Additive manufacturing equipment

Abstract

The present invention relates to an additive manufacturing apparatus (40), which comprises a chamber (11, 21), a driving device, a molding chamber (43), and a powder laying device, the chamber (11, 21) having a support table (13b, 24) arranged in a sealed manner in the chamber (11, 21), a quick release assembly arranged at the bottom of the support table (13b, 24) to be connected to the driving device so that the driving device can be quickly connected to or disconnected from the support table (13b, 24), and the chamber A first part (14a) of the assembly transfer structure is arranged on (11, 21), which cooperates with a second part (14b) of the assembly transfer structure arranged on the additive manufacturing device (40) to realize the rapid transfer of the chambers (11, 21) in the additive manufacturing device (40). Thus, after additive manufacturing is completed, the post-processing of the molding table (13) can be quickly performed and the chambers (11, 21) can be quickly replaced, significantly reducing the time required for maintenance and reducing potential risks in the maintenance process.

Description

[Technical Field]

[0001] (CROSS-REFERENCE TO RELATED APPLICATIONS) This application claims priority from Patent Application No. 202311331817.2, filed with the China Patent Office on October 16, 2023, the entire contents of which are incorporated herein by reference.

[0002] The present invention relates to the field of additive manufacturing technology, and more particularly to an additive manufacturing device. [Background technology]

[0003] In additive manufacturing processes, material handling units such as powder chambers, molding chambers, etc. are important assemblies for storing and handling build materials. Typically, the build materials are stored in the powder chamber in powder form and are precisely moved and dispensed into the molding chamber via a driving device to build structures.

[0004] Currently, chambers such as the molding chamber and powder chamber are typically fixedly attached to additive manufacturing equipment. Because the powder chamber is not removable, operators typically must perform tedious cleaning procedures within the powder chamber to ensure that the build material does not interfere with the next build process (e.g., when using a different build material). This not only increases production time but also operational complexity. While the molding chamber's base plate can be removed, tedious powder cleaning procedures are typically required before the base plate and its components can be removed. This cleaning process must be completed within the molding chamber, reducing the overall efficiency of 3D printing and posing a risk of contamination and potential damage to the various precision sensors and assemblies within the molding chamber. Furthermore, cleaning procedures increase the time cost of the production process, limiting the production speed of additive manufacturing technology, especially when multiple parts need to be produced serially. Therefore, this drawback of existing technology poses a constraint on achieving an efficient additive manufacturing process. Summary of the Invention [Problem to be solved by the invention]

[0005] The present invention aims to realize fast transfer in a chamber additive manufacturing apparatus. [Means for solving the problem]

[0006] In order to realize a fast transfer in the chamber additive manufacturing apparatus, one aspect of the present invention provides an additive manufacturing apparatus including: a chamber, the chamber having a support table disposed in sealing relation with the chamber, a cavity formed by the support table and the chamber being used to contain a structure and / or a powder build material for molding the structure; a drive device for driving the support table to move up and down along a side wall of the chamber; and a molding chamber for constructing a closed space for the additive manufacturing process, the closed space being a closed space between the powder build material and an optical path system. The powder laying device is provided with a molding chamber having a partial space therebetween, and a powder laying device for uniformly laying powder build material on a molding table during the additive manufacturing stage, the molding table being arranged on a support table, and a quick release assembly is arranged on the bottom of the support table and is connected to the drive device so that the drive device can be quickly connected to or disconnected from the support table, and a first part of an assembly transfer structure is arranged in the chamber and cooperates with a second part of the assembly transfer structure arranged in the additive manufacturing apparatus to enable the chamber to be quickly transferred in the additive manufacturing apparatus.

[0007] Preferably, the chamber is a molding chamber, and the drive device drives the support table to move from top to bottom in an additive manufacturing process so that the powder laying device lays down the powder build material evenly on the molding table.

[0008] Preferably, the chamber is a powder chamber, and the drive device drives the support table to move from bottom to top along the chamber sidewall in the additive manufacturing process so that the powder build material of the structure provided by the powder laying device moves towards another end.

[0009] Preferably, at least during the additive manufacturing stage, one end of the drive device is firmly connected to the support base so that the support base moves up and down along the chamber side wall under the action of the drive device, and at least during the structure formation completion stage, the drive device separates from the support base and one end of the drive device leaves the chamber.

[0010] Preferably, a base is arranged in the chamber, and the drive device includes a second drive unit, which is used to support the base and stably support the chamber on the rack of the additive manufacturing apparatus at least during the additive manufacturing stage.

[0011] Preferably, the first part of the assembly transfer structure is disposed in the chamber and the second part is disposed on the rack, and at least when the structure formation is completed, when the second drive unit removes the support, the first part moves downward and contacts the second part to complete the mutual cooperation.

[0012] Preferably, the chamber can be quickly attached / detached and / or transported to / from the additive manufacturing apparatus through cooperation between the assembly transport structure and the transport device, and the transport path is for transporting the chamber from a specific position to the additive manufacturing apparatus and / or for transporting the additive manufacturing apparatus to a specific position.

[0013] Preferably, the first portion of the assembly transfer structure is a slider and the second portion is a guide rail.

[0014] Preferably, the powder laying effect is improved to overcome the phenomenon of powder sticking or agglomeration during the powder laying process, and the powder build material is made to stick to the surface of the powder laying device during the powder laying process.

[0015] Preferably, the powder build material applied to the surface of the powder laying device is formed by a pre-application process that occurs prior to powder laying on the platform.

[0016] Preferably, the layer of powder build material applied to the surface of the powder laying device has a thickness of 10 to 80 μm.

[0017] Preferably, the powder laying device is a roller that, in a moving process, evenly lays down the powder build material in the powder chamber onto the mold table.

[0018] Preferably, the surface of the roller has an uneven structure to allow the powdered building material to adhere to the surface of the roller.

[0019] Preferably, prior to the pre-application process, the surface of the powder laying device is subjected to a material application process.

[0020] Preferably, an electrostatic generating device is disposed within the powder laying device for generating static electricity on the surface of the powder laying device to attract the powder build material.

[0021] Preferably, a heating device is arranged inside the powder laying device for pre-heating the surface of the powder laying device prior to the pre-application process.

[0022] Preferably, in order to reduce gas cleaning time and increase utilization rate of the apparatus, the additive manufacturing apparatus further comprises a gas cleaning device for performing a gas cleaning operation on the molding chamber in a gas cleaning stage, the volume of the molding chamber being variable, and the volume has at least a first volume corresponding to the additive manufacturing stage and a second volume corresponding to the gas cleaning stage, the first volume being larger than the second volume.

[0023] Preferably, the moulding chamber comprises a first wall and a second wall arranged opposite each other, the first wall and the second wall being movable relative to each other so as to vary the volume of the moulding chamber.

[0024] Preferably, the first and second walls are the top and bottom walls of the moulding chamber or are side walls of the moulding chamber.

[0025] Preferably, the first wall and the second wall are arranged parallel to each other on the inside of the top and bottom walls of the molding chamber or on the inside of the side walls of the molding chamber.

[0026] Preferably, the molding chamber further comprises a contraction / expansion device, which is inside the molding chamber at least during the gas cleaning stage, and the volume of the contraction / expansion device has a contracted state and an expanded state, and during the additive manufacturing stage, the volume of the contraction / expansion device is in a contracted state, and during the gas cleaning stage, the volume of the contraction / expansion device is in an expanded state.

[0027] Preferably, the contractible-expandable device is a flexible inflatable device.

[0028] Preferably, the contractible-expandable device is a telescoping accordion-style folding assembly.

[0029] Preferably, the contractible / expandable device is arranged in two layers, an inner layer and an outer layer, and the strength of the material of the contractible / expandable device of the outer layer ensures that deformation does not occur at least in response to changes in the vacuum level in the molding chamber, and the material of the contractible / expandable device of the inner layer is an airtight material.

