configured to accommodate the powder(s) to be fused. The support surface 12 may have a planar shape as in the example illustrated in [Fig.l]. The support surface 12 may also have a concave or convex shape. The support surface 12 may be heated by heating means. The support surface 12 may have a dimension, for example a diameter, a width or a length along the X or Y axes, greater than or equal to 700 mm, reaching for example 1000 mm.

[0040] The support surface may accommodate a single variety of powder, or several different powders. The powder may be a metal powder, i.e., a powder comprising metal particles. The powder may also be a thermoplastic powder, i.e., a powder comprising thermoplastic particles.

[0041] The installation 1 also comprises at least one laser transmitter 13. The laser transmitter 13 is configured to emit a laser 14 directed towards the support surface 12. The installation 1 according to the invention makes it possible to easily use several lasers 14 and / or several laser transmitters 13, for example to produce the parts more quickly or to produce several parts simultaneously.

[0042] The laser 14 is directed along a first fixed direction Di. The trajectory of the laser 14 therefore extends along the first direction Di. The position of the trajectory of the laser 14 is therefore fixed in the X, Y, Z reference frame of the installation 1. The length of the trajectory of the laser 14 can vary along the first direction Dp. The first direction Di preferably extends along the axis of the dimensions Z. As the laser(s) are fixed, the risk of overlap at the level of the powder layer between two different lasers is greatly reduced.

[0043] The laser transmitter 13 may be a complete optical system. The shaping of the laser 14 may be carried out by means of a beam expander. The variation of the diameter of the laser 14 may be carried out by means of a focusing system. A collimator may be used in a well-known manner on the path of the laser 14 to allow or prohibit its contact with the powder(s) arranged on the support surface 12.

[0044] It does not depart from the scope of the invention if the laser emitter is configured to vary the shape of the laser beam. Thus, it does not depart from the scope of the invention if the shape of the laser beam varies during the manufacturing process of the invention. It also does not depart from the scope of the invention if the laser emitter is configured to vary the energy distribution of the laser beam. Thus, it does not depart from the scope of the invention if the energy distribution of the laser beam varies during the manufacturing process of the invention.

[0045] The support surface 12 is movable relative to the frame 11. Thus, the support surface 12 moves in the X, Y, Z reference frame of the installation 1.

[0046] The support surface 12 can be movable in a second direction D2 and a third direction D3 belonging to the same mobility plane, the first direction D i being secant to this mobility plane. Preferably, the second direction D2 and a third direction D3 are perpendicular. Preferably, the first direction Di is perpendicular to the second and third directions D2 and D3. Consequently, in order to obtain a simple installation 1, the first direction Di preferably extends along the Z-axis, the second direction D2 preferably extends along the X-axis and the third direction D3 preferably extends along the Y-axis, as illustrated in the schematic example of [Fig.l].

[0047] When it is indicated that the support surface 12 can be movable in a second direction D2 and a third direction D3 belonging to the same mobility plane, it must be understood that the support surface 12 is movable in said mobility plane and can follow curved trajectories in said mobility plane. The mobility of the support surface 12 in the second direction D2 and the third direction D3 can be physically obtained by the combination of a sliding connection in the second direction D2 and a sliding connection in the third direction D3, as illustrated in [Fig.l]. It is of course not beyond the scope of the invention if other types of connection are used to achieve this mobility.

[0048] Such mobility in the mobility plane makes it possible to produce parts of larger dimensions. It is thus possible to produce parts of which at least one dimension is greater than 700 mm, whereas the installations according to the prior art make it difficult to produce parts of which at least one dimension is greater than 800 mm, or even greater than 400 mm.

