WO2024223592A1 - Dispositif et procédé d'alimentation dirigée en gaz d'un espace de construction pour la fabrication additive - Google Patents
Dispositif et procédé d'alimentation dirigée en gaz d'un espace de construction pour la fabrication additive Download PDFInfo
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- WO2024223592A1 WO2024223592A1 PCT/EP2024/061131 EP2024061131W WO2024223592A1 WO 2024223592 A1 WO2024223592 A1 WO 2024223592A1 EP 2024061131 W EP2024061131 W EP 2024061131W WO 2024223592 A1 WO2024223592 A1 WO 2024223592A1
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- WIPO (PCT)
- Prior art keywords
- nozzle
- gas
- flow
- construction platform
- nozzle device
- Prior art date
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Classifications
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B22—CASTING; POWDER METALLURGY
- B22F—WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
- B22F10/00—Additive manufacturing of workpieces or articles from metallic powder
- B22F10/30—Process control
- B22F10/32—Process control of the atmosphere, e.g. composition or pressure in a building chamber
- B22F10/322—Process control of the atmosphere, e.g. composition or pressure in a building chamber of the gas flow, e.g. rate or direction
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B22—CASTING; POWDER METALLURGY
- B22F—WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
- B22F10/00—Additive manufacturing of workpieces or articles from metallic powder
- B22F10/20—Direct sintering or melting
- B22F10/28—Powder bed fusion, e.g. selective laser melting [SLM] or electron beam melting [EBM]
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B22—CASTING; POWDER METALLURGY
- B22F—WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
- B22F10/00—Additive manufacturing of workpieces or articles from metallic powder
- B22F10/70—Recycling
- B22F10/77—Recycling of gas
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B22—CASTING; POWDER METALLURGY
- B22F—WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
- B22F12/00—Apparatus or devices specially adapted for additive manufacturing; Auxiliary means for additive manufacturing; Combinations of additive manufacturing apparatus or devices with other processing apparatus or devices
- B22F12/70—Gas flow means
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C64/00—Additive manufacturing, i.e. manufacturing of three-dimensional [3D] objects by additive deposition, additive agglomeration or additive layering, e.g. by 3D printing, stereolithography or selective laser sintering
- B29C64/10—Processes of additive manufacturing
- B29C64/141—Processes of additive manufacturing using only solid materials
- B29C64/153—Processes of additive manufacturing using only solid materials using layers of powder being selectively joined, e.g. by selective laser sintering or melting
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C64/00—Additive manufacturing, i.e. manufacturing of three-dimensional [3D] objects by additive deposition, additive agglomeration or additive layering, e.g. by 3D printing, stereolithography or selective laser sintering
- B29C64/30—Auxiliary operations or equipment
- B29C64/364—Conditioning of environment
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C64/00—Additive manufacturing, i.e. manufacturing of three-dimensional [3D] objects by additive deposition, additive agglomeration or additive layering, e.g. by 3D printing, stereolithography or selective laser sintering
- B29C64/30—Auxiliary operations or equipment
- B29C64/364—Conditioning of environment
- B29C64/371—Conditioning of environment using an environment other than air, e.g. inert gas
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B33—ADDITIVE MANUFACTURING TECHNOLOGY
- B33Y—ADDITIVE MANUFACTURING, i.e. MANUFACTURING OF THREE-DIMENSIONAL [3-D] OBJECTS BY ADDITIVE DEPOSITION, ADDITIVE AGGLOMERATION OR ADDITIVE LAYERING, e.g. BY 3-D PRINTING, STEREOLITHOGRAPHY OR SELECTIVE LASER SINTERING
- B33Y10/00—Processes of additive manufacturing
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B33—ADDITIVE MANUFACTURING TECHNOLOGY
- B33Y—ADDITIVE MANUFACTURING, i.e. MANUFACTURING OF THREE-DIMENSIONAL [3-D] OBJECTS BY ADDITIVE DEPOSITION, ADDITIVE AGGLOMERATION OR ADDITIVE LAYERING, e.g. BY 3-D PRINTING, STEREOLITHOGRAPHY OR SELECTIVE LASER SINTERING
- B33Y30/00—Apparatus for additive manufacturing; Details thereof or accessories therefor