[0030] Preferably, the molding chamber further comprises a vacuum exhaust device for evacuating the molding chamber in a gas cleaning step, and / or an inert gas filling device for injecting an inert gas into the molding chamber in a gas cleaning step, and when the gas cleaning device includes the vacuum exhaust device and the inert gas filling device, the vacuum exhaust device and the inert gas filling device operate synchronously. [Brief explanation of the drawings]

[0031] [Figure 1] 1 shows a schematic diagram of a mounting state of a molding chamber in an additive manufacturing apparatus according to one embodiment of the present invention. [Figure 2] 1 shows a schematic diagram of a mounting state of a molding chamber in an additive manufacturing apparatus according to one embodiment of the present invention. [Figure 3]1 shows a schematic diagram of a molding chamber in an additive manufacturing apparatus in a removed state, according to one embodiment of the present invention; [Figure 4] 1 shows a schematic diagram of a mounting state of a molding chamber in an additive manufacturing apparatus according to one embodiment of the present invention. [Figure 5] 1 shows a schematic diagram of a mounting state of a molding chamber in an additive manufacturing apparatus according to one embodiment of the present invention. [Figure 6] 1 shows a structural schematic diagram of a rack according to one embodiment of the present invention. [Figure 7] 1 shows a schematic view of the installation of a powder chamber in an additive manufacturing apparatus according to one embodiment of the present invention; FIG. [Figure 8] 1 shows a schematic diagram of the application of a powder deposition device in an additive manufacturing apparatus, according to one embodiment of the present invention; [Figure 9] 1 shows a schematic diagram of the application of a powder deposition device in an additive manufacturing apparatus, according to one embodiment of the present invention; [Figure 10] 1 shows a schematic diagram of the operation of a roller of a static electricity generating device according to one embodiment of the present invention. [Figure 11(a)] 1 shows a schematic diagram of the structure of a build chamber during an additive manufacturing stage, according to one embodiment of the present invention. [Figure 11(b)] 1 shows a schematic diagram of the structure of a molding chamber during a gas flushing stage according to one embodiment of the present invention. [Figure 12(a)] 1 shows a schematic diagram of the structure of a build chamber during an additive manufacturing stage, according to one embodiment of the present invention. [Figure 12(b)] 1 shows a schematic diagram of the structure of a molding chamber during a gas flushing stage according to one embodiment of the present invention. [Figure 13(a)] 1 shows a schematic diagram of the structure of a build chamber during an additive manufacturing stage, according to one embodiment of the present invention. [Figure 13(b)] 1 shows a schematic diagram of the structure of a molding chamber during a gas flushing stage according to one embodiment of the present invention. [Figure 14] 1 shows a schematic diagram of an application of a molding chamber in an additive manufacturing apparatus according to one embodiment of the present invention. [Figure 15(a)]1A-1D show schematic diagrams of an expandable device during the additive manufacturing stage, according to one embodiment of the present invention. [Figure 15(b)] 1 shows a state diagram of an inflatable device during a gas scrubbing stage, according to one embodiment of the present invention. [Figure 16(a)] 1A-1C show schematic diagrams of an accordion-style folding assembly during the additive manufacturing stage, according to one embodiment of the present invention. [Figure 16(b)] 1 shows a state schematic diagram of an accordion folding assembly during a gas scrubbing stage according to one embodiment of the present invention. [Figure 17] 1 shows a model schematic of one possible implementation of an additive manufacturing apparatus with a gas cleaning device. [Figure 18a] FIG. 18 shows a schematic model of one of the vacuum exhaust devices in the additive manufacturing apparatus of FIG. 17. [Figure 18b] FIG. 18 shows a schematic model of one of the inert gas filling devices in the additive manufacturing apparatus of FIG. 17. [Figure 18c] FIG. 18 shows a schematic view of a model of a contraction / expansion device in the additive manufacturing apparatus of FIG. 17 in an open state. [Figure 19] FIG. 1 is a schematic model of one possible implementation of an additive manufacturing apparatus with a gas cleaning device. DETAILED DESCRIPTION OF THE INVENTION

[0032] A first aspect of the present invention provides a molding chamber in an additive manufacturing apparatus.

[0033] According to one embodiment of the present invention, the molding chamber has a structure shown in Figure 1. The molding chamber 10 comprises a chamber 11 and a support base 13b. The driving device 12 can be connected to or separated from the support base 13b. Specifically, the driving device 12 can include a driver (not shown) and a ball screw. The ball screw moves vertically along the chamber 11 under the action of the driver. A quick-release assembly, such as a zero-point positioner, is attached to the top end of the ball screw or the bottom of the support base 13b. The ball screw precisely couples the zero-point positioner to the support base 13b, thereby realizing the coupling or separation between the screw and the support base 13b. The top and bottom ends of the chamber 11 are positioned in an open state, and a support 13b is positioned within the chamber 11, which supports powder build materials 30 to form powder layers within the chamber 11 and is used to build a structure 31 layer by layer by a high-energy beam from above, and the types of powder build materials 30 include, but are not limited to, metal powders, nylon powders, polymer powders, biomaterial powders, ceramic powders, and mixed powders.

[0034] In some embodiments, a molding base plate 13a can be attached to the top of the support table 13b, and the molding base plate 13b is used to carry powder build material 30 and form a powder layer in the chamber 11, building a structure 31 with a high-energy beam from above. The two support table structures are described in detail below. In summary, in some engineering applications, a platform mechanism for carrying a printed structure and / or powder, consisting of a separate support table 13b or the addition of a molding base plate 13a to the support table 13b, may be collectively referred to as a building table 13. The driving device 12 can drive the building table 13 to move along the Z-axis direction to promote synchronous movement of the powder build material 30 above the building table 13 in the Z-axis direction. For example, in an additive manufacturing process, after each layer of the structure 31 is built, the drive device 12 controls the platform 13 to lower a precise distance, typically the thickness of one layer, to allow the structure 31 to begin building the next layer, and this process is repeated to gradually build the required structure 31.

[0035] 1 shows that the molding table 13 is arranged by combining a molding base plate 13a and a support table 13b side by side. The molding base plate 13a is located above the support table 13b and is used to support the powder build material 30 to form the structure 31. The support table 13b can move up and down along the inner wall of the chamber 11 by the action of the driving device 12. Therefore, there is no required limitation on the size of the molding base plate 13a, and this size can be smaller than the width of the support table 13b in the X direction. The molding base plate 13a and the support table 13b can be combined by placing the molding base plate 13a directly above the support table 13b, but a more preferred method is to removably attach the molding base plate 13a to the top of the support table 13b via a fixing assembly (e.g., bolts). In an alternative combination method, the molding base plate 13a and the support table 13b can be designed to be integrally molded. Such a separate design of the support base 13b and the molding base plate 13a is very suitable for removing the part after molding is completed.

[0036] In 3D printing, once printing of a part is complete, the part and its supporting base (sometimes referred to as the molding base plate 13a) must be removed together, and then the molding base plate 13a and the part must be separated by cutting. When the molding base plate 13a and the support base 13b are arranged as an integral structure, the support base 13b must also be removed to frequently remove the molded part. The support base 13b often requires a better sealing effect with the chamber 11 to prevent isolation of the molding chamber on the top of the platform from the outside gas and ensure stability of the gas within the molding chamber. Such frequent removal of the support base inevitably leads to problems with loosening the seal of the molding chamber, which in turn destabilizes the atmosphere within the molding chamber and affects the molding quality of the structure.

[0037] In addition, the chamber 11 in this embodiment has an assembly transfer structure, and the design of the assembly transfer structure allows the molding chamber 10 to be quickly attached to or detached from the additive manufacturing apparatus. This is suitable for application scenarios such as when maintenance, cleaning, or build material replacement is required. The assembly transfer structure can be quickly separated, allowing the molding chamber 10 to be easily removed from the additive manufacturing apparatus. This process significantly reduces maintenance time and reduces risks in the maintenance process, such as reducing waste of powder material and potential damage to the apparatus.

[0038] The assembly transfer structure is arranged in two parts, a first part 14a arranged in the chamber 11, and a second part 14b arranged in the additive manufacturing apparatus, preferably arranged in a rack 32 of the additive manufacturing apparatus, the rack 32 being a solid base having a predetermined thickness, which may be the chamber bottom of the molding chamber, i.e., the molding chamber 10 is removably attached to the bottom of the molding chamber, and the upper surface of the rack 32 is understood to be the working surface for additive manufacturing. In the example of Fig. 1, the first parts 14a are arranged symmetrically on both sides of the chamber 11 and near the top end of the chamber 11.

[0039] The assembly transfer structure may have various optional forms, for example, a guide rail structure. Other forms, including but not limited to, latch structures, retaining ring structures, screw structures, and magnetic attraction structures, may also be used. Each form has its own advantages and applicability and can be selected based on specific circumstances. In the guide rail structure form, the first portion 14a may be a slider, and the second portion 14b may be a guide rail. The slider formed by the first portion 14a can simply slide on the guide rail formed by the second portion 14b. In some specific embodiments, the first portion 14a may also be a pulley set formed by multiple pulleys, and the second portion 14b may be a guide rail. The pulleys can slide along the guide rail, thereby transferring the molding chamber 10 to a specific position from the additive manufacturing apparatus.

[0040] Below, we will use a guide rail structure as an example of a specific form of assembly transfer structure to explain the molding chamber 10 of the present invention in detail. Unless otherwise specified, the assembly transfer structure described below is by default a guide rail structure consisting of a slider and a guide rail, but this does not limit the form of the assembly transfer structure.

[0041] According to one embodiment of the present invention, the molding chamber has the structure or mounting state shown in FIG. 2 . A base 33 is disposed below the chamber 11, which can stably support the chamber 11 on the rack 32 during the additive manufacturing stage and maintain a predetermined force to ensure a sealing effect between the chamber and the rack. Specifically, referring to FIG. 6 , in some embodiments, the top of the chamber 11 can include a flange structure 34, and the flange structure 34 and the entire periphery of the opening secured in the rack 32 can be sealed by the upward force of the chamber 11. In this way, the chamber 11 can be integrally connected to the rack 32. When the chamber 11 is attached to the rack 32, the rack 32 itself does not provide a fixing effect to the chamber 11, but rather the fixing of support is achieved via the lower base 33. Furthermore, it can be seen that the first part 14a and the second part 14b of the assembly transfer structure are also staggered rather than being joined together to create a sealing effect. The supporting function of the base 33 on the chamber 11 can be completed through one or more hydraulic devices, for example, four hydraulic devices (not shown) are mounted on the base, which can provide a predetermined upward supporting force on the chamber 11, and the magnitude of the supporting force can be monitored in real time through a pressure sensor, when the chamber 11 needs to be separated from the rack 32, the hydraulic device releases the pressure, the support arm retracts, and the chamber 11 moves slowly downward, thereby separating from the rack 32, and when they are separated to a predetermined distance, the first part 14a and the second part 14b can come into contact with each other, completing the cooperation.

