AM Device

Abstract

To provide a structure for supplementing a powder material to a material supply device during molding through an AM method.SOLUTION: According to an embodiment, an AM device is provided, and the AM device has a DED nozzle for ejecting a powder material, a gantry mechanism for moving the DED nozzle, and a material supply device for supplying the powder material to the DED nozzle. The gantry mechanism has a Y-axis member which can move in an X-direction that is a horizontal direction, and extends in a Y-direction which is perpendicular to the X-direction and is a horizontal direction. The DED nozzle and the material supply device are attached to the Y-axis member of the gantry mechanism. The gantry mechanism has a Y-axis moving mechanism for moving, in the Y-direction on the Y-axis member, the DED nozzle and the material supply device.SELECTED DRAWING: Figure 1

Description

[Technical field]

[0001] This application relates to AM devices. [Background technology]

[0002] There are known techniques for directly forming three-dimensional objects from three-dimensional data on a computer that represents the three-dimensional object. For example, the Additive Manufacturing (AM) method is known. One example is the deposition-based AM method called Direct Energy Deposition (DED). DED is a technology that forms objects by melting and solidifying a base material with a suitable heat source while supplying metal material locally. Another example of an AM method is Powder Bed Fusion (PBF). In PBF, a two-dimensionally spread metal powder is irradiated with a laser beam or an electron beam, which is a heat source, on the part to be formed, and the metal powder is melted, solidified, or sintered to form each layer of the three-dimensional object. In PBF, the desired three-dimensional object can be formed by repeating such processes. [Prior art documents] [Patent documents]

[0003] [Patent Document 1] Japanese Patent Application Publication No. 10-278902 [Patent Document 2] JP 2019-137038 A Summary of the Invention [Problem to be solved by the invention]

[0004] In both the DED method and the PBF method, AM molding is currently used to manufacture relatively small objects. To manufacture a relatively large object by the AM method, a large amount of powder material is required, and it is important to supply the powder material appropriately. When manufacturing a large object by the DED method, a material supply device that supplies powder material to the DED nozzle is required, but if the object is large, the material supply device may not be able to hold a sufficient amount of powder material. For example, if a material supply device is provided outside the modeling area and the powder material is supplied to a movable DED nozzle, it becomes possible to provide a large material supply device to the AM device. However, since the DED nozzle performs modeling while moving within the modeling area, the material supply pipe from the material supply device to the DED nozzle may deform as the DED nozzle moves, making it difficult to supply the material stably. On the other hand, if the material supply device is configured to be movable together with the DED nozzle, the flow path of the material supply pipe is stabilized, and the powder material can be stably supplied to the DED nozzle. However, if the material supply device is made movable together with the DED nozzle, it is difficult to make the material supply device large. Therefore, it is necessary to replenish the powder material to the material supply device during modeling. One object of the present invention is to provide a structure for replenishing the powder material to the material supply device during modeling by the AM method. [Means for solving the problem]

[0005] According to one embodiment, an AM apparatus is provided, the AM apparatus comprising: a DED nozzle for ejecting powder material; a gantry mechanism for moving the DED nozzle; and a material supplying device for supplying powder material to the DED nozzle, the gantry mechanism having a Y-axis member movable in an X-direction, which is a horizontal direction, and extending in a Y-direction, which is perpendicular to the X-direction and is a horizontal direction, the DED nozzle and the material supplying device are attached to the Y-axis member of the gantry mechanism, and the gantry mechanism has a Y-axis movement mechanism for moving the DED nozzle and the material supplying device on the Y-axis member along the Y direction. [Brief description of the drawings]

[0006] [Figure 1] FIG. 1 illustrates a schematic diagram of an AM apparatus for producing a structure, according to one embodiment. [Diagram 2] FIG. 1 is a schematic perspective view of a Y-axis member on which a DED nozzle and a material supply device are mounted, according to one embodiment. [Diagram 3] 1 is a schematic perspective view of a material supply device according to one embodiment; [Figure 4] 1 is a schematic cross-sectional view showing a structure of a material supply device according to one embodiment. [Diagram 5] FIG. 2 is a cross-sectional view that illustrates a schematic of a cap attached to a hopper according to one embodiment. [Figure 6] FIG. 2 is a cross-sectional view showing a schematic structure of a material replenishment tube according to one embodiment. [Figure 7] FIG. 2 is a schematic cross-sectional view of a material refill tube inserted into a hopper according to one embodiment. [Figure 8] FIG. 4 is an enlarged view of the vicinity of the sensor shown in FIG. [Figure 9] 1 is an example of a graph showing the relationship between powder flow rate passing through a transparent tube and light intensity detected by a light receiving element, according to one embodiment. [Figure 10] FIG. 4 is a close-up view of the vicinity of the sensor shown in FIG. 3 according to one embodiment. [Figure 11] FIG. 13 shows examples of a calibration curve for a new state where no powder material remains on the surface of a transparent tube, a calibration curve for a state where a moderate amount of powder material adheres to or remains on the surface of the transparent tube, and a calibration curve for a state where a large amount of powder material adheres to or remains on the surface of the transparent tube, according to one embodiment. [Figure 12] 2 is a schematic diagram illustrating a cross-section of a hopper of a material feeding apparatus according to one embodiment. [Figure 13A] FIG. 1 is a schematic top view of an AM device, according to one embodiment. [Figure 13B] FIG. 1 is a schematic top view of an AM device, according to one embodiment. [Figure 13C] FIG. 1 is a schematic top view of an AM device, according to one embodiment. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0007] Hereinafter, an embodiment of an AM apparatus for manufacturing a shaped object according to the present invention will be described with reference to the accompanying drawings. In the accompanying drawings, identical or similar elements are given identical or similar reference symbols, and duplicated descriptions of identical or similar elements may be omitted in the description of each embodiment. Furthermore, features shown in each embodiment can be applied to other embodiments as long as they are not mutually inconsistent.