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B33—ADDITIVE MANUFACTURING TECHNOLOGY
- B33Y—ADDITIVE MANUFACTURING, i.e. MANUFACTURING OF THREE-DIMENSIONAL [3-D] OBJECTS BY ADDITIVE DEPOSITION, ADDITIVE AGGLOMERATION OR ADDITIVE LAYERING, e.g. BY 3-D PRINTING, STEREOLITHOGRAPHY OR SELECTIVE LASER SINTERING
- B33Y40/00—Auxiliary operations or equipment, e.g. for material handling
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B33—ADDITIVE MANUFACTURING TECHNOLOGY
- B33Y—ADDITIVE MANUFACTURING, i.e. MANUFACTURING OF THREE-DIMENSIONAL [3-D] OBJECTS BY ADDITIVE DEPOSITION, ADDITIVE AGGLOMERATION OR ADDITIVE LAYERING, e.g. BY 3-D PRINTING, STEREOLITHOGRAPHY OR SELECTIVE LASER SINTERING
- B33Y50/00—Data acquisition or data processing for additive manufacturing
- B33Y50/02—Data acquisition or data processing for additive manufacturing for controlling or regulating additive manufacturing processes
Definitions
- the present invention relates to a device and a method for the directed gas exposure of a construction space for additive manufacturing.
- 3D printing makes it possible to produce a wide variety of three-dimensional components with complex geometries.
- Three-dimensional workpieces are built up layer by layer.
- the construction is computer-controlled from one or more liquid or solid materials according to specified dimensions and shapes (CAD).
- CAD specified dimensions and shapes
- Typical materials for 3D printing are plastics, synthetic resins, ceramics and metals.
- 3D printing refers to generative or additive manufacturing processes.
- the most important 3D printing techniques are selective laser melting (SLM) or laser powder bed fusion (LPBF), laser cladding (LA) and electron beam melting (EBM) for metals and selective laser sintering (SLS) for polymers, ceramics and metals.
- SLM selective laser melting
- LPBF laser powder bed fusion
- LA laser cladding
- EBM electron beam melting
- SLS selective laser sintering
- the material is melted at specific points or selectively, causing it to solidify in a different form.
- metal powder or metal wire is melted and solidified layer by layer, allowing a three-dimensional component to be generated.
- the locally limited energy input using a laser beam means that the size of the melt pool formed is small. This makes it possible to create delicate structures.
- Corresponding processes are sold commercially as Laser Engineered Net Shaping (LENS), Direct Metal Deposition (DMD), Laser Additive Manufacturing (LAM), Selective Laser Melting (SLM) or Laser Metal Deposition (LMD), among others.
- SLS/LMF selective laser sintering
- a layer of powder material is applied to a work surface (construction platform).
- the loose powder is melted selectively or at specific points using a laser beam.
- the powder particles are bonded in the layer and with the layer below.
- Two different processes can be used to produce metallic components. fundamental development directions can be differentiated.
- direct metal laser sintering the production of metallic components using a combination of SLS of plastic-coated metal powder with subsequent thermal treatment (IMLS) has already been established at an early stage.
- Direct metal laser sintering uses either single-component or multi-component metal materials.
- DMLS multi-component powders are used, which consist of various alloying elements.
- the low-melting component contained in the powder is melted by a laser beam and flows around the high-melting component, which serves as the structure generator.
- EBM Electron Beam Melting
- selective laser melting introduces significantly more energy into the powder bed via a laser beam, so that a real melt of material occurs in the affected areas. This creates a more homogeneous object with greater density than the SLS process.
- Laser cladding is a type of welding process in which a workpiece is welded by applying and simultaneously melting almost any material. This can be done in powder form, e.g. as metal powder, or with a welding wire or strip.
- a high-power laser is used as the heat source, primarily a diode laser or fiber laser, but previously also CO2 and Nd:YAG lasers.
- the laser In laser cladding with powder, the laser usually heats the workpiece in a defocused manner and melts it locally. At the same time, an inert gas mixed with fine metal powder is fed in. The metal powder melts at the heated point and bonds with the metal of the workpiece.