[0049] The support surface 12 can also be movable along a fourth direction D4. In a manner well known in powder fusion additive manufacturing installations, the support surface 12 can be movable along the laser emission direction Di. The support surface 12 is thus movable along this fourth direction D4 identical to the first direction Db. Alternatively, the support surface 12 can be movable along the axis of the dimensions Z. The support surface 12 is then movable along this fourth direction D4 coincident with the axis of the dimensions Z. In the example illustrated in [Fig.l], the first direction Di and the axis of the dimensions Z are coincident. The fourth direction D4 then corresponds simultaneously to the first direction Di and to the axis of the dimensions Z.

[0050] The mobility of the support surface 12 along the fourth direction D4 can be physically obtained by a sliding connection along the fourth direction D4, as illustrated in [Fig.l]. It is of course not outside the scope of the invention if other types of connection are used to achieve this mobility.

[0051] The support surface 12 can also be movable in rotation about a first rotation axis belonging to the mobility plane following a first rotation R5. Preferably, in order to simplify the installation 1, this first rotation axis extends in the second direction D2 or in the third direction D3. Thus, the surface support surface 12 can be movable in rotation around the second direction D2 or around the third direction D3. In the example illustrated in [Fig.l], the support surface 12 is movable following the first rotation R5 around the third direction D 3-

[0052] The mobility of the support surface 12 following the first rotation R5 can be physically obtained by a pivot connection whose axis extends along the first axis A of rotation belonging to the plane of mobility, as illustrated in [Fig.l]. It is of course not outside the scope of the invention if other types of connection are used to achieve this mobility.

[0053] The support surface 12 can also be movable in rotation about a second axis of rotation perpendicular to said support surface 12 following a second rotation R6. Preferably, this second axis of rotation intersects the support surface 12 at its center. Thus, the support surface 12 rotates on itself. When the support surface is perpendicular to the first direction Db, the second axis of rotation can then coincide with the first direction Di.

[0054] The mobility of the support surface 12 following the second rotation R6 can be physically obtained by a pivot connection whose axis extends along the second axis of rotation, as illustrated in [Fig.l]. It is of course not outside the scope of the invention if other types of connection are used to achieve this mobility.

[0055] An installation according to the invention can comprise these five mobilities D2, D3, D4, R5, R6. The installation is then of the “5-axis” type.

[0056] The installation may also comprise a support surface that is movable only according to certain mobilities. The installation may thus comprise a support surface that is movable only according to the second direction D2 and the third direction D3. The installation may comprise a support surface that is movable only according to the second direction D2, the third direction D3 and the fourth direction D4. The installation may comprise a support surface that is movable only according to the second direction D2, the third direction D3, the fourth direction D4 and the first rotation R5. The installation may comprise a support surface that is movable only according to the second direction D2, the third direction D3, and the first rotation R5. The installation may comprise a support surface that is movable only according to the third direction D3 and the first rotation R5.The installation may comprise a support surface movable only in the third direction D3, the fourth direction D4 and the first rotation R5. Other combinations of mobilities which could be envisaged by those skilled in the art are of course possible.

[0057] The installation according to the invention may comprise a servo system. Such a servo system may be configured so as to synchronize the movements of the support surface 12 with the emission or not of the laser 14, for example by synchronizing the movements of the support surface 12 with a collimator as described previously.

[0058] The installation according to the invention may also comprise, in a well-known manner, a powder feed bin. It may also comprise a system for depositing the powder on the support surface 12, such systems being well known to those skilled in the art. The system for depositing the powder on the support surface 12 may, for example, comprise a scraper configured to spread a layer of powder on the support surface 12. The scraper may, for example, be in the form of a roller, a reel or a brush. The installation according to the invention may comprise, in a well-known manner, a recycling bin for recovering excess powder. This recycling bin may also be referred to as an “overflow bin” or “ashtray”.

[0059] We will now describe an example of a method according to the invention, implementing an installation as described previously, in relation to figures 2 and 3.

[0060] According to the method of the invention, the part is produced by laser powder fusion, by successively producing several layers Pi to P8 of the part to be obtained.