[0008] FIG. 1 is a schematic diagram of an AM apparatus for manufacturing a molded object according to one embodiment. As shown in FIG. 1, the apparatus includes a base plate 102. A molded object is to be molded on the base plate 102. The base plate 102 can be a plate formed of any material capable of supporting a molded object. In one embodiment, the base plate 102 is connected to a lift mechanism that can move in the height direction (Z direction). For example, after one layer is molded by the DED nozzle 150, the base plate 102 is lowered by the lift mechanism by the amount of the molded layer, and the next layer is molded. By repeating this process, a three-dimensional structure can be molded. In one embodiment, the base plate 102 may be connected to an XY stage that can move in orthogonal X and Y directions in a horizontal plane.

[0009] The AM apparatus 100 includes a DED nozzle 150 for ejecting powder material. The DED nozzle 150 is attached to a gantry mechanism 200 for moving the DED nozzle 150 in orthogonal X and Y directions in a horizontal plane. In addition, a material supply device 300 is attached to the gantry mechanism 200 for supplying a carrier gas and powder material to the DED nozzle 150.

[0010] In one embodiment, as shown in FIG. 1, the gantry mechanism 200 is movable in the X direction and includes a Y-axis member 202 extending in a Y direction perpendicular to the X direction. 1, the Y-axis member 202 is a gate-like structure including a horizontal portion 202a extending in the Y direction above the printing region 110 and vertical portions 202b extending downward (in the Z direction) from both ends of the horizontal portion 202a toward the printing region 110. The vertical portions 202b of the Y-axis member 202 are connected to an X-axis moving mechanism 204. In one embodiment, the X-axis moving mechanism 204 may be a moving mechanism including, for example, a ball screw. As shown in FIG. 1, the X-axis moving mechanism 204 is disposed along the X-axis at both ends of the printing region 110 in the Y direction.

[0011] In one embodiment, the Y-axis member 202 of the gantry mechanism 200 includes a Y-axis moving mechanism 206 for moving the DED nozzle 150 and the material supply device 300 along the Y direction on the horizontal portion 202a of the Y-axis member 202. In one embodiment, the Y-axis moving mechanism 206 can be a moving mechanism including a ball screw. In the embodiment shown in FIG. 1, the DED nozzle 150 and the material supply device 300 are moved in the Y direction simultaneously by the Y-axis moving mechanism 206.

[0012] In one embodiment, the Y-axis member 202 has a Z-axis movement mechanism for moving the DED nozzle 150 in the Z direction. In one embodiment, the Z-axis movement mechanism can be, for example, a movement mechanism including a ball screw. The Z direction is a direction perpendicular to the X direction and the Y direction, and can also be called a height direction. By moving the DED nozzle 150 in the Z direction, the distance of the DED nozzle 150 to the printing region 110 can be adjusted.

[0013] In one embodiment, the AM apparatus includes a controller 500. The controller 500 is configured to control the operation of various operating mechanisms of the AM apparatus. The controller 500 can be configured as a general computer or a dedicated computer.

[0014] Fig. 2 is a perspective view that shows a schematic diagram of a Y-axis member 202 on which a DED nozzle 150 and a material supply device 300 are mounted according to one embodiment. In the embodiment shown in Fig. 2, the Y-axis member 202 is provided with two DED nozzles 150 and two material supply devices 300. In the embodiment shown in Fig. 2, one material supply device 300 is provided for supplying powder material to one DED nozzle 150, but a configuration may be adopted in which powder material can be supplied from one material supply device 300 to two DED nozzles 150.