- ceramic powder materials especially hard materials, can also be used.
- Laser cladding with wire or strip works in a similar way to the process with powder, but with wire or strip as the additional material.
- EP 3 015 197 B1 describes a device for producing or repairing a three-dimensional object.
- the device comprises two inlet nozzles.
- a process gas is introduced into the construction space or the process chamber of the device via the inlet nozzles.
- the process gas is in particular a protective or inert gas.
- WO 2017 013454 A2 discloses a device for generative manufacturing and a flow device for use with such a device.
- the flow device has a gas flow system for controlling the condensate generated during the laser melting process.
- This comprises a first gas nozzle with a plurality of gas outlets and a gas outlet with a gas inlet.
- the gas outlets and the gas inlet are arranged such that they generate a horizontal gas flow over a working surface of the powder bed formed on the build platform.
- the nozzle and the outlet are intended to generate a laminar flow with a flow direction from the nozzle to an outlet.
- DE 11 2019 003 725 T5 describes an additive manufacturing device. It comprises a lower nozzle that ejects an inert gas in a horizontal direction through a lower opening into a process chamber and an upper nozzle that ejects the inert gas through an upper opening into the chamber, and an inclined nozzle that ejects the inert gas in an obliquely downward direction from the upper portion of the first side wall.
- the inclined nozzle comprises a first nozzle that has a flow path extending in a first direction from the upper portion of the first side wall to a lower portion of the second side wall through which the inert gas flows and ejects the inert gas in the first direction, and a second nozzle that has a flow path extending in a second direction from the upper portion of the first side wall to an upper surface of the platform through which the inert gas flows and ejects the inert gas in the second direction.
- WO 2020 041 438 A1 discloses a system and method for flow control for a system for additive manufacturing. This comprises a lower gas supply device with a lower gas inlet with openings and an upper gas supply device and an upper gas inlet with Openings. According to this document, a laminar flow should be generated in the area of a construction platform.
- US 9,592,636 B2 relates to a laminating molding apparatus, wherein the laminating molding apparatus comprises a chamber with an inert gas supply opening and an inert gas supply space for a separate smoke diffusion section.
- EP 3 147 047 A1 shows a device for producing a three-dimensional workpiece, wherein a process chamber has a first gas inlet (horizontal direction) and a second gas inlet (vertical direction).
- the second gas inlet is approximately trapezoidal in shape in a plan view and has a large number of gas inlet openings in order to supply a construction platform with gas as evenly as possible.
- EP 1 839 781 B1 describes a device for producing objects by building up powdered material in layers, whereby two protective gas supply lines are provided.
- the protective gas supply line opens into nozzles.
- the protective gas supply line opens into several protective gas inlets.
- DE 10 2010 052 206 B4 shows a device for producing three-dimensional objects.
- the device has a process chamber with a protective gas injection and a protective gas extraction, with protective gas being circulated in the process chamber 6.
- DE 10 2016 112 652 A1 discloses a metal 3D printer that works with the powder bed method.
- This metal 3D printer comprises a housing, a recoating head, a material supply device, a protective gas supply device, a table and a laser irradiation device for sintering metal powder.
- the protective gas supply device has a first discharge connection, which is arranged on one side of the recoating head. The protective gas is thus released into the forming chamber at the recoating head, flows along the powder bed to a first outlet connection, at which a suction device is provided. The recoating head can be moved over the powder bed, whereby the corresponding discharge connection is also moved.
- a second discharge port is arranged in a fixed position in the forming chamber so that a protective gas flow can be generated across the powder bed to the first intake port even when the recoating head is in a remote position.
- This 3D printing device also has a third discharge port, which is located adjacent to the discharge port but slightly higher on a side wall.
- the protective gas In particular, nitrogen gas fed from a third exhaust port prevents a decrease in the concentration of nitrogen gas in the forming chamber.
- DE 10 2016 121 770 A1 shows a 3D printing device with vertically offset inflow elements for protective gas, so that several vertically offset flow layers are also produced in a process chamber of a device for the additive production of three-dimensional objects.
- the lowest inflow elements are aligned diagonally downwards.