[0061] The method according to the invention comprises the deposition of a plurality of layers Ci to C8 of powder on the support surface 12 of the installation 1. The layers Ci to C8 of powder are deposited so as to superimpose themselves. The layers Ci to C8 of powder are deposited directly in contact with each other.

[0062] When the laser 14 comes into contact with a layer of powder, the contact zone is called the “focal spot” and depends on the diameter of the laser 14. The installation of the invention makes it possible to obtain a focal spot which changes shape little during movement, compared to the installations of the prior art.

[0063] We start by applying a first layer Ci of powder to the support surface 12. Then, we proceed with the emission by at least one laser emitter of at least one laser directed towards the first layer C of powder so as to locally fuse the powder to obtain a first layer Pi of the part to be manufactured.

[0064] A second layer C2 of powder is then applied to the support surface 12. Then, one or more lasers are emitted directed towards the second layer D2 of powder so as to locally fuse the powder to obtain a first layer Pi of the part to be manufactured.

[0065] These operations are repeated several times so as to deposit a plurality of layers C1 to C8 of powder on the support surface 12, with the emission of a laser after the deposition of each layer so as to obtain a layer of the part to be manufactured.

[0066] In the example illustrated in Figures 2 and 3, a shaped part is producedfrustoconical having a significant inclination. The presence of the first rotation R5 is particularly interesting for the production of parts having a significant inclination on several layers Pi to P8 of the part. Such a first rotation R 5 makes it possible to change the inclination of the support platform 12 relative to the emitted laser 14, and thus to align the direction of the inclination of the part with the first direction Di in which the laser 14 is emitted. While the installations of the prior art made it difficult to produce parts with significant inclinations on several layers of the part, the present installation makes it possible to produce parts whose smallest angle between the wall of said part and the support surface is less than 40°, for example less than 30°.Furthermore, by aligning the emitted laser 14 with the walls of the part to be produced, a more satisfactory surface condition is obtained, in particular at the level of the inclined surfaces in contact with the powder after fusion.

[0067] The method according to the invention makes it possible to improve the surface condition and to reduce material defects, it is particularly suitable for the manufacture of parts for aeronautics. The method of the invention can in particular make it possible to produce rectifiers, bearing supports or parts of the vein of an aircraft.

[0068] [Fig.4] illustrates an installation 2 according to another embodiment of the invention, which in particular makes it possible to produce large parts.

[0069] The installation 2 comprises a frame 21. The frame 21 is conventionally fixed relative to the ground. The reference frame of the installation 2 is defined by an abscissa axis X, an ordinate axis Y and a coordinate axis Z. Conventionally, these three axes X, Y and Z are perpendicular to each other. Conventionally, the coordinate axis Z extends in the direction of the acceleration of gravity.

[0070] The installation 2 further comprises at least one support surface 22 configured to accommodate the powder(s) to be fused. The support surface 22 may have a planar shape as in the example illustrated in [Fig.4]. The support surface 22 may also have a concave or convex shape. The support surface 22 may be heated by heating means. The support surface 22 may have a dimension, for example a diameter, a width or a length along the X or Y axes, greater than or equal to 700 mm, reaching for example 800 mm.

[0071] The installation 2 also comprises at least one laser transmitter 23. The laser transmitter 23 is configured to emit a laser 24 directed towards the support surface 22. The installation 2 according to the invention makes it possible to easily use several lasers 24 and / or several laser transmitters 23, for example to produce the parts more quickly or to produce several parts simultaneously.

[0072] The laser 24 is directed along a first fixed direction D2i. The trajectory of the laser 24 therefore extends along the first direction D2i. The position of the trajectory of the laser 24 is therefore fixed in the X, Y, Z reference frame of the installation 2. The length of the trajectory of the laser 24 can vary along the first direction D2i. The first direction D2[ preferably extends along the axis of the dimensions Z. As the laser(s) are fixed, the risk of overlap at the level of the powder layer between two different lasers is greatly reduced.