[0015] FIG. 3 is a perspective view that shows a schematic of a material supplying apparatus 300 according to an embodiment. FIG. 4 is a schematic cross-sectional view that shows a structure of the material supplying apparatus 300 according to an embodiment. The material supplying apparatus 300 according to an embodiment includes a hopper 302 for holding a powder material. The hopper 302 functions as a container for holding the powder material. An opening 304 is provided on an upper surface of the hopper 302. The powder material is supplied into the hopper 302 from the opening 304. As shown in FIG. 4, a closing member 306 for closing the opening 304 is attached to an upper surface of the hopper 302. The closing member 306 is biased by an elastic member 308 in a direction to close the opening 304. In an embodiment, the elastic member 308 can be a torsion spring.

[0016] In one embodiment, the upper end of the hopper 302 may be provided with a cap 310 including the opening 304, the closing member 306, and the elastic member 308 as described above. FIG. 5 is a cross-sectional view showing a schematic view of the cap 310 attached to the hopper 302 according to one embodiment. In one embodiment, the cover disclosed in Japanese Patent Application No. 2020-169369 may be used as the cap 310 attached to the hopper 302.

[0017] In one embodiment, a material refill tube can be used to supply powder material into the hopper 302 through the opening 304. Figure 6 is a cross-sectional view that shows a schematic structure of a material refill tube 400 according to one embodiment. In the embodiment shown in Figure 6, the material refill tube 400 has a substantially cylindrical shape. In one embodiment, the material refilling tube 400 includes a powder passage 402 through which the powder material passes. In the embodiment shown in Fig. 6, the end of the material refilling tube 400 that is inserted into the opening 304 of the hopper 302 includes a tapered surface 404. In the illustrated material refilling tube 400, a powder port 406 for supplying the powder material to the hopper 302 is provided on a side surface of the material refilling tube 400 adjacent to the lowest position of the tapered surface 404.

[0018] In one embodiment, the material refill tube 400 includes a gas passage 408 for the passage of gas, as shown in Figure 6. The tapered surface 404 includes an opening 410 that communicates with the gas passage 408.

[0019] FIG. 7 is a cross-sectional view showing a state in which the material refill tube 400 is inserted into the hopper 302 according to one embodiment. In the embodiment shown in FIGS. 6 and 7, the material refill tube 400 is inserted into the opening 304 of the hopper 302, so that the material refill tube 400 can push down the closure member 306 and access the inside of the hopper 302. In the embodiment shown in FIGS. 6 and 7, the end of the material refill tube 400 is a tapered surface 404, and a powder port 406 is provided on the side. Therefore, the powder material that has passed through the powder passage 402 is supplied obliquely from the powder port 406 along the tapered surface 404, which is the bottom surface. Therefore, it is possible to prevent the powder material from adhering to the upper surface of the closure member 306. If the powder material adheres to the upper surface of the closure member 306, the sealing performance of the closure member 306 will be impaired. Furthermore, while powder material is being supplied from the material refill pipe 400 into the hopper 302 , air within the hopper 302 can be discharged to the outside of the hopper 302 through the opening 410 and the gas passage 408 .

[0020] In one embodiment, the material supplying apparatus 300 includes a weight sensor 320 for measuring the gravity of the powder material supplied from the hopper 302 to the DED nozzle 150, as shown in FIG. 4. As shown in FIG. 4, the weight sensor 320 is configured to measure the weight of the metering disk 322 disposed in the case 312 connected to the hopper outlet 312 of the hopper 302 and the powder material supplied to the metering disk 322. The metering disk 322 is connected to a motor 323 and configured to be rotatable. A gas supply pipe 332 from a carrier gas source 330 is connected to the case 312. Furthermore, a powder supply pipe 334 for supplying the carrier gas and the powder material to the DED nozzle 150 is connected to the metering disk 322. The powder material supplied from the hopper 302 to the metering disk 322 is supplied to the DED nozzle 150 from the powder supply pipe 334 together with the carrier gas. By using the material supplying apparatus 300 including the weight sensor 320 as described above, the weight of the powder material supplied from the hopper 302 to the DED nozzle 150, i.e., the powder material used, can be known. Also, in one embodiment, the weight sensor 320 may be configured to measure the weight of the hopper 302 and the powder material held therein.

[0021] As described above with reference to FIG. 1, the material supplying device 300 can be moved in the Y direction (horizontal direction) by the Y-axis moving mechanism 206, and the Y-axis member 202 can also be moved in the X direction because it is connected to the X-axis moving mechanism 204. Therefore, the material supplying device 300 equipped with the weight sensor 320 can be moved in the X direction and the Y direction (i.e., two directions perpendicular to each other in a horizontal plane), and therefore the weight sensor 320 is also subjected to acceleration in the X direction and the Y direction. For this reason, it is desirable to use a weight sensor 320 that will not break down even if acceleration in the X direction and the Y direction is applied. For example, in the case of a weight sensor with a rated capacity of 15 kg and an allowable load of 150%, when a load of 15 kg (the total weight of the hopper 302 and the powder material, etc.) is placed on the weight sensor, it is considered that the weight sensor can tolerate an acceleration of up to 0.5 G in total in the X direction and / or the Y direction. Note that "G" stands for the gravitational acceleration (=9.8 m / s 2 ).