- DE 10 2008 030 186 A1 discloses another 3D printer with a process chamber for selective laser melting, which has an inlet and an outlet for a process gas, which is an inert gas that flows over the surface of the component to be produced in order to avoid causing undesirable reactions in the melt pool.
- a feed is provided with which a reactive gas can be fed. By feeding reactive gas, the composition of the surface of the component can be changed.
- DE 10 2018 215 301 A1 relates to a 3D printer with a flow device for generating a gas flow.
- the flow device is characterized by the fact that it comprises many channels, whereby the channels have a varying cross-section. These channels can be used to generate a homogeneous or inhomogeneous flow with turbulence.
- Devices for 3D printing are known from the state of the art that provide several nozzles in order to supply a construction platform with process gas as evenly as possible.
- Active extraction devices are also known from the state of the art.
- Additive manufacturing processes use a powder bed, a powder feed or a wire feed, whereby these starting materials are then melted and then solidified using a laser beam, electron beam, plasma/arc.
- Inert or active gases are also used as process gases in generative manufacturing processes.
- the object of the present invention is to provide a device and a method for the directed gas exposure of a construction space for additive manufacturing, which provides an improved protective gas atmosphere during the process.
- a further object of the present invention is to provide a device and a method for the directed gas exposure of a construction space for additive manufacturing, which ensure the most efficient possible energy input.
- a device for the directed gas exposure of a construction space for additive manufacturing comprises: a process chamber delimiting a construction space with a construction platform extending in an X/Y plane, wherein a first edge region of the construction platform extending in the Y direction forms a gas supply side, and wherein a second end region of the construction platform opposite the gas supply side in the X direction and extending in the Y direction forms a gas discharge side, a first nozzle device which is arranged on the gas supply side immediately adjacent to the construction platform and which is designed to emit a horizontal first gas stream flowing approximately parallel to the surface of the construction platform in the X direction, and a third nozzle device which is arranged in a vertical Z direction orthogonal to the X/Y plane above the construction platform and in the X direction horizontally offset in the flow direction of the first gas stream from the first nozzle device, and is directed towards the construction platform, and which is designed to emit a third gas stream flowing in the direction of the construction platform, wherein the first and the third nozzle device
- the first nozzle device is arranged on the gas supply side immediately adjacent to the construction platform and emits a horizontal gas flow flowing approximately parallel to the surface of the construction platform in the X direction
- a third nozzle device is arranged in a vertical Z direction orthogonal to the X/Y plane above the construction platform and horizontally offset in the X direction from the first nozzle device and emits a third gas flow flowing in the direction of the construction platform, an overall gas flow is formed which generates a substantially laminar flow in the region of the construction platform from the gas supply side towards the gas discharge side.
- the third nozzle device Since the third nozzle device is offset in the flow direction of the first gas stream and aligned in the direction of the construction platform, the third gas stream presses the first gas stream against the construction platform. This allows the first gas stream to flow reliably in a laminar manner over a much larger area than if it were not exposed to the third gas stream.
- This offset is at least 20% or at least 30% or at least 40% or at least 50% of the total length of the powder bed in the flow direction of the first gas stream.
- the device can have a second nozzle device which is arranged in the vertical Z direction above or above the first nozzle device and below the third nozzle device, and is directed towards the construction platform, and which is designed to emit a second gas stream flowing in the direction of the construction platform, which is a component of the total gas stream, and wherein the second nozzle device is designed such that, in conjunction with the first and third nozzle devices, the first, second and third gas streams and thus the total gas stream generate a substantially laminar flow in the region of the construction platform.
- the first nozzle device can extend approximately over 70% to approximately 100% or 110% or 120% of an entire width of the construction platform in the Y direction and comprise between one and eight first nozzle elements, in particular conically widening in the Y direction, each with a flow channel, which form the first nozzle device.
- the first nozzle device extends approximately over the entire width of the build platform in the Y direction, it is possible to constantly supply the build platform with gas in the Y direction.
- At least one flow channel of the first nozzle device extends approximately parallel to the construction platform.