[0073] The laser transmitter 23 may be a complete optical system. The shaping of the laser 24 may be carried out by means of a beam expander. The variation of the diameter of the laser 24 may be carried out by means of a focusing system. A collimator may be used in a well-known manner on the path of the laser 24 to allow or prohibit its contact with the powder(s) arranged on the support surface 22.

[0074] The support surface 22 is movable relative to the frame 21. Thus, the support surface 22 moves in the X, Y, Z reference frame of the installation 2.

[0075] In this embodiment, the support surface 22 is supported by a first table 20 and by a second table 30. The first table 20 and the second table 30 may be five-axis machines.

[0076] The first table 20 can be movable along a second direction D22 and a third direction D23 belonging to the same mobility plane, the first direction D2i being secant to this mobility plane. Preferably, the second direction D22 and a third direction D23 are perpendicular. Preferably, the first direction D2[ is perpendicular to the second and third directions D22 and D23. As explained in the context of the first embodiment of the invention, the first direction D2[ preferably extends along the Z axis, the second direction D22 preferably extends along the X axis and the third direction D23 preferably extends along the Y axis, as illustrated in the schematic example of [Fig.4].

[0077] Similarly, the second table 30 can be movable in a second direction D32 and a third direction D33 belonging to the same mobility plane, the first direction D2[ being intersecting this mobility plane. The second direction D22 of the first table 20 extends in the same direction as the second direction D32 of the second table 30. The third direction D23 of the first table 20 extends in the same direction as the third direction D33 of the second table 30.

[0078] Thus, the support surface 22 can be movable along the second direction D22 / D32 and along the third direction D23 / D33 belonging to the same mobility plane. It should be understood that the support surface 22 is movable in said mobility plane and can follow curved trajectories in said mobility plane.

[0079] Such mobility in the mobility plane makes it possible to produce parts of larger dimensions. It is thus possible to produce parts of which at least one dimension is greater than 700 mm, or even greater than 1000 mm, whereas the installations according to the prior art make it difficult to produce parts of which at least at least one dimension is greater than 400 mm.

[0080] The first table 20 and the second table 20 can also allow mobility along a fourth direction D24 / D34. Thus, the support surface 22 can be movable along the fourth direction D24 / D34. In a manner well known in powder fusion additive manufacturing installations, the support surface 22 can be movable along the laser emission direction D2[. The support surface 22 is thus movable along this fourth direction D24 / D34 identical to the first direction D2i. Alternatively, the support surface 22 can be movable along the axis of the dimensions Z. The support surface 22 is then movable along this fourth direction D24 / D34 coincident with the axis of the dimensions Z. In the example illustrated in [Fig.4], the first direction D2[ and the axis of the dimensions Z coincide. The fourth direction D24 / D34 then corresponds simultaneously to the first direction D2i and to the axis of the dimensions Z.

[0081] The first table 20 and the second table 20 can also allow mobility following a first rotation R23 / R35 around a first axis of rotation belonging to the mobility plane. Thus, the support surface 22 can be movable following the first rotation R25 / R35.

[0082] Preferably, in order to simplify the installation 2, the first axis of rotation extends along the second direction D22 / D32 or along the third direction D23 / D33. Thus, the support surface 22 can be movable in rotation around the second direction D22 / D32 or around the third direction D23 / D33. In the example illustrated in [Fig.4], the support surface 22 is movable along the first rotation R25 / R35 around the third direction D23 / D33.