[0022] However, a weight sensor 320 with a large rated capacity has a low resolution for measuring weight. Therefore, the operations of the X-axis moving mechanism 204 and the Y-axis moving mechanism 206 may be controlled so that the horizontal acceleration is small without increasing the rated capacity of the weight sensor 320 too much. In one embodiment, the material supplying device 300 includes an acceleration sensor 340 as shown in FIG. 3. It is preferable that the acceleration sensor 340 is capable of measuring acceleration in two directions, the X direction and the Y direction. Alternatively, the material supplying device 300 may be provided with two acceleration sensors capable of measuring acceleration in one direction so that the acceleration in the X direction and the Y direction can be measured. In one embodiment, the acceleration sensor 340 may be a capacitance type acceleration sensor or an acceleration sensor of any other measurement type.

[0023] In one embodiment, the X-axis moving mechanism 204 and the Y-axis moving mechanism 206 are controlled so that the acceleration in the X-direction and the Y-direction is equal to or less than a predetermined value. Specifically, the control device 500 receives the output from the acceleration sensor 340, and controls the operation of the X-axis moving mechanism 204 and the Y-axis moving mechanism 206 based on the output from the acceleration sensor 340. In one embodiment, the material supplying device 300 may not include the acceleration sensor 340 and may control the operation of the X-axis moving mechanism 204 and the Y-axis moving mechanism 206 so that the acceleration in the X-direction and the Y-direction is equal to or less than a predetermined value.

[0024] In one embodiment, the weight sensor 320 is configured to perform weight measurement only when the material supplying device 300 is stopped or moving at a uniform speed. By performing weight measurement only when the weight sensor 320 is stopped or moving at a uniform speed, weight measurement can be performed without horizontal acceleration acting on the weight sensor, and accurate weight measurement can be performed.

[0025] 3 and 4, the material supply device 300 includes a powder supply pipe 334 for supplying the powder material supplied from the hopper 302 to the DED nozzle 150. In the illustrated embodiment, one end of the powder supply pipe 334 is connected to the metering disc 322, and the other end is connected to the DED nozzle 150.

[0026] In one embodiment, the material supplying apparatus 300 includes a sensor 350 for measuring the amount of powder material passing through the powder supplying tube 334. FIG. 8 is an enlarged view of the vicinity of the sensor 350 shown in FIG. 3. In one embodiment, as shown in FIG. 8, a part of the powder supplying tube 334 is composed of an optically transparent tube 334t. In this embodiment, the sensor 350 includes a light source 352 for irradiating light toward the transparent tube 334t and a light receiving element 354 for receiving the light that has passed through the transparent tube 334t. As shown in FIG. 8, the light source 352 is disposed on one side of the transparent tube 334t, and the light receiving element 354 is disposed on the other side. In one embodiment, the light source 352 can be an LED light source. Although the sensor 350 in FIG. 8 is a transmission type sensor, a reflection type sensor may be adopted as another embodiment. A reflective sensor may be configured, for example, by arranging a reflector at the position of light receiving element 354 in FIG. 8 described above, and arranging a light source and a light receiving element at the position of light source 352 in FIG. 8 described above, and receiving light reflected from the reflector by the light receiving element.

[0027] When the optical sensor 350 shown in FIG. 8 is used, light is irradiated onto the flow of powder material passing through the transparent tube 334t. The more the amount of powder material passing through the transparent tube 334t, the more the light attenuates, and the lower the luminous intensity of the light received by the light receiving element 354 becomes. For example, FIG. 9 is an example of a graph showing the relationship between the powder flow rate passing through the transparent tube 334t and the luminous intensity detected by the light receiving element 354. By measuring in advance a calibration curve showing the relationship between the amount of powder material passing through the transparent tube 334t and the luminous intensity as shown in the figure, the flow rate of the powder material passing through the transparent tube 334t can be detected by measuring the luminous intensity. By integrating the luminous intensity of the light received by the light receiving element 354 over time, the amount of powder material supplied from the hopper 302 to the DED nozzle 150, i.e., the amount of powder material used in AM modeling, can be measured. In addition, if the amount of powder material used is known, the amount of powder material used in the AM modeling can be measured. The remaining amount of powder material held in the powder 302 can also be estimated.