- the second nozzle device can extend approximately over 80% to approximately 100% or 110% or 120% of a total width of the construction platform in the Y direction and comprise between one and eight second nozzle elements, in particular conically widening in the Y direction, each with a flow channel, which form the second nozzle device.
- corresponding processing heads with swivel arms of a device for additive manufacturing are only slightly affected when moving within the installation space, or there is enough space for the processing heads to move almost freely.
- the second nozzle device extends over approximately the entire width of the build platform, it is possible to expose the entire surface of the build platform to a laminar gas flow.
- At least one flow channel of the second nozzle device can be inclined at an acute angle of at least 5° and a maximum of 45° relative to the construction platform.
- Such an arrangement of the at least one flow channel or flow channels of the second nozzle device supports or improves the formation of a laminar flow of the overall gas flow.
- the third nozzle device can extend approximately over 40% to approximately 100% or 110% or 120% of a total width in the Y direction of the construction platform and comprise between two and eight third nozzle elements, in particular conically widening in the Y direction, each with a flow channel, which form the third nozzle device.
- the third nozzle device also helps to ensure that the total gas flow is as laminar as possible on the build platform.
- At least one flow channel of the third nozzle device can be inclined at an acute angle of at least 30° and a maximum of 90° relative to the construction platform.
- Such an orientation or alignment of the flow channel or channels improves the laminar flow of the overall gas flow in the area of the build platform.
- the device can have at least one gas supply device which opens via a branch into three lines which are each connected to the first, second and third nozzle elements via distribution channels, wherein flow control elements can be arranged in the three lines and/or in the distribution channels and/or wherein cross-sectional areas of the lines of the distribution channels can be designed such that all nozzle elements of the respective nozzle device output approximately the same volume flow of process gas.
- nozzle elements which are arranged adjacent to or at a smaller distance from the gas supply device are subjected to a low flow resistance and thus to a lower flow velocity in the corresponding sections of the distribution channel.
- nozzle elements that are further away from the gas supply device. These have a higher flow resistance and are therefore subjected to a higher flow velocity.
- Means for designing the distribution channel accordingly can be realized by cross-sectional constrictions, resistance elements and/or the surface finish of the distribution channel.
- the device may comprise a suction device which is arranged on the gas discharge side immediately adjacent to the construction platform and which is designed to discharge the total gas flow and which extends approximately over 50% to approximately 100% of a total width in the Y direction and is preferably designed as a single suction nozzle element.
- the build platform can extend in the X-direction over a length of approximately 0.5m to 2m.
- the build platform can extend in the Y direction over a length of approximately 0.7m to 2.5m.
- the gas supply device can be designed such that the nozzle devices output the process gas at a speed of at least 1 m/s to approximately 3 m/s and preferably of approximately 2 m/s.
- Argon or nitrogen may be used as protective gas and/or functional gas.
- the gas supply device opens via a branch into three lines, which are each connected accordingly to the first, second and third nozzle devices.
- all first nozzle elements of the first nozzle device, all second nozzle elements of the second nozzle device and all third nozzle elements of the third nozzle device are each supplied with a different volume flow of process or functional gas and/or protective gas via the three lines, so that the individual nozzle elements of the first, second and third nozzle devices each output approximately the same volume flow.
- a first, second and third flow control element or a component for controlling the flow of gases can be arranged in the lines in order to control the gas flow of the first, second and third nozzle elements in such a way that all nozzle elements of a nozzle device each output approximately the same volume flow.
- all nozzle elements together can deliver a roughly uniform total gas flow of 2 m/s, since, for example, the nozzle elements further away from the edge area are supplied with a lower volume flow of gas, but with a higher flow velocity due to a higher flow resistance in the corresponding line.
- the first, second and third nozzle devices can be supplied with gas from a lateral edge region of the device via the distribution channel and the lines. Supplying the nozzle device from the edge region enables a space-saving and compact construction and, in particular, easier assembly of the device 1.
- the nozzle elements arranged in the edge region have a lower flow resistance than the other branches due to the flow control elements 37, 38, 39, so that the nozzle elements arranged in this region are subjected to a lower flow velocity.
- One or more flow measuring devices can be arranged in the construction space in the area of the construction platform.