[0083] The installation may also comprise a support surface that is movable only according to certain mobilities. The installation may thus comprise a support surface that is movable only along the second direction D22 / D32 and the third direction D23 / D33. The installation may comprise a support surface that is movable only along the second direction D22 / D32, the third direction D23 / D33 and the fourth direction D24 / D34. The installation may comprise a support surface that is movable only along the second direction D22 / D32, the third direction D23 / D33, the fourth direction D24 / D34 and the first rotation R25 / R35. The installation may comprise a support surface that is movable only along the second direction D22 / D32, the third direction D23 / D33, and the first rotation R25 / R35. The installation may comprise a support surface that is movable only along the third direction D23 / D33 and the first rotation R25 / R35.The installation may comprise a support surface movable only in the third direction D23 / D33, the fourth direction D24 / D34 and the first rotation R25 / R35. Other combinations of mobilities which could be envisaged by those skilled in the art are of course possible.

[0084] The installation according to the invention may comprise a servo-control system. Such a The servo system can be configured so as to synchronize the movements of the support surface 22 with the emission or not of the laser 24, for example by synchronizing the movements of the support surface 22 with a collimator as described previously.

[0085] The installation according to the invention may also comprise, in a well-known manner, a powder feed bin. It may also comprise a system for depositing the powder on the support surface 22, such systems being well known to those skilled in the art. The system for depositing the powder on the support surface 22 may, for example, comprise a scraper configured to spread a layer of powder on the support surface 22. The scraper may, for example, be in the form of a roller, a reel or a brush. The installation according to the invention may comprise, in a well-known manner, a recycling bin for recovering excess powder. This recycling bin may also be referred to as an “overflow bin” or “ashtray”.

Claims

Claims

1. Installation (1; 2) for the additive manufacturing of a part by powder fusion, the installation (1; 2) comprising a fixed frame (11; 21), a support surface (12; 22) configured to receive the powder and at least one laser emitter (13; 23) configured to emit a laser (14; 24) directed in a first direction (Di; D2i) towards the support surface (12; 22), the installation (1; 2) being characterized in that the first direction (Di; D2i) is fixed relative to the frame (11; 21) and in that the support surface (12; 22) is movable relative to the frame (11; 21).

2. Installation (1; 2) according to claim 1, in which the support surface (12; 22) is movable in the first direction (Di; D2[).

3. Installation (1; 2) according to claim 1 or 2, in which the support surface (12; 22) is movable at least in a second direction (D2; D22, D32) and a third direction (D3; D23, D33) intersecting belonging to the same mobility plane, the first direction (Di; D2J being intersecting with said mobility plane.

4. Installation (1; 2) according to claim 3, in which the support surface (12; 22) is movable in rotation (R5; R25, R35) around the third direction (D3; D23, D33).

5. Installation (1) according to any one of claims 1 to 4, in which the support surface (12; 22) is movable in rotation (R6) around an axis perpendicular to said support surface (12; 22).

6. Installation (1; 2) according to any one of claims 1 to 5, in which the powder is a metallic powder.

7. A method of manufacturing a part by additive manufacturing by powder fusion, the method comprising: - depositing one or more layers (Ci, C2, C3, C4, C5, C6, C7, C8) of powder on a support surface (12) of an installation (1), said installation (1) further comprising a fixed frame (11), and - emitting by at least one laser emitter (13) a laser (14) directed towards the layer of powder (Ci, C2, C3, C4, C5, C6, C7, C8) after the deposition of each layer of powder (Cb C2, C3, C4, C5, C6, C7, C8) so as to locally fuse the powder to obtain a stratum (Pb P2, P3, P4, P5, P6, P7, P8) of the part to be manufactured, said method being characterized in that the emitted laser (14) is emitted in a direction (Di; D2[) fixed relative to the frame (11) during the emission of said laser (14) and in that the support surface (12) is movable during the emission of the laser (14).

8. Manufacturing method according to claim 7, in which the laser (14) is directed in a first direction (DJ) towards the powder layer (Ci, C2, C3, C4, C5, C6, C7, C8), the support surface (12) being movable at least in second and third intersecting directions (D2, D3) belonging to the same mobility plane, the first direction (DJ) being intersecting said mobility plane.

9. A manufacturing method according to claim 8, wherein the support surface (12) is rotatable (R5) about the third direction (D3).

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