[0028] If a non-conductive material is used as the material of the transparent tube 334t, the powder material may adhere to the inner surface of the transparent tube 334t due to electrostatic force, and the amount of the powder material passing through the transparent tube 334t may not be measured properly. Therefore, in one embodiment, the transparent tube 334t may be made of a conductive material. In one embodiment, the transparent tube 334t may be made of a conductive or non-conductive material that has been treated to be antistatic. As the conductive transparent material, semiconductive polyurethane, transparent conductive glass, or any other material may be used. As the transparent tube 334t that has been treated to be antistatic, a PFA-AS tube (Nichias Corporation) may be used.

[0029] FIG. 10 is an enlarged view of the vicinity of the sensor 350 shown in FIG. 3 according to one embodiment. In the embodiment shown in FIG. 10, a branch is provided upstream of the transparent tube 334t, and one end of the branch is connected to a gas source 356. In the embodiment shown in FIG. 10, pressurized gas can be supplied from the gas source 356 to the transparent tube 334t. The gas of the gas source 356 can be the same as the carrier gas, for example, argon gas. The gas source 330 of the carrier gas may also be used as the gas source 356. In the embodiment shown in FIG. 10, the pressurized gas can be flowed from the gas source 356 to the transparent tube 334t to push away the powder material attached to the surface of the transparent tube 334t. For example, when the modeling of one layer is completed by the DED nozzle 150, the pressurized gas can be flowed from the gas source 356 to the transparent tube 334t to push away the powder material attached to the surface of the transparent tube 334t. In one embodiment, instead of providing a branch section and gas source 356 as shown in FIG. 10, and without supplying powder material, carrier gas for transporting the powder material supplied from the hopper 302 to the DED nozzle 150 may be supplied at high pressure from the carrier gas source 330 to the powder supply pipe 334 and the transparent pipe 334t.

[0030] As described above, even if antistatic measures are taken for the transparent tube 334t or the powder material attached to the transparent tube 334t is removed by high-pressure gas, the powder material may get into the unevenness of the inner surface of the transparent tube 334t, making it impossible to remove the powder material attached to the transparent tube 334t. If this happens, the transparency of the transparent tube 334t changes with the time of use, and it becomes impossible to accurately measure the amount of powder material used by the optical method as described above. For this reason, it is desirable to use a transparent tube 334t with a smooth inner surface to which the powder material does not easily adhere. The surface roughness of the inner surface of the transparent tube 334t is desirably 1 / 2 or less of the average particle diameter of the powder material used. The surface roughness refers to the width dimension of the concave portion of the unevenness of the inner surface of the transparent tube 334t. As an example, when a powder material with an average particle diameter of 50 μm is used, it is desirably 25 μm or less in the dimension of the concave portion of the unevenness of the inner surface of the transparent tube 334t.

[0031] In one embodiment, when the transparent tube 334t is replaced with a new one, the powder material is allowed to continue to flow into the transparent tube 334t for a certain period of time, and a certain amount of the powder material is allowed to adhere to the transparent tube 334t before AM modeling. In the case of a new transparent tube 334t, the powder material is likely to adhere to the transparent tube 334t, and the change in the transparency of the transparent tube 334t during AM modeling increases. As in the present embodiment, after replacing the transparent tube 334t, the powder material is allowed to flow into the transparent tube 334t before use in AM modeling, so that a certain amount of the powder material is allowed to adhere to the inner surface of the transparent tube 334t, thereby reducing the change in the transparency of the transparent tube 334t during use in AM modeling. For example, the powder material can be allowed to flow into the transparent tube 334t until the transparency of the transparent tube 334t when the powder material is not flowing reaches a predetermined value, and then the transparent tube 334t can be used in AM modeling. In addition, by continuing to use the transparent tube 334t in AM modeling, when the transparency of the transparent tube 334t when no powder material is flowing therethrough reaches a lower predetermined value, the transparent tube 334t is replaced with a new one.

[0032] In one embodiment, the calibration curve for calculating the powder flow rate may be changed according to the degree of powder material remaining on the inner surface of the transparent tube 334t. For example, FIG. 11 shows examples of a calibration curve in a new state where no powder material remains on the surface of the transparent tube 334t, a calibration curve in a state where a medium amount of powder material adheres to and remains on the surface of the transparent tube 334t, and a calibration curve in a state where a large amount of powder material adheres to and remains on the surface of the transparent tube 334t. As an example, before starting modeling, the light intensity of the transparent tube 334t may be measured without passing the powder material, the degree of the powder material adhered to and remaining on the transparent tube 334t may be detected, and the calibration curve to be used may be selected. Also, during modeling, the light intensity of the transparent tube 334t may be periodically measured without passing the powder material, the degree of the powder material adhered to and remaining on the transparent tube 334t may be detected, and the calibration curve to be used may be selected. As an example, the calibration curve may be selected in the above procedure after modeling of one layer is completed and before starting modeling of the next layer.