[0042] According to one embodiment of the present invention, the molding chamber 10 is in the removal state shown in Fig. 3. During the removal process of the chamber 11, the driving device 12 first drives the molding table 13 to descend to a predetermined height within the chamber 11, ensuring that at least the top layer of the powder layer / structure 31 after the descent is lower than the height of the top end of the chamber 11 to prevent the powder build material 30 remaining in the chamber 11 from overflowing from the chamber 11 during the transfer process. The driving device 12 then controls itself to descend along the Z-axis direction, retreating into the chamber 11 and being removed. The driving device 12 includes an elevator unit and a driving unit that controls the elevation and lowering of the elevator unit. It should be understood that the described elevation and lowering of the driving device 12 (moving along the Z-axis) refers to the operating behavior of the elevator unit. As can be seen, in each drawing, only the elevator unit is depicted as a schematic representation of the driving device 12. Subsequently, the hydraulic device on the base 33 retracts, and the rack 32 itself does not provide a fixing action to the chamber 11. Simultaneously with the retraction of the hydraulic device, the chamber 11 also moves toward the base 33 (i.e., downward movement in the schematic diagram), thereby gradually separating from the rack 32 and moving downwards on the rack 32 until the first part 14a contacts the second part 14b, and in particular, fits into the second part 14b. At this point, the first part 14a can slide along the Y direction on the second part 14b, i.e., the chamber 11 can slide in the Y direction along the second part 14b under the action of the first part 14a. At this point, the support switching is completed, i.e., the support by the base 33 is transferred to the support by the second part 14b. At this time, the chamber 11 and the base 33 are separated, and the chamber 11 can slide out of the additive manufacturing apparatus along the y axis along the trajectory direction of the second part 14b, completing the removal process.

[0043] Similar to the drive device 12, the hydraulic device on the base 33 has a lifting rod 332 and a base (sometimes referred to as a drive) 331 (see Figure 3) that drives the lifting rod 332 to move up and down along the Z-axis direction.

[0044] In some embodiments, the base 33 itself can also be moved and controlled by the drive device 12, for example, the telescopic portion of the drive device 12 is arranged as a ball screw, and the base 33 is attached to the ball screw, and the rotation of the ball screw causes linear movement, thereby realizing a support action for the chamber.

[0045] In the process of attaching the chamber 11, first, the chamber 11 (via the first part 14a) is slid into the second part 14b of the assembly transfer structure so that the chamber 11 faces the target attachment position on the rack 32. In this process, the chamber 11 is carefully slid until it is directly below the target attachment position. Once the chamber 11 is positioned directly below the target attachment position, the raising process of the base 33 begins, and the base 33, as a single support, lifts the chamber 11 upward to the target attachment position through a lifting motion and attaches it to the rack 32. Once the chamber 11 is successfully attached to the target position, the drive device 12 moves upward along the Z-axis direction and extends into the interior of the chamber 11, and its other end portion comes into close contact with the support base 13b, ensuring a stable connection between the support base 13b and the chamber 11 and also helping to maintain the horizontal and vertical position of the support base 13b; through the action of the drive device 12, the support base 13b can move up and down accurately within the chamber 11 in the additive manufacturing process to build the structure 31 layer by layer.

[0046] To ensure that the drive device 12 can effectively drive the lifting and lowering movement of the molding table 13, in one embodiment of the present invention, a detachable connection structure is used at the end of the drive device 12 to the support table 13b, thereby achieving a tight connection and maintaining stability. For example, one possible connection structure is a magnetic attraction connection, in which contact between the end (top) of the drive device 12 and the support table 13b generates a magnetic force, thereby firmly connecting them together. This magnetic attraction connection is detachable because the drive device 12 and the support table 13b can be separated by canceling the magnetic force as needed. Other possible fastening structures can also be considered to replace or complement the magnetic attraction connection, including screw structures, latch structures, retaining ring structures, etc. Each structure has its own advantages and applicability and can be selected based on actual needs. Regardless of which connection method is used, they all aim to support a firm connection between the support table 13b and the chamber 11 to ensure accurate additive manufacturing operations.

[0047] In one embodiment of the present invention, the assembly transfer structure of chamber 11 and a transfer device (not shown) work in cooperation to provide for fast loading / unloading and / or transfer in an additive manufacturing apparatus.

[0048] The transfer device is an automated device (e.g., an AGV trolley), typically with autonomous navigation and steering capabilities, capable of transporting and moving the molding chamber 10, transferring the molding chamber 10 from one location to another, for example, from a storage area to an additive manufacturing apparatus, or from an additive manufacturing apparatus to a storage area. The transfer device may be equipped in different ways. For example, the transfer device may be equipped with a structure similar to the second portion 14b, such as a slide rail, so that the molding chamber 10 can slide directly from the transfer device to the second portion 14b. The transfer device may also be equipped with a clamping device that can clamp the molding chamber 10 and secure it to the second portion 14b, thereby ensuring a safe and reliable transfer process.

[0049] It should be particularly clear that the mounting, removal, and transfer of chamber 11 described above does not only refer to these operations of chamber 11 itself, but also includes other assemblies associated therewith. For example, in a removal or transfer process, these operations are not limited to the mounting or movement of chamber 11 alone, but also include a series of related steps, such as the processing of mold platform 13 already mounted within chamber 11, structure 31 above mold platform 13 that has already completed the shaping process, and powder build material 30 residing within chamber 11. In the mounting phase, these operations also encompass the placement of mold platform 13, although the mounting of chamber 11 may be considered separately to the extent possible, after which mold platform 13 (particularly mold base plate 13a) can be further mounted within chamber 11. It should be clarified that in the mounting, removal and transfer processes described above, operation of the drive device 12 is excluded, i.e., the drive device 12 retracts during the process of the molding table 13 being released from the chamber 11 and is not involved in the above-mentioned mounting, removal and transfer processes.

[0050] In one embodiment of the present invention, the base 33 is arranged as part of the additive manufacturing apparatus, wherein the first part 14a of the assembly transfer structure is arranged at or near the bottom of the chamber 11 and the second part 14b is arranged on the base 33.

[0051] In the example shown in FIG. 4 , the first portion 14a of the assembly transfer structure is disposed at the bottom of the chamber 11, and the second portion 14b is disposed at the top of the base 33. This configuration allows the chamber 11 to slide downward to integrate with the base 33 and position the chamber 11 at a predetermined position in the additive manufacturing apparatus. Specifically, when the chamber 11 needs to be attached, the chamber 11 is slid to the top of the base 33 to contact the second portion 14b, and the base 33 is then raised to drive the chamber 11 to move to the target attachment position and attach it to the rack 32. When the chamber 11 needs to be removed or transported, assuming that the lifting device 12 has completed retraction and disengagement from within the chamber 11, the base 33 moves in a direction away from the chamber 11 to allow the chamber 11 to disengage from the rack 32 and subsequently slide out from within the second portion 14b at the top of the base 33.

[0052] In the example shown in FIG. 5 , the first part 14a of the assembly transfer structure is positioned close to the bottom of the chamber 11, specifically, close to the bottom of the outer wall of the chamber 11, and the second part 14b is positioned on one side of the base 33, i.e., on one side of the lifting rod 332 shown in FIG. 3 . This configuration allows the chamber 11 to slide into the base 33 from the side and then connect with the second part 14b. Specifically, when the chamber 11 needs to be attached, the chamber 11 is slid onto one side of the base 33 (particularly the lifting rod 332 shown in FIG. 3 ) and brought into contact with the second part 14b. At this time, the lifting rod 332 is in a retracted state and is positioned slightly at the height of the second part 14b in the Z-axis direction. The lifting rod 332 is then raised to contact the bottom of the chamber 11, and the chamber 11 is then moved to the target attachment position and attached to the rack 32. When the chamber 11 needs to be removed or transported, the base 33 is moved away from the chamber 11 (the lifting rod 332 is retracted), provided that the lifting device 12 retracts and disengages from within the chamber 11, causing the chamber 11 to disengage from the rack 32 and gradually lower to contact the second part 14b; at this point, the first part 14a can slide along the Y direction on the second part 14b, i.e., the chamber 11 can also slide along the Y direction on the second part 14b under the action of the first part 14a, and the chamber 11 can slide out of the additive manufacturing apparatus along the second part 14b, completing the removal of the chamber 11.