- the flow measuring device is or are designed to measure whether there is a laminar flow in the construction space in the area in the Z direction slightly spaced from the construction platform.
- a control device (not shown) which is connected to the flow control elements and to the flow measuring device(s) and which, on the basis of the corresponding flow values, controls the flow control elements accordingly and thus controls the volume flow from the first, second and third nozzle elements in such a way that a laminar, uniform flow is present in the area of the construction platform.
- a device for additive manufacturing is provided with a device as shown above for the directed gas exposure of a construction space, wherein processing heads including swivel arms are preferably round in cross-section in order to reduce turbulence in the process chamber.
- At least one nozzle device of the device for the directed gas exposure of a construction space can be manufactured by means of an additive manufacturing process.
- nozzle element or nozzle device By using an additive manufacturing process to produce a nozzle element or nozzle device, these can be manufactured with any geometry and easily and cost-effectively.
- a method for the directed gas supply to a construction space for additive manufacturing is provided with a device for the directed gas supply to a construction space as shown above, wherein a process chamber delimiting a construction space has a construction platform extending in a horizontal X/Y plane, and wherein a first end region of the construction platform extending in the Y direction forms a gas supply side, and wherein a second end region of the construction platform opposite the gas supply side in the X direction and extending in the Y direction forms a gas discharge side, and a first nozzle device which is arranged on the gas supply side immediately adjacent to the construction platform and which emits a horizontal first gas stream flowing approximately parallel to the surface of the construction platform in the X direction, and a third nozzle device which is arranged in a vertical Z direction orthogonal to the X/Y plane above the construction platform and in the X direction horizontally offset from the first nozzle device in the flow direction of the first gas stream, and in is directed towards the construction platform and which emits a third
- the device can have a second nozzle device which is arranged in the vertical Z direction above the first nozzle device and below the third nozzle device and is directed towards the construction platform and which emits a second gas stream flowing in the direction of the construction platform, which is a component of the total gas stream, and wherein the first, the second and the third gas stream and thus the total gas stream generate a substantially laminar flow in the region of the construction platform.
- the device can have at least one gas supply device for supplying the nozzle devices with a gas flow, which is connected to the nozzle devices via a branch and three lines and distribution channels, and wherein cross-sectional areas of the distribution channels and/or the lines are designed in such a way, and/or have flow control elements, that nozzle elements of the nozzle devices output approximately the same volume flow of process gas.
- the total gas flow and thus the gas flows of the individual flow channels of the nozzle elements can have a flow velocity between 1 m/s and 3 m/s.
- the total gas flow can thus have a flow velocity of at least 1 m/s or 1.2 m/s or 1.4 m/s and a maximum of 3 m/s or 2.5 m/s and in particular 2 m/s.
- Figure 1 is a perspective view of a device according to the invention for the directed gas exposure of a construction space of a process chamber for additive manufacturing
- Figure 2 is a side view of the device of Figure 1
- Figure 3 is a perspective view of nozzle devices of the device and the process chamber of the device
- Figure 4 shows the nozzle arrangement from Figure 3 in a side view
- Figure 5 shows the nozzle view from Figure 3 in a top view.
- a device 1 is provided for the directed gas exposure of a construction space 2 of a process chamber 3 for additive manufacturing ( Figures 1 - 5).
- a construction platform 5 extending in an X/Y plane 4 for additive manufacturing is arranged.
- a first end region 7 of the construction platform 5 extending in the Y direction 6 forms a gas supply side 8.
- the device comprises a first nozzle device 12.
- the first nozzle device 12 is arranged on the gas supply side 8 directly adjacent to the construction platform 5.
- the first nozzle device 12 extends in the Y direction 6 and, according to this embodiment, comprises five first nozzle elements 13. Each of the nozzle elements 13 is designed to widen conically in the X direction 9 and has a uniform or constant cross-section in the Y direction 6.
- each of the first nozzle elements 13 forms a first flow channel 14 which is arranged approximately parallel to the surface of the construction platform 5 in the X-direction 9 and is designed to emit a first gas stream 15 flowing in the X-direction 9.