[0033] In one embodiment, the material supplying apparatus 300 includes a sensor 360 for measuring the height of the powder material held in the hopper 302. FIG. 12 is a schematic diagram showing a cross section of the hopper 302 of the material supplying apparatus 300 according to one embodiment. In the embodiment shown in FIG. 12, the sensor 360 of the material supplying apparatus 300 includes a light source 362 oriented to irradiate light horizontally toward the inside of the hopper 302 at the first height position of the hopper 302, and a light receiving element 364 for receiving the light that has passed through the inside of the hopper 302. In the material supplying apparatus 300 according to such an embodiment, when the powder material is being replenished into the hopper 302 and the light receiving element 364 cannot detect the light because the powder material blocks the light passing through the hopper 302, the supply of the powder material to the hopper 302 can be stopped, assuming that a sufficient amount of powder material has been replenished into the hopper 302. Although the sensor 360 in FIG. 12 is a transmission type sensor, a reflection type sensor may be adopted as another embodiment. A reflective sensor may be configured, for example, by arranging a reflector at the position of the light receiving element 364 in FIG. 12 described above, and arranging a light source and a light receiving element at the position of the light source 362 in FIG. 12 described above, and receiving light reflected from the reflector by the light receiving element.

[0034] 12, when the powder material is being refilled into the hopper 302, the supplied powder material may form a pile, making it impossible to correctly detect the amount of powder material supplied into the hopper 302. Therefore, in one embodiment, when the powder material is being supplied into the hopper 302, vibration may be applied to the hopper 302 to prevent the powder material from forming a pile. The vibration applied to the hopper 302 may be generated by, for example, the above-mentioned X-axis moving mechanism 204 or Y-axis moving mechanism 206.

[0035] Additionally, in one embodiment, the amount of powder material refilled into the hopper 302 may be detected by the weight sensor 320 described above.

[0036] 13A, 13B, and 13C are top views that diagrammatically show the AM apparatus 100 during AM modeling. In the embodiment shown in FIGS. 13A to 13C, the AM apparatus 100 includes a plurality of gantry mechanisms 200 and a plurality of DED nozzles 150. Each DED 150 is configured to be movable within a predetermined modeling region 110 by its respective gantry mechanism 200. The AM apparatus 100 according to this embodiment includes a large modeling region using the plurality of DED nozzles 150 and gantry mechanisms 200, and can manufacture a relatively large modeled object.

[0037] 13A to 13C are top views that diagrammatically show an AM apparatus according to one embodiment, illustrating the state during modeling. FIG. 13A shows the state during modeling, in which the positions of the gantry mechanism 200 and the DED nozzle 150 move to various positions depending on the modeling position. FIG. 13B shows a state in which modeling of one layer has been completed, with each DED nozzle 150 waiting in a retracted position, and each gantry mechanism 200 waiting in a predetermined position. Note that each gantry mechanism 20 While the DED nozzle 150 and the DED nozzle 150 are on standby, the material supply device 300 may be replenished with powder material.

[0038] In the embodiment shown in FIGS. 13A to 13C, the AM apparatus 100 includes a powder-laying mechanism 130. The powder-laying mechanism 130 has a function of laying powder material in the modeling region 110. The powder-laying mechanism 130 may have any structure, and may be a powder-laying mechanism used in a PBF-type AM apparatus. As shown in FIG. 13C, when the DDED nozzle 150 and the gantry mechanism 200 are in the retracted position and waiting, the powder-laying mechanism 130 can lay powder material in the modeling region 110. As an example, the powder-laying mechanism 130 moves under the Y-axis member 202 of the gantry mechanism 200 and lays powder material in the modeling region 110. Thereafter, as shown in FIG. 13A, the next layer can be modeled.

[0039] At least the following technical ideas can be understood from the above-described embodiments. [Form 1] According to Form 1, there is provided an AM apparatus having a DED nozzle for ejecting powder material, a gantry mechanism for moving the DED nozzle, and a material supplying device for supplying powder material to the DED nozzle, the gantry mechanism having a Y-axis member movable in an X-direction which is a horizontal direction and extending in a Y-direction which is perpendicular to the X-direction and is a horizontal direction, the DED nozzle and the material supplying device are attached to the Y-axis member of the gantry mechanism, and the gantry mechanism has a Y-axis moving mechanism for moving the DED nozzle and the material supplying device on the Y-axis member along the Y direction.

[0040] [Mode 2] According to Mode 2, in the AM apparatus according to Mode 1, the gantry mechanism has a Z-axis movement mechanism for moving the DED nozzle in a Z direction perpendicular to the X direction and the Y direction.

[0041] [Form 3] According to Form 3, in the AM apparatus according to Form 1 or Form 2, the material supplying device has a container for holding powder material and a cap attached to an upper end of the container, the cap having an opening communicating with the inside of the container, a closing member movable between a closed position that closes the opening and an open position that opens the opening, and an elastic member that biases the closing member to the closed position.