[0053] According to one embodiment of the present invention, the rack has a structure shown in Fig. 6. A flange structure 34 is disposed on the rack 32, and the chamber 11 is attached to the rack 32 via the flange structure 34. Specifically, the flange structure 34 can be made of a sturdy material, such as metal or a synthetic material, and designed to have a structure compatible with the chamber 11, ensuring effective sealing. A sealing gasket or sealing ring may typically be disposed around the connection point between the chamber 11 and the rack 32 to ensure no leakage of material (powder build material 30) or gas (e.g., inert gas injected into the molding chamber) during the operating process.

[0054] 1 to 5, the assembly transfer structures are all depicted as guide rail structures composed of sliders and guide rails, but it should be understood that any specific form of the assembly transfer structure included in the present invention, such as a latch structure, a retaining ring structure, a screw structure, a magnetic attraction structure, etc., is within the scope of protection of the present invention. Therefore, based on different application needs and specific circumstances, various embodiments of the present invention can provide flexible options to meet the needs of different users.

[0055] For example, for certain applications, a latching structure may be a more appropriate choice because it provides additional security and prevents accidental removal or loosening. In such situations, the first portion 14a can be designed as a latch, and the second portion 14b can have a corresponding latch receptacle to ensure a firm connection during the assembly process. A retaining ring structure may be suitable for applications requiring frequent removal and assembly because it allows for quick connection and release, improving operational convenience. A threaded structure can provide strong fastening force and is an ideal choice for applications requiring higher structural stability. A magnetic attraction structure can be used in applications requiring reduced mechanical contact during the removal process, which can reduce wear and maintenance. A magnetic element can be introduced between the first portion 14a and the second portion 14b to achieve a magnetic attraction effect, generating a magnetic force when they come into contact and dissipating the magnetic force when the contact is released, thereby enabling quick removal and assembly.

[0056] In other words, various embodiments of the present invention provide users with multiple alternative assembly transfer structure configurations to accommodate different application scenarios and needs, thereby providing greater flexibility. Regardless of which assembly transfer structure is selected, all can be quickly installed, removed, and maintained within the additive manufacturing device, thereby increasing the efficiency and operability of the device.

[0057] In alternative applications of these assembly transfer structures, some embodiments of the present invention are alternatives. For example, when the rack 32 and the chamber 11 are connected via screws, the screw structure can firmly and rigidly fix the chamber 11 to the rack 32, and in such a situation, the base 33 is an alternative assembly, and the screw structure itself can provide sufficient structural stability, so the base 33 is no longer needed in such a situation.

[0058] The assembly transfer structure provided by the present invention enables the molding chamber to be quickly installed and removed from the additive manufacturing apparatus, facilitating the rapid post-processing of the molding table after additive manufacturing is completed and the rapid replacement of the molding chamber, significantly reducing the time required for maintenance and reducing potential risks in the maintenance process. It is particularly worth emphasizing that this design helps reduce the waste of powder material and prevent potential damage to the apparatus, thereby significantly improving production efficiency.

[0059] A second aspect of the present invention provides a powder chamber in an additive manufacturing apparatus.

[0060] According to one embodiment of the present invention, the powder chamber 20 has a structure shown in FIG. 7 . The powder chamber 20 is composed of a chamber 21 and a support base 24. The drive device 22 can be connected to or separated from the support base 24. Specifically, the drive device 22 can include a driver (not shown) and a ball screw, which can move vertically along the chamber 21 under the action of the driver. A quick-release assembly, such as a zero-point positioner, is attached to the top end of the ball screw or the bottom of the support base 24. The ball screw can be precisely connected via the zero-point positioner and the support base 24, thereby realizing the connection or disconnection between the screw and the support base 24. The material storage cavity 25 is a space in a portion of the chamber 21, i.e., the space above the support base 24, for storing the powder build material 30 to be processed. The support platform 24 is positioned at the bottom of the material storage cavity 25 and can move up and down along the inner wall of the material storage cavity 25, and the upper part of the support platform 24 is used to support the powder build material 30 in the material storage cavity 25 and also acts as a piston, and can move up and down along the inner wall of the chamber 21 under the action of the drive device 22.

[0061] 1 to 5 is supplied from the powder build material 30 in chamber 11, which is typically provided by a powder laying device, which transports and evenly lays the powder build material 30 overflowing from the top of chamber 21 onto the molding table 13 of chamber 11, and sinters / melts it with a high-energy beam to build a structure 31. For example, in an additive manufacturing process, each time the construction of each layer of structure 31 is completed, drive device 12 controls molding table 13 to descend a precise distance, typically the thickness of one layer, and then drive device 22 drives powder build material 30 in material storage cavity 25 to rise by the thickness of one layer. The powder laying device transports the powder build material 30 overflowing from the top of material storage cavity 25 above molding table 13, where it is evenly laid down, allowing structure 31 to begin construction of the next layer. This process is repeated to gradually build the required structure 31.

[0062] This embodiment also has an assembly transfer structure, the design of which allows the powder chamber 20 to be quickly attached to or detached from the additive manufacturing apparatus, and its application scenarios are suitable for, for example, when maintenance, cleaning, or replacement of build material is required. The assembly transfer structure can be quickly separated, allowing the powder chamber 20 to be easily removed from the additive manufacturing apparatus. This process significantly reduces maintenance time and reduces risks in the maintenance process, such as reducing waste of powder material and potential damage to the apparatus.

[0063] The assembly transfer structure is arranged in two parts, a first part 14a is arranged in the chamber 11 and a second part 14b is arranged in the additive manufacturing apparatus, preferably in the rack 32 of the additive manufacturing apparatus.

[0064] It should be understood that the assembly transfer structure applied to the powder chamber 20 is similar to the assembly transfer structure applied to the molding chamber 10 shown in Figures 1 to 5, and that the powder chamber 20 can be quickly installed, removed, or replaced in the additive manufacturing apparatus. The assembly transfer structure also has multiple alternative forms, such as a guide rail structure consisting of a slider and a guide rail, a latch structure, a retaining ring structure, a screw structure, a magnetic attraction structure, etc. It can be understood that the powder chamber 20 has the same application structure and implementation process as those shown in Figures 1 to 6, and therefore no further description will be provided here.

[0065] A third aspect of the present invention provides a powder laying device applicable to an additive manufacturing apparatus (i.e., applicable to both the powder chamber and the molding chamber), which transports powder build material overflowing from the powder chamber to the molding chamber and lays it uniformly, specifically on the molding table of the molding chamber. In practical application, the laying device can take the form of a rolling structure, i.e., a rolling member such as a roller or drum, or can take the form of a planar movement such as a scraper, and the rolling structure has a better powder laying effect for laying ultrafine metal powder.

[0066] When using ultrafine metal powder (a type of powder build material) for powder laying, the ultrafine metal powder often has low fluidity, and even the microscopic forces between the powder particles can cause serious sticking or agglomeration of the powder, which significantly reduces the powder laying effect and makes it difficult to lay the powder evenly.

[0067] To overcome this problem, the inventors conducted further research and experiments and discovered a unique phenomenon: if metal powder adheres to the roller, it can have a very beneficial effect on powder application. This is because if a thin layer of metal powder adheres to the roller, when the powder is applied, the powder to be applied will come into contact with the powder that has adhered to the roller, but will not come into direct contact with the material surface of the roller. In this situation, the existing metal powder acts as a kind of barrier, preventing direct adhesion and agglomeration between the new powder and the roller surface. This barrier effect greatly improves the powder application effect.

[0068] Therefore, by depositing a thin layer of metal powder on the roller, the powder laying device can more effectively and evenly distribute the powder onto the bed during the powder laying operation without interference from application issues. This discovery makes the powder laying process more efficient and feasible when using difficult-to-process build materials such as ultra-fine metal powders, thereby improving the quality and uniformity of the powder laying.

[0069] The powder spreading device of the present invention will be described in detail below, taking a roller as a specific example.

[0070] According to one embodiment of the present invention, the roller exhibits a movement process shown in Fig. 8. The roller 41 is disposed in the molding chamber 43 of the additive manufacturing apparatus 40, specifically, above the powder chamber 20 and the molding chamber 10, i.e., at the bottom of the molding chamber 43, in other words, above the rack 32. When the powder build material (i.e., powder) 30 to be laid above the material storage cavity 25 is formed, the roller 41 moves from the left side to the right of the molding chamber 43, moving the laid powder to the right as it passes above the powder chamber 20, and transporting and laying it above the molding table 13. The powder is applied to the roller 41, for example, by a rolling motion as it passes above the powder chamber 20. In the powder laying process, the roller first passes through the powder chamber 20 area, and as it passes through this area, the roller 41 not only picks up at least one applied layer of metal powder, but also continues to move excess metal powder towards the molding table 13, thereby ensuring that the powder is laid evenly on the molding table 13.

[0071] To achieve pre-application of powder to the roller, at least several approaches can be used:

[0072] 1) A special material is applied to the surface of roller 41 to form a special coating layer. For example, specifically, before the pre-adhesion process, the surface of roller 41 is first subjected to a material application process. Through research, the inventors have found that coating the surface of roller 41 with a layer of parylene coating material has a significant effect. This coating material can achieve an adhesion force that adheres the powder to the surface of roller 41, typically achieving an adhesion layer thickness of 10 to 80 μm, preferably 10 to 50 μm. When using roller 41 coated with such powder, excellent application of ultrafine metal powder can be achieved.