- the first nozzle elements 13 of the first nozzle device 11 or their first flow channels 14 are designed to discharge the horizontal first gas stream 15 flowing in the X direction 9 parallel to the surface of the construction platform 5.
- a second nozzle device 16 is provided, which is arranged in a vertical Z-direction 17 above or above the first nozzle device 12.
- the second nozzle device 16 comprises five second nozzle elements 18, each of which forms a second flow channel 19.
- the second nozzle elements are designed to widen conically in the X-direction 9 and have an approximately constant cross-section in the Y-direction 6.
- the second nozzle elements 18 of the second nozzle device 16 are inclined at an angle of approximately 5° relative to the X/Y plane 14 or relative to the construction platform, so that a second gas flow 20 is output via the second flow channels 19, which is directed in the direction of the construction platform 5.
- the device comprises a third nozzle device 21, which is arranged in the vertical Z direction 17 orthogonal to the X/Y plane 4 above or above the construction platform 5 and the second nozzle device 16 and in the X direction 9 horizontally or offset from the first nozzle device 12.
- the third nozzle device 21 also comprises five third nozzle elements 22.
- the third nozzle elements 22 each have a third flow channel 23, wherein the third nozzle elements 22 or the third flow channels 23 are arranged at an angle of approximately 60° relative to the X/Y plane 4 or the construction platform 5.
- the third nozzle elements 22 are designed to expand approximately conically in the X direction 9 and have an approximately constant cross-section in the Y direction 6.
- a third gas stream 24 flowing in the direction of the construction platform 5 is emitted via the third nozzle elements 22 of the third nozzle device 21.
- the first nozzle device 12 and the second nozzle device 16 extend approximately over 100% of the width of the construction platform 5 in the region of the gas supply side 8.
- the third nozzle device 21 extends approximately over 90% of the width of the construction platform 5 in the X direction 9.
- the device comprises a gas supply device 25.
- the gas supply device 25 is designed to supply process or functional gas and/or protective gas, such as argon or nitrogen.
- the gas supply device 25 opens via a branch 27 into three lines 34, 35 and 36, which are each connected to the first, second and third nozzle elements 13, 18 and 22 via distribution channels 26.
- all first nozzle elements 13 of the first nozzle device 12, all second nozzle elements 18 of the second nozzle device 16 and all third nozzle elements 22 of the third nozzle device 21 are supplied with an equal volume flow of process or functional gas and/or protective gas via the three lines 34, 35 and 36 and the distribution channels 26.
- the nozzle devices 12, 16, 21 and/or the three lines 34, 35, 36 and/or the branches 26 are structurally designed in such a way that the individual nozzle elements 13, 18, 22 of the first, second and third nozzle devices 12, 16, 21 output approximately the same volume flow.
- first, second and a third flow control elements 37, 38, 39 or a component for controlling the flow of gases, such as a valve or a flap, are arranged in the lines 34, 35 and 36 and/or the branches 26 in order to control the gas flow of the first, second and third nozzle devices 12, 16, 21 in such a way that all nozzle elements 13, 18, 22 of the Nozzle devices 12, 16, 21 each output approximately the same volume flow.
- the flow control elements 37, 38, 39 are shown in the lines 34, 35, 36.
- flow control elements can also be arranged in the branches 26 from the lines 34, 35, 36 to the individual nozzle elements 13, 28, 22.
- flow control elements 37, 38, 39 can be dispensed with if necessary through structural design, such as cross-sectional reductions or cross-sectional expansions of the lines 34, 35, 36 and/or the distribution channels 26.
- structural design such as cross-sectional reductions or cross-sectional expansions of the lines 34, 35, 36 and/or the distribution channels 26.
- the only decisive factor is that the individual nozzle elements 13, 18, 22 of the nozzle devices 12, 16, 21 each output approximately the same volume flow or output the process or functional gas and/or protective gas at approximately the same flow rate.
- all nozzle elements together emit an approximately uniform total gas flow 33 of 2 m/s, since the nozzle elements further away from the edge region 28 are subjected to a lower volume flow of gas, but with a higher flow velocity due to a higher flow resistance in the distribution channel.
- the first, second and third nozzle devices 12, 16 and 21 are supplied with gas from an edge region 28 of the device 1 via the lines 34, 35, 36.