[0042] [Form 4] According to Form 4, the AM apparatus according to Form 3 has a powder refill tube that can be inserted into the opening of the cap, and the powder refill tube has a powder passage through which powder material passes and a gas passage separate from the powder passage through which gas passes.

[0043] [Form 5] According to Form 5, in the AM apparatus according to Form 4, the powder refill tube has a tapered surface at the tip side that is inserted into the opening of the cap, and a powder port for supplying powder material to the container is formed on the side adjacent to the lowest position of the tapered surface.

[0044] [Mode 6] According to Mode 6, in the AM apparatus according to any one of Modes 1 to 5, a weight sensor is provided for measuring a weight of powder material supplied from the material supply device to the DED nozzle.

[0045] [Mode 7] According to Mode 7, in the AM apparatus according to Mode 6, the Y-axis movement mechanism is configured to control the movement of the material supply device so that the horizontal acceleration applied to the weight sensor is equal to or less than a predetermined value.

[0046] [Embodiment 8] According to embodiment 8, in the AM apparatus according to embodiment 6 or embodiment 7, The sensor has an acceleration sensor for measuring an acceleration applied thereto.

[0047] [Form 9] According to Form 9, in the AM apparatus according to any one of Forms 6 to 8, the weight sensor is configured to measure the weight of the material supply device only when the material supply device is stationary or performing a constant speed linear motion.

[0048] [Form 10] According to form 10, in the AM apparatus according to any one of forms 1 to 9, the apparatus has a powder supply pipe for supplying powder material from the material supply device to the DED nozzle, and a sensor for measuring the amount of powder material passing through the powder supply pipe.

[0049] [Form 11] According to Form 11, in the AM device according to Form 10, at least a portion of the powder supply tube is made of an optically transparent tube, and has a light source for irradiating light toward the transparent tube, and a light receiving element for receiving light that has passed through the transparent tube.

[0050] [Feature 12] According to feature 12, in the AM device according to feature 11, the transparent tube is made of an antistatic material.

[0051] [Mode 13] According to Mode 13, in the AM apparatus according to Mode 11 or Mode 12, the powder supply pipe is connected to a gas source upstream of the transparent pipe.

[0052] [Feature 14] According to feature 14, in the AM apparatus according to any one of features 11 to 13, the surface roughness of the inner surface of the transparent tube is configured to be equal to or greater than 1 / 2 of the average particle size of the powder material.

[0053] [Form 15] According to Form 15, in an AM apparatus according to any one of Forms 1 to 14, the material supply device has a container for holding powder material, and has a light source for irradiating light toward the inside of the container at a first height of the container, and a light receiving element for receiving light that has passed through the container at the first height.

[0054] [Form 16] According to form 16, in the AM apparatus according to any one of forms 1 to 15, the material supplying device is configured to impart vibration to the material supplying device when powder material is supplied to the material supplying device. [Explanation of symbols]

[0055] 100…AM device 110...Printing area 130…Powder filling mechanism 150…DED nozzle 200…gantry mechanism 202...Y-axis member 204...X-axis movement mechanism 206...Y-axis movement mechanism 300…Material supply device 302…Hopper 304…Aperture 306... Closing member 308...Elastic member 310…Cap 312…Hopper exit 320...Weight sensor 322…Measuring disc 330…Carrier gas source 330…Gas source 332...Gas supply pipe 334…Powder supply pipe 334t…Transparent tube 340…Accelerometer 352…Light source 354...Photo-detector 356…Gas source 362…Light source 364...Photodetector 400…Material replenishment pipe 402…Powder passage 404...Tapered surface 406…Powder port 408...Gas passage 410...Aperture 500...Control device

Claims

1. An AM device, comprising: A DED nozzle for projecting a powder material; A gantry mechanism for moving the DED nozzle; A material supplying device for supplying a powder material to the DED nozzle, the gantry mechanism has a Y-axis member movable in an X-direction which is a horizontal direction and extending in a Y-direction which is perpendicular to the X-direction and is a horizontal direction; the DED nozzle and the material supply device are attached to the Y-axis member of the gantry mechanism; The gantry mechanism has a Y-axis moving mechanism for moving the DED nozzle and the material supply device along the Y direction on the Y-axis member, The material supplying device includes a container for holding a powder material and a cap attached to an upper end of the container; The cap is an opening communicating with the interior of the container; a closing member movable between a closing position for closing the opening and an opening position for opening the opening; a resilient member for biasing the closing member to the closed position; having AM device.

2. 2. The AM device according to claim 1, The gantry mechanism has a Z-axis movement mechanism for moving the DED nozzle in a Z direction perpendicular to the X direction and the Y direction. AM device.