[0073] 2) An electrostatic generating device 411 is installed inside the roller 41 (see FIG. 10). The electrostatic generating device 411 generates electrostatic action on the surface of the roller 41, making the powder adhere to the surface of the roller 41. The electrostatic action effectively attracts the powder and helps to disperse the powder during the laying process, thereby improving the uniformity of the powder laying.

[0074] 3) A heating device (not shown) is installed inside the roller 41 to preheat the surface of the roller 41 before the pre-application process, providing more favorable conditions for pre-application of the powder. The heating device heats the surface of the roller 41 to a predetermined temperature, which is usually set to a temperature that can effectively improve the adhesion between the powder and the surface of the roller 41. Once the surface of the roller 41 is preheated to an appropriate temperature, the powder to be applied begins to come into contact with the roller 41. Because the surface of the roller 41 is preheated, the contact between the powder and the roller 41 makes it easier for the powder to adhere to the surface of the roller 41. Such pre-heating treatment helps to reduce powder sticking or agglomeration, improves the adhesion between the powder and the roller 41, and thereby achieves a good powder application effect in the powder application process.

[0075] 4) Creating a fine texture on the surface of the roller 41 increases the adhesion of the powder. Such a fine texture can increase the surface area and improve the contact points between the powder and the surface of the roller 41, thereby strengthening the adhesion of the powder. The fine texture can be achieved by forming a fine texture on the surface of the roller 41 using a physical or chemical method, such as laser etching or corrosion technology. In some engineering applications, such a fine texture can also be formed by arranging an uneven microstructure on the surface of the roller. That is, by arranging an uneven microstructure on the surface of the roller 41, the adhesive effect of the roller 41 on ultrafine powder can be greatly increased. It should be noted here that the distance between the highest and lowest points of the uneven structure on the surface of the roller 41 is related to the particle size of the powder.

[0076] In practical applications, the pre-application of powder to roller 41 can utilize a combination of the above methods to ensure optimal powder application and performance. For example, in some situations, a special material coating can be applied to the surface of roller 41 to form a coating layer with good adhesion, and an electrostatic generating device 411 can be installed inside roller 41 to enhance the powder's adhesion. This combination effectively improves adhesion and ensures uniform distribution of the powder during the application process. For example, in some situations, a heating device and fine texture treatment can be simultaneously used to increase the adhesion of the surface of roller 41. The surface of pre-heated roller 41 can provide better adhesion in the initial stage, and the fine texture can increase the number of contact points and enhance powder adhesion.

[0077] The roller 41 can rotate during the powder application process. In some embodiments of the present invention, the linear speed of the roller 41 rotation is preferably the same as the linear speed at which the case wall to which the roller 41 is attached moves relative to the molding table 13, thereby avoiding relative sliding between the roller 41 and the molding table 13. Specifically, by contacting and pre-applying the powder to the surface of the roller 41, a rotation speed that matches the movement speed of the molding table 13 ensures cooperative movement of the powder between the roller 41 and the molding table 13, minimizing relative sliding between the powder and the roller 41 and thereby improving powder application. Matching the rotation speed of the roller 41 also helps ensure that the powder is uniformly applied to the surface of the molding table 13, transporting and dispersing the powder by the roller 41 in a manner that matches the movement speed of the molding table 13, thereby avoiding uneven powder application and deposition.

[0078] The powder laying device of the present invention is applicable to additive manufacturing apparatuses, and particularly when it operates above a powder chamber and a molding chamber, the specific structures of the powder chamber and the molding chamber are not limited and may be structures such as those shown in Fig. 8 . It is applicable not only to ordinary powder chambers and molding chambers, but also to molding chambers having assembly transfer structures shown in Figs. 1 to 5 and / or the powder chamber 20 shown in Fig. 7 . For example, in the additive manufacturing apparatus 400 shown in Fig. 9 , it encompasses the molding chamber 10 shown in Figs. 1 to 5 and the powder chamber 20 shown in Fig. 7 . It should be understood that the specific inclusions are not limited to those shown in the figures and should be based on the interpretation and definitions shown in the figures described above. More specifically, the powder laying device of the present invention is applicable to the molding chamber of the additive manufacturing apparatus provided by the first aspect of the present invention described above and the powder chamber of the additive manufacturing apparatus provided by the second aspect of the present invention. That is, the additive manufacturing apparatus 40 (see FIG. 9) provided by the present invention includes the molding chamber 10 provided by the first aspect of the present invention described above, the powder chamber 20 provided by the second aspect of the present invention, and the powder laying device provided by the third aspect of the present invention. The additive manufacturing apparatus 40 shown in FIGS. 8 and 9 further includes a high-energy beam emitting device 42 for selectively generating a high-energy beam (e.g., a laser beam) to act on the powder surface on the molding table 13 and sinter / melt the powder surface, thereby building a structure layer by layer.

[0079] A fourth aspect of the present invention provides a molding chamber adapted for use in an additive manufacturing apparatus.

[0080] The mold chamber serves as the working chamber for additive manufacturing and is located above the powder chamber because it must contain the build materials required for the molding process, typically powdered metallic materials, which are processed and treated in the mold chamber to build the structure. The mold chamber is also located above the mold chamber because this is where the structure is ultimately built; in an additive manufacturing process, powder material is transported from inside the mold chamber to the mold table of the mold chamber and then laid down layer by layer by techniques such as high energy beam sintering or melting to gradually build the required object.

[0081] The term "molding chamber" as used in this application refers to an enclosed space in an additive manufacturing device, typically comprising a molding table, an optical path system, and surrounding sheet metal structures. The main function of the molding chamber is to ensure the successful construction of a structure by providing a controlled environment during the additive manufacturing process. The closed nature of the molding chamber helps to prevent external impurities from entering the manufacturing process, and also helps to maintain the required atmospheric and temperature conditions.

[0082] It should be noted that the definition of the molding chamber usually does not include the space inside the molding chamber. In actual additive manufacturing, to ensure that the gas environment in the molding chamber meets the specified requirements, it is usually necessary to use a gas cleaning device to repeat gas cleaning operations multiple times. For example, the gas cleaning process, i.e., the process of removing the air, can be carried out by injecting an inert gas (e.g., argon gas) into the molding chamber to create an inert gas environment in the molding chamber, or by removing the gas from the molding chamber through a vacuum exhaust device to remove the air from the molding chamber.

[0083] During the gas cleaning process, the equipment is often in a shutdown state, waiting for various controllable factors to reach the required levels before the printing or additive manufacturing operation can continue, resulting in reduced equipment utilization. The length of the gas cleaning phase is usually considered unavoidable because the gas environment within the molding chamber is critical to the quality of the final structure, and therefore shortening the gas cleaning time may sacrifice structure quality, which is undesirable.

[0084] However, the inventors' research has revealed that the length of the gas scrubbing step is closely related to the volume of the molding chamber. Simply put, the larger the volume of the molding chamber, the longer the gas scrubbing step, and molding chambers with smaller volumes require shorter gas scrubbing times. Prior art techniques often use molding chambers with fixed volumes, which limits the possibility of shortening the gas scrubbing time. However, the time for the gas scrubbing step can be reduced by changing the volume of the molding chamber, provided that the quality of the gas scrubbing is maintained.

[0085] The present invention therefore provides a molding chamber with a variable volume, which can be adjusted between the additive manufacturing phase and the gas flushing phase, and such flexible adjustment allows the required gas environment to be reached more quickly during the gas flushing phase, thereby increasing the utilization rate of the equipment and not sacrificing the quality of the structure.

[0086] Specifically, the molding chamber of the present invention has at least a first volume corresponding to the additive manufacturing stage and a second volume corresponding to the gas cleaning stage, with the first volume being larger than the second volume, thereby adjusting the container of the molding chamber for different stages. The so-called "first volume corresponding to the additive manufacturing stage" refers to the molding chamber having the first volume during the additive manufacturing stage (or 3D printing stage). The so-called "second volume corresponding to the gas cleaning stage" refers to the molding chamber having the second volume during the gas cleaning stage (i.e., before 3D printing or between two 3D printings). Because the second volume is smaller than the first volume, gas cleaning is performed using a molding chamber with a smaller volume during the gas cleaning stage, and then the larger volume of the molding chamber is restored during the additive manufacturing stage, thereby shortening the gas cleaning time and improving the equipment utilization rate.

[0087] According to one embodiment of the present invention, the molding chamber has a structure shown in Figures 11 and 12. The molding chamber 43 includes a first wall portion 431a and a second wall portion 431b arranged relative to each other, and the first wall portion 431a and the second wall portion 431b can move relative to each other to change the volume of the molding chamber.

[0088] In the example of Figure 11, the first wall portion 431a and the second wall portion 431b are side walls of the molding chamber 43, and the molding chamber 41 further includes a third wall portion 431c and a fourth wall portion 431d that are fixedly arranged relative to each other, and the third wall portion 431c and the fourth wall portion 431d are the top wall and bottom wall of the molding chamber 43, respectively.

[0089] In the example of Figure 12, the first wall portion 431a and the second wall portion 431b are the top wall and bottom wall of the molding chamber 43, respectively, and the molding chamber 41 further includes a third wall portion 431c and a fourth wall portion 431d that are fixedly arranged relative to each other, and the third wall portion 431c and the fourth wall portion 431d are side walls of the molding chamber 43.

[0090] Specifically, during the additive manufacturing stage, a larger volume of the molding chamber 43 is required to accommodate the structure being built. In this case, the first wall 431a and the second wall 431b move relative to each other (or remain in their original maximized state) to expand the volume of the molding chamber 43. Performing the additive manufacturing process within the larger volume of the molding chamber 43 involves powder deposition, laser scanning, or other processing steps to build the structure layer by layer. The larger volume allows for more powder material to be accommodated, thereby supporting the creation of larger or more numerous structures. After the primary additive manufacturing is complete, the molding chamber 43 must undergo a gas flushing operation to prepare for the next cycle of work. During this stage, the first wall 431a and the second wall 431b move relative to each other to reduce the volume of the molding chamber. Using a gas flushing device to perform a gas flushing operation typically involves evacuating the air in the molding chamber 43 to ensure that the gas content in the molding cavity area is within a controllable range; for example, the smaller the volume, the shorter the time required for injecting an inert gas or using a vacuum pumping device to achieve the required gas environment. Once the gas flushing operation is complete, the positions of the first wall 431 a and the second wall 431 b are readjusted to restore the larger volume of the molding chamber 43 and prepare the apparatus for the additive manufacturing stage of the next cycle.

[0091] In some embodiments, in implementations where the first wall 431a and the second wall 431b move relative to each other, for example, they move on the third wall 431c and the fourth wall 431d using a slide rail structure.

[0092] According to one embodiment of the present invention, the molding chamber has a structure shown in FIG. 13. In this embodiment, the first wall 431a and the second wall 431b are separate components that are arranged inside the side walls of the molding chamber 43 and are parallel to the side walls. During the gas cleaning stage, the first wall 431a and the second wall 431b move relative to each other to change the volume of the molding chamber 43. This design allows for highly flexible adjustment of the size of the molding chamber 43 without sacrificing performance. In actual operation, when the volume of the molding chamber 43 needs to be reduced, the first wall 431a and the second wall 431b move relative to each other toward the center, gradually moving away from the side walls of the molding chamber 43, thereby keeping the side walls of the molding chamber 43 fixed.

[0093] It is worth noting that although the example of Figure 13 depicts relative sidewall movement between the first wall portion 431a and the second wall portion 431b, in an alternative embodiment, the first wall portion 431a and the second wall portion 431b are also arranged parallel to the inside of the top and bottom walls of the molding chamber 43, respectively, so as to remain fixed when the top and bottom walls of the molding chamber 43 are in the gas cleaning stage, and the first wall portion 431a and the second wall portion 431b move relative to the top and bottom walls, and volume adjustment can be achieved in the same manner.

[0094] In Figures 11 to 13, part (a) shows the position where the first wall portion 431a and the second wall portion 431b are in the molding chamber 43 during the additive manufacturing stage, and part (b) shows the position where the first wall portion 431a and the second wall portion 431b are in the molding chamber 43 during the gas cleaning stage.As can be seen from the figures, the corresponding volume V1 of the molding chamber 43 during the additive manufacturing stage is larger than the corresponding volume V2 during the gas cleaning stage.

[0095] In some embodiments, the relative movement of the first wall 12 and the second wall 14 can be achieved by controlling a movable device, which can be realized using mechanisms such as slide rails, gears, racks, etc.

[0096] It should be understood that the described relative movement of the first wall portion 431a and the second wall portion 431b includes both the first wall portion 431a and the second wall portion 431b being in a moving state, or only one of them moving while the other remains fixed.

[0097] In some embodiments, the molding chamber 43 includes a contraction-expansion device for realizing a variable volume of the molding chamber 43. The contraction-expansion device is present inside the molding chamber at least during the gas flushing stage, and the volume of the contraction-expansion device has a contracted state and an expanded state, whereby the volume of the contraction-expansion device is in a contracted state during the additive manufacturing stage and in an expanded state during the gas flushing stage. That is, during the gas flushing stage, the volume of the contraction-expansion device is in an expanded state, thereby occupying a larger space in the molding chamber and reducing the space required for gas flushing inside the molding chamber. During the additive manufacturing stage, the contraction-expansion device can be restored to its contracted state, thereby allowing the molding chamber to process a structure with a larger volume.

[0098] The collapsible and expandable device has various possible forms, for example, in the example shown in Fig. 15, the collapsible and expandable device is a flexible inflatable device 51, which can freely adjust its dimensions as needed, thereby realizing the change in the volume of the molding chamber 43. The design inspiration of the inflatable device 51 is somewhat similar to a balloon, but the structure and material aspects are somewhat different, and the main purpose of the inflatable device 51 is to adjust the volume of the molding chamber at different work stages to meet specific needs.

[0099] Specifically, the outer surface of the inflatable device 51 is made of a robust material, ensuring that it can maintain its shape and stability in an expanded state and is airtight, preventing external gas from penetrating into the molding chamber. As shown in FIG. 15(b), during the gas flushing stage of the additive manufacturing apparatus, the inflatable device 51 is filled with air and expanded to its expanded state. At this time, the expandable device 51 occupies a portion of the space inside the molding chamber 43, thereby reducing the effective space required for gas flushing within the molding chamber 43, helping to more intensively treat the atmosphere during the gas flushing process, improving the efficiency of gas flushing, and reducing the time required for gas flushing. As shown in FIG. 15(a), during the additive manufacturing stage, when the apparatus needs to process a structure, the inflatable device 51 is released and returned to its deflated state, freeing up more internal space and allowing the molding chamber 43 to print and mold structures with a larger volume.

[0100] 15, in some implementations, the walls of the molding chamber 43 are provided with air passages 52 in fluid communication with the inflatable device, thereby enabling the filling and deflation of the flexible inflatable device 51 through the air passages 52. It should be appreciated that an air compressor can be used to fill the inflation device 51 with gas through the air passages 52, and a vacuum pumping device can be used to fill the inflation device 52 with gas through the air passages 52.

[0101] For example, the air flow path 52 can be sealed and connected to the side wall of the molding chamber 43, and the opening and closing of the air flow path 52 can be controlled by a valve. The outside of the air flow path 52 can be connected to a gas injection device (not shown). The air flow path 52 can be located at one end of the molding chamber and connected to a flexible inflatable device 51, which expands when gas is injected (note that the gas in the inflatable device 51 can be isolated from the space within the molding chamber 43). After printing is completed, the inflatable device 51 expands when gas is injected, thereby occupying a substantial space within the molding chamber 43. This substantial space compresses the space within the molding chamber 43. If gas flushing is performed at this time, the gas flushing time can be significantly reduced. After waiting for the completion of gas flushing and opening the valve, the inflatable device 51 shrinks, thereby restoring the actual space within the molding chamber 43.

[0102] In some embodiments, the inflatable device 51 has a maximum expansion limit. If the gas cleaning process is a vacuum evacuation process, the maximum expansion limit can ensure that the inflatable device 51 does not expand infinitely due to the vacuum in the molding chamber 43 and cause contamination or impact on other assemblies in the molding chamber 43. Specifically, when performing a gas cleaning operation on an additive manufacturing apparatus, it is usually necessary to evacuate the interior of the molding chamber 43 to ensure that the internal atmosphere meets requirements. In this process, the inflatable device 51 is in an expanded state so as to occupy a portion of the space inside the molding chamber 43. However, if the inflatable device 51 does not have a maximum expansion limit, it can continue to expand, which would affect the vacuum in the molding chamber 43 and cause a series of problems, such as impacts on the quality of the structure, safety during the manufacturing process, and the lifespan of the apparatus. Therefore, the existence of a maximum expansion limit ensures that the behavior of the inflatable device 51 during the gas cleaning process is strictly controlled. Once the maximum expansion limit is reached, the device will not expand any further, thereby preventing any negative impact on the vacuum level inside the molding chamber 43. This helps ensure stability in the gas flushing process and control of the atmosphere inside the molding chamber 43, while reducing potential risks and the possibility of equipment failure.

[0103] In one possible form of the collapsible-expandable device, for example the example shown in FIG. 16, the collapsible-expandable device is an expandable accordion-style folding assembly 53.

[0104] The extendable accordion-style folding assembly 53 preferably comprises a series of foldable plates interconnected by connecting members between the plates. At the start of the gas scrubbing process, the extendable assembly is in a contracted state, occupies a smaller space, and does not affect the internal volume of the molding chamber 43. However, when it is necessary to perform the gas scrubbing operation, the extendable assembly can be easily expanded to occupy a larger space, filling a portion of the molding chamber 43.