3. 3. The AM device according to claim 1, a powder refill tube insertable into the opening of the cap; The powder refill tube is a powder passageway for passing the powder material; and a gas passage separate from the powder passage for gas to pass through. AM device.

4. 4. The AM device according to claim 3, The powder refill tube has a tapered surface at the tip side that is inserted into the opening of the cap, and a powder port for supplying powder material to the container is formed on a side surface adjacent to the lowest position of the tapered surface. AM device.

5. 5. The AM device according to claim 1 , A weight sensor for measuring a weight of the powder material supplied from the material supply device to the DED nozzle. AM device.

6. An AM device, A DED nozzle for projecting a powder material; A gantry mechanism for moving the DED nozzle; A material supplying device for supplying a powder material to the DED nozzle, the gantry mechanism has a Y-axis member movable in an X-direction which is a horizontal direction and extending in a Y-direction which is perpendicular to the X-direction and is a horizontal direction; the DED nozzle and the material supply device are attached to the Y-axis member of the gantry mechanism; The gantry mechanism has a Y-axis moving mechanism for moving the DED nozzle and the material supply device along the Y direction on the Y-axis member, The AM device further includes a weight sensor for measuring a weight of the powder material supplied from the material supply device to the DED nozzle; The Y-axis movement mechanism is configured to control the movement of the material supply device so that the horizontal acceleration applied to the weight sensor is equal to or less than a predetermined value. AM device.

7. An AM device, A DED nozzle for projecting a powder material; A gantry mechanism for moving the DED nozzle; A material supplying device for supplying a powder material to the DED nozzle, the gantry mechanism has a Y-axis member movable in an X-direction which is a horizontal direction and extending in a Y-direction which is perpendicular to the X-direction and is a horizontal direction; the DED nozzle and the material supply device are attached to the Y-axis member of the gantry mechanism; The gantry mechanism has a Y-axis moving mechanism for moving the DED nozzle and the material supply device along the Y direction on the Y-axis member, The AM device further includes a weight sensor for measuring a weight of the powder material supplied from the material supply device to the DED nozzle; an acceleration sensor for measuring an acceleration applied to the weight sensor; AM device.

8. An AM device, A DED nozzle for projecting a powder material; A gantry mechanism for moving the DED nozzle; A material supplying device for supplying a powder material to the DED nozzle, the gantry mechanism has a Y-axis member movable in an X-direction which is a horizontal direction and extending in a Y-direction which is perpendicular to the X-direction and is a horizontal direction; the DED nozzle and the material supply device are attached to the Y-axis member of the gantry mechanism; The gantry mechanism has a Y-axis moving mechanism for moving the DED nozzle and the material supply device along the Y direction on the Y-axis member, The AM device further includes a weight sensor for measuring a weight of the powder material supplied from the material supply device to the DED nozzle; The weight sensor is configured to measure the weight of the material supplying device only when the material supplying device is stationary or moving at a uniform speed in a straight line. AM device.

9. 9. The AM device according to claim 1 , A powder supply pipe for supplying a powder material from the material supply device to the DED nozzle; a sensor for measuring the amount of powder material passing through the powder supply tube; having AM device.

10. An AM device, comprising: A DED nozzle for projecting a powder material; A gantry mechanism for moving the DED nozzle; A material supplying device for supplying a powder material to the DED nozzle, the gantry mechanism has a Y-axis member movable in an X-direction which is a horizontal direction and extending in a Y-direction which is perpendicular to the X-direction and is a horizontal direction; the DED nozzle and the material supply device are attached to the Y-axis member of the gantry mechanism; The gantry mechanism has a Y-axis moving mechanism for moving the DED nozzle and the material supply device along the Y direction on the Y-axis member, The AM device further includes a powder supply pipe for supplying a powder material from the material supply device to the DED nozzle; a sensor for measuring the amount of powder material passing through the powder supply tube; having At least a portion of the powder supply pipe is made of an optically transparent pipe, A light source for irradiating light toward the transparent tube; A light receiving element for receiving light that has passed through the transparent tube. AM device.

11. 11. The AM device of claim 10, The transparent tube is made of an antistatic material. AM device.

12. 12. The AM device according to claim 10 or 11, The powder supply pipe is connected to a gas source upstream of the transparent pipe. AM device.

13. 13. The AM device according to any one of claims 10 to 12, The surface roughness of the inner surface of the transparent tube is configured to be equal to or greater than 1 / 2 of the average particle size of the powder material. AM device.

14. 14. The AM device according to claim 1, the material supplying device has a container for holding a powder material; a light source for emitting light toward an interior of the container at a first elevation of the container; a light receiving element for receiving light that has passed through the container at the first height.

15. 15. The AM device according to any one of claims 1 to 14, The material supplying device is configured to impart vibration to the material supplying device when the powder material is supplied to the material supplying device. AM device.

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