[0105] In some embodiments, the extendable accordion-style folding assembly 53 is pulled and moved within the molding chamber 43 via a single movable device, thereby enabling seamless switching between the additive manufacturing stage and the gas cleaning stage. Specifically, the movable device can control the position of the accordion-style folding assembly 53 during different operational stages. During the additive manufacturing process, the movable device can firmly push the accordion-style folding assembly 53 to one side of the molding chamber 43 (as shown in FIG. 16(a)). At this time, the accordion-style folding assembly 53 does not occupy the majority of the space in the molding chamber 43, leaving sufficient space for building a structure. Once additive manufacturing is complete and a gas cleaning operation is required, the movable device can simply pull the accordion-style folding assembly 53, causing it to unfold and occupy most of the space in the entire molding chamber 43 (as shown in FIG. 16(b)). Such a layout optimizes the space utilization of the molding chamber 43 and significantly reduces the air volume that needs to be processed within the molding chamber 43, thus allowing for faster and more effective gas scrubbing operations, thereby significantly shortening the gas scrubbing time.

[0106] In some embodiments, to ensure the quality and control of the gas scrubbing operation, the expandable accordion-style folding assembly 53 is made of an airtight material, which can effectively isolate the inside and outside of the assembly and ensure that the gas scrubbing operation is not affected by the external environment. In addition, a valve 54 can be used to connect the inside and outside of the accordion-style folding assembly 53, which can maintain the same air pressure inside and outside and allow the accordion-style folding assembly 53 to remain in an expanded state during the process of moving.

[0107] In situations where vacuum evacuation is required during the gas cleaning process, the design of the accordion-type folding assembly 53 has a certain strength to ensure that the material of the accordion-type folding assembly 53 will not be damaged or deformed under the vacuum conditions in the molding chamber 43. Such a design ensures that the accordion-type folding assembly 53 performs this function reliably at each stage, improves the gas cleaning efficiency of the molding chamber 43, and maintains the air quality and gas environment inside the molding chamber 43.

[0108] In some embodiments, to accommodate changes in the vacuum level within the molding chamber 43 during the gas flushing process, the collapsible / expandable device can be configured with two layers: an inner and an outer layer. The outer layer of the collapsible / expandable device is made of a material with sufficient strength and pressure resistance to at least ensure that changes in the vacuum level within the molding chamber will not cause deformation or damage. The inner layer of the collapsible / expandable device is made of an airtight material, which can be flexible. When the interior of the collapsible / expandable device is filled with gas from the outside, allowing the collapsible / expandable device to occupy the space within the molding chamber 43, the inner layer material maintains its designed shape due to the action of the outer layer material. It should be understood that in such a two-layer design of the collapsible / expandable device, whether the outer layer material of the collapsible / expandable device is breathable is an optional requirement.

[0109] According to one embodiment of the present invention, the application of the molding chamber in an additive manufacturing apparatus is shown with reference to Fig. 14. This embodiment further provides a vacuum exhaust device 45 for evacuating the molding chamber 43 in a gas flushing step, and an inert gas filling device 46 for injecting an inert gas into the molding chamber 43 in the gas flushing step. It should be understood that in some practical engineering applications, the vacuum exhaust device 45 and the inert gas filling device 46 may be referred to as a gas flushing device 44, either separately or in combination.

[0110] In some embodiments, to maintain the pressure in the molding chamber 43 at a safe threshold, a vacuum exhaust device 45 used in the gas cleaning process can be used to remove air from the molding chamber 43, and an inert gas filling device 46 can be used to introduce inert gas into the molding chamber 43. This method can improve the efficiency of gas cleaning and also ensure that a predetermined air pressure is maintained in the molding chamber 43 to prevent damage to the molding chamber 43 caused by excessively high or low pressure in the molding chamber 43, including, but not limited to, excessively low pressure in the molding chamber and external atmospheric pressure exerting excessive pressure on the structure of the molding chamber 43, resulting in deformation of the closure structure of the molding chamber 43.

[0111] In addition to the flexible inflatable device 51 shown in FIG. 15 and the expandable accordion-style folding assembly 53 shown in FIG. 16, there are other possible configurations of the contractible and expandable device, and the following are examples of some possible potential configurations:

[0112] Spring-loaded device The retractable and expandable device can include a spring (wrapped in an airtight material) to achieve automatic deployment and contraction. When pressure or tension is applied, the spring can expand the device and automatically restore it to its original state when released.

[0113] Mating Devices The device can consist of multiple members fitted together, which can be deployed separately to increase volume when inflation is required.

[0114] Magnetic Devices Magnetic materials or magnetic forces are used to control the deployment and contraction of the contraction-expandable device, and an external magnetic field affects the alignment of the internal material, thereby changing the volume of the device.

[0115] The molding chamber 43 of the present invention is applied to an additive manufacturing apparatus, and in particular, when it acts above a powder chamber and a molding chamber, the specific structure of the powder chamber and the molding chamber is not limited, and it can be applied not only to a normal powder chamber and a molding chamber, but also to a molding chamber and a powder chamber 20 having an assembly transfer structure as shown in FIG. 14 , and it should be understood that the specific inclusion content is not limited to what is shown in the figure, but should rely on the interpretation and definition given with respect to the above-mentioned figures in the preceding sentence.

[0116] More specifically, the molding chamber 43 of the present invention applies to the molding chamber of the additive manufacturing apparatus provided by the first aspect of the present invention described above, the powder chamber of the additive manufacturing apparatus provided by the second aspect of the present invention, and the powder laying device provided by the third aspect of the present invention (which can also be described as applying to the molding chamber 43 provided by the fourth aspect of the present invention). In other words, the additive manufacturing apparatus 40 (see FIG. 14) provided by the present invention includes the molding chamber 10 provided by the first aspect of the present invention described above, the powder chamber 20 provided by the second aspect of the present invention, the powder laying device provided by the third aspect of the present invention, and the molding chamber 43 provided by the fourth aspect of the present invention. The additive manufacturing apparatus 40 shown in FIG. 14 further includes a high-energy beam emitting device 42, a gas cleaning device 43, a vacuum evacuation device 45, and an inert gas filling device 46.

[0117] 17 is a model schematic diagram of one possible implementation of the gas cleaning device in an additive manufacturing apparatus, along with a schematic diagram of using a synchronous belt mechanism to achieve expansion and contraction of the contraction-expansion device 50. As shown in FIG. 17, the additive manufacturing apparatus 40 can include a molding chamber 43, a powder laying device 60, a high-energy beam emitting device 42, a gas cleaning device 44, the contraction-expansion device 50, a powder chamber 201, a powder chamber 202, and a molding table 13.

[0118] The gas cleaning device 44 can be connected to the side wall of the molding chamber 43 via a piping connection port. The gas cleaning device 44 can inject a gas such as filled helium gas or argon gas into the molding chamber 43, thereby discharging the air inside the molding chamber 43 and creating an inert gas environment inside the molding chamber 43. The gas cleaning device 44 can include a vacuum exhaust device 45 that evacuates the molding chamber 43 during the gas cleaning stage, and an inert gas filling device 46 that injects an inert gas into the molding chamber 43 during the gas cleaning stage.

[0119] FIG. 18a shows a schematic model diagram of a vacuum exhaust device in the additive manufacturing apparatus of FIG. 17. FIG. 18b shows a schematic model diagram of an inert gas filling device in the additive manufacturing apparatus of FIG. 17. As shown in FIGS. 17, 18a, and 18b, the vacuum exhaust device 45 can be connected to the interior space of the molding chamber 43 via piping members to extract air from the molding chamber 43, reducing the oxygen content in the molding area and preventing oxidation of the metal material. The inert gas filling device 46 can include an inert protective gas source disposed outside the molding chamber 43, which is connected to the interior space of the molding chamber 43 via piping members (e.g., a pressure gauge, a solenoid valve, etc.) to inject the inert protective gas into the molding chamber 43. The vacuum exhaust device 45 may further include an air outlet 412 and an air outlet 413 disposed within the molding chamber 43, a dust filtering unit 414 disposed outside the molding chamber 43, and a circulation fan 415. The air outlet 412 and the air outlet 413 are typically disposed on opposite sides of the molding chamber 43. In some embodiments, the oxygen content in the molding chamber 43 after gas cleaning may be less than 100 ppm.

[0120] In the above-described embodiment, the vacuum exhaust device 45 may include a vacuum pump and a piping system, which corresponds to the gas circulation system of the additive manufacturing apparatus 40 in FIG. 17 . During the printing process, the pumping of the inert gas can be stopped, and the gas in the sealed compartment can be circulated within a single closed system via the vacuum exhaust system 45. Of course, the above-described structural design is intended to achieve economy and compactness of the apparatus. However, when considering functionality alone, a separate vacuum exhaust system can be designed. The system may include a vacuum pump and piping, which is communicatively connected to the molding chamber. When it is necessary to quickly exhaust gas from the molding chamber, the vacuum exhaust system can be activated to quickly exhaust gas from the molding chamber.

[0121] FIG. 18c is a schematic model diagram of the expandable / contractible device 50 in the additive manufacturing apparatus of FIG. 17 in an open state. As shown in FIGS. 17 and 18c, the expandable / contractible device 50 may be a flexible accordion-type folding assembly 53 arranged on one side of the molding chamber 43. One side of the accordion-type folding assembly 53 is fixed to one side wall (e.g., the left side wall) of the molding chamber 43, and the other side is connected to a synchronous belt 62 via a connecting rod 61, which operates by driving a reducer and a pulley. The accordion-type folding assembly 53 moves within the molding chamber 43 by pulling the connecting rod 61 and the movable device (synchronous belt 62), i.e., it can perform opening and closing operations within the molding chamber 43. The operating process of the accordion-type folding assembly 53 will be described below.

[0122] For example, in an additive manufacturing process, the synchronous belt 62 can compress the accordion-style folding assembly 53 tightly against one side of the molding chamber 43, and the volume of the molding chamber 43 at this time is a first volume corresponding to the additive manufacturing stage, as shown in FIG. 17. If gas flushing is required after additive manufacturing is completed, the synchronous belt 62 can pull the accordion-style folding assembly 53 and move it toward another side of the molding chamber 43, as shown in FIG. 18c. The synchronous belt 62 can pull the accordion-style folding assembly 53 to occupy most of the space of the entire molding chamber 43, and the volume of the molding chamber 43 at this time is a second volume corresponding to the gas flushing stage, as shown in FIG. 18c. After gas flushing is completed, the synchronous belt 62 pulls the accordion-style folding assembly 53 and compresses it against the left wall of the molding chamber 43. This corresponds to performing gas cleaning using a small-volume molding chamber 43 in the gas cleaning stage, and then restoring the large volume of the molding chamber 43 to perform additive manufacturing in the additive manufacturing stage. Because the second volume is smaller than the first volume, this reduces the absolute space of the molding chamber 43, which helps to reduce gas cleaning time and improves equipment utilization rate.

[0123] The accordion-type folding assembly 53 is made of an airtight material that can separate the inside and outside of the assembly to make it airtight. In addition, the side walls of the mounting accordion-type folding assembly 53 connect the inside and outside of the folding assembly with a valve, so that the air pressure inside and outside of the accordion-type folding assembly 53 can be kept the same during the process of movement, and the accordion-type folding assembly 53 can be kept in the unfolded state.

[0124] FIG. 19 is a schematic diagram of a model of one possible implementation of an additive manufacturing apparatus having a gas scrubbing device, and is also a schematic diagram illustrating how the contraction-expansion device 50 is expanded and contracted using a motorized chamber mechanism. As shown in FIG. 19 , the contraction-expansion device 50 may be an expandable and contractible accordion-type folding assembly 53 disposed on one side of the molding chamber 43. One side of the accordion-type folding assembly 53 is fixed to one side wall (e.g., the left wall) of the molding chamber 43, and the other side is connected to a motorized chamber 63. The motorized chamber 63 may be a single-stage chamber or a multi-stage chamber, for example, a three-stage chamber. The accordion-type folding assembly 53 can move within the molding chamber 43 by pulling the motorized chamber 63, i.e., it performs opening and closing operations within the molding chamber 43. The operation process of the accordion-type folding assembly 53 will be described below.

[0125] During the additive manufacturing process, the motorized chamber 63 retracts, compressing the accordion-style folding assembly 53 tightly to one side of the molding chamber 43, where the volume of the molding chamber 43 is a first volume corresponding to the additive manufacturing stage. If gas flushing is required after additive manufacturing is completed, the motorized chamber 63 gradually expands, pulling the accordion-style folding assembly 53 to move it toward another side of the molding chamber 43. The motorized chamber 63 pulls the accordion-style folding assembly 53 to occupy most of the entire space of the molding chamber 43, where the volume of the molding chamber 43 is a second volume corresponding to the gas flushing stage. After gas flushing is completed, the motorized chamber 63 pulls the accordion-style folding assembly 53 and compresses it to the left wall of the molding chamber 43. This corresponds to performing gas flushing using a small-volume molding chamber 43 during the gas flushing stage, and then restoring the large volume of the molding chamber 43 to perform additive manufacturing during the additive manufacturing stage. The second volume is smaller than the first volume, which reduces the absolute space of the molding chamber 43, which helps reduce gas flushing time and improves equipment utilization.

Claims

1. An additive manufacturing apparatus, a chamber comprising a support disposed in sealing relation to the chamber, wherein a cavity formed by the support and the chamber is used to contain a structure and / or a powder build material for forming the structure; a drive device for driving the support table to move up and down along the sidewall of the chamber; a high energy beam generating device for melting portions of the powder build material to form the structure; a molding chamber for constructing an enclosed space for molten powder construction material of the high-energy beam generating device; a powder laying device for uniformly laying powder build material on a mold table during an additive manufacturing stage, the mold table being disposed on the support table; a quick release assembly is disposed at the bottom of the support base and is connected to the driving device so that the driving device can be quickly connected to or disconnected from the support base; An additive manufacturing apparatus, characterized in that a first part of an assembly transfer structure is arranged in the chamber and cooperates with a second part of an assembly transfer structure arranged in the additive manufacturing apparatus to enable rapid transfer of the chamber in the additive manufacturing apparatus.

2. the chamber is a molding chamber; 2. The additive manufacturing apparatus according to claim 1, wherein the driving device drives the support table to move from top to bottom in an additive manufacturing process so that the powder laying device uniformly lays the powder build material on the molding table.

3. the chamber is a powder chamber; 2. The additive manufacturing apparatus of claim 1, wherein the drive device drives the support table to move from bottom to top along the chamber side wall during an additive manufacturing process so that the powder build material of the structure provided by the powder laying device moves toward another end.

4. 4. The additive manufacturing apparatus of claim 2 or 3, wherein, at least during the additive manufacturing stage, one end of the drive device is firmly connected to the support table so that the support table moves up and down along the chamber side wall under the action of the drive device, and at least during the structure formation completion stage, the drive device is separated from the support table and one end of the drive device leaves the chamber.

5. A base is disposed in the chamber, 2. The additive manufacturing apparatus of claim 1, wherein the drive device comprises a second drive unit, the second drive unit being used to support the base and stably support the chamber on a rack of the additive manufacturing apparatus at least during the additive manufacturing stage.

6. 6. The additive manufacturing apparatus of claim 5, wherein a first part of the assembly transfer structure is disposed in the chamber and a second part is disposed on the rack, and at least upon completion of the formation of a structure, when the second drive unit removes the support, the first part moves downward and contacts the second part, completing the mutual cooperation.

7. The chamber completes quick attachment / detachment and / or transfer in the additive manufacturing apparatus through cooperation of an assembly transfer structure and a transfer device; The additive manufacturing apparatus according to claim 1 , wherein the transport path is for transporting a chamber from a specific position to the additive manufacturing apparatus and / or for transporting the additive manufacturing apparatus to a specific position.

8. The additive manufacturing apparatus of claim 1 , wherein the first part of the assembly transfer structure is a slider and the second part is a guide rail.

9. The additive manufacturing apparatus includes: a gas cleaning device for performing a gas cleaning operation on the molding chamber in a gas cleaning step; 2. The additive manufacturing apparatus according to claim 1, wherein the molding chamber has a first volume corresponding to the additive manufacturing stage and a second volume corresponding to the gas cleaning stage, the first volume being larger than the second volume.

10. 10. The additive manufacturing apparatus according to claim 9, wherein the molding chamber comprises a first wall portion and a second wall portion arranged opposite each other, and the first wall portion and the second wall portion are capable of moving relative to each other so as to change the volume of the molding chamber.

11. The additive manufacturing apparatus according to claim 10, wherein the first wall portion and the second wall portion are a top wall and a bottom wall of the molding chamber, or are side walls of the molding chamber.

12. 10. The additive manufacturing apparatus of claim 9, further comprising a contraction / expansion device, the contraction / expansion device being inside the molding chamber at least during the gas cleaning stage, the volume of the contraction / expansion device having a contracted state and an expanded state, the volume of the contraction / expansion device being in the contracted state during the additive manufacturing stage, and the volume of the contraction / expansion device being in the expanded state during the gas cleaning stage.

13. The additive manufacturing apparatus of claim 12, wherein the contractible and expandable device is a flexible inflatable device.

14. The additive manufacturing apparatus of claim 12 , wherein the contraction / expansion device is an expandable / contractible accordion-style folding assembly.

15. The additive manufacturing apparatus according to any one of claims 9 to 14, characterized in that the shrinkable / expandable device is arranged in two layers, an inner layer and an outer layer, the strength of the material of the shrinkable / expandable device of the outer layer ensures that deformation does not occur at least in response to changes in the vacuum level in the molding chamber, and the material of the shrinkable / expandable device of the inner layer is an airtight material.

16. The gas cleaning device a vacuum exhaust device for evacuating the molding chamber in a gas cleaning step, and / or an inert gas filling device for injecting an inert gas into the molding chamber in a gas cleaning step; The additive manufacturing apparatus described in any one of claims 9 to 14, wherein when the gas cleaning device includes a vacuum exhaust device and an inert gas filling device, the vacuum exhaust device and the inert gas filling device operate synchronously.

17. 2. The additive manufacturing apparatus of claim 1, wherein the powder laying device is a roller, which in a moving process uniformly lays down the powder build material in the powder chamber onto the molding table.

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