- the supply of the nozzle devices 12, 16 and 21 from the edge region 28 enables a space-saving and compact construction and in particular a simpler assembly of the device 1.
- distribution channels 26 of the lines 34, 35, 36 arranged in the edge region 28 to the nozzle elements 13, 28, 22 have a low flow resistance due to the flow control elements 37, 38, 39, which becomes increasingly greater the further the nozzle elements are spaced from the edge region 28, so that the nozzle elements are subjected to an increasingly greater flow velocity starting from the edge region 28.
- all nozzle elements 13, 28, 22 of the first, second and third nozzle devices 12, 16 and 21 then output an approximately equal volume flow with an approximately equal flow velocity.
- one or more flow measuring devices are arranged in the area of the construction platform. The flow measuring device is or are designed to measure whether a laminar flow is present in the construction space in the area in the Z direction slightly spaced from the construction platform.
- a control device is provided (not shown), which is connected to the flow control elements 37, 38, 39 and to the flow measuring device(s) and, on the basis of the corresponding flow values, controls the flow control elements accordingly and thus controls the volume flow from the first, second and third nozzle elements 13, 18, 22 in such a way that a laminar flow is present in the area of the construction platform.
- An extraction device 29 is arranged in the area of the gas discharge side 11.
- the suction device 29 comprises a suction nozzle 30 which extends in the Y direction 6 approximately over 100% or the entire width of the construction platform 5.
- a single suction nozzle element 31 is provided, wherein in the suction nozzle element according to the present embodiment five suction channels 32 are formed which have a conically tapering cross-section.
- the suction nozzle element 31 has an approximately constant cross-section in the Y direction 6.
- a device 33 for additive manufacturing which comprises the device 1 described above for the directed gas exposure of a construction space 2 for additive manufacturing (not shown).
- This device 33 comprises one and preferably several processing heads with swivel arms (not shown).
- the processing heads and/or the swivel arms are round in cross-section in order to reduce turbulence in the process chamber 3.
- the first and/or the second and/or the third nozzle device 12, 16 and 21 can be manufactured by means of an additive manufacturing process.
- a method for the directed gas supply to a construction space 2 for additive manufacturing is also provided with a device 1 as shown above for the directed gas supply to a construction space 2, wherein a process chamber delimiting a construction space has a construction platform extending in a horizontal X/Y plane, and wherein a first end region of the construction platform extending in the Y direction forms a gas supply side, and wherein a gas supply side in the X direction opposite second end region of the build platform extending in the Y direction forms a gas discharge side, and a first nozzle device which is arranged on the gas supply side immediately adjacent to the build platform and which emits a horizontal first gas stream flowing approximately parallel to the surface of the build platform in the X direction, and a third nozzle device which is arranged in a vertical Z direction orthogonal to the X/Y plane above the build platform and horizontally offset in the X direction from the first nozzle device, and is directed towards the build platform and which emits a third gas stream flowing in the direction of the build platform
- the device can have a second nozzle device which is arranged in the vertical Z direction above the first nozzle device and below the third nozzle device and is directed towards the construction platform and which emits a second gas stream flowing in the direction of the construction platform, which is part of the total gas stream, and wherein the first, the second and the third gas stream and thus the total gas stream generate a substantially laminar flow in the region of the construction platform.
- the device can have at least one gas supply device with a branch and distribution channels, wherein cross-sectional areas of the distribution channel are designed and/or flow control elements are provided such that all nozzle elements of the nozzle device output approximately the same volume flow of process gas.
- the total gas flow and thus the gas flows of the individual flow channels of the nozzle elements can have a flow velocity between 1 m/s and 3 m/s.
- the total gas flow can thus have a flow velocity of at least 1 m/s or 1.2 m/s or 1.4 m/s and a maximum of 3 m/s or 2.5 m/s and in particular 2 m/s.
- the first part concerns simulation results after geometrical improvement of the components, while the second part concerns optimization results of flow rates.
- the third section summarizes the simulation cases, such as the effect of a heated powder bed at 200 °C, the use of air instead of nitrogen, and the case where obstacles such as laser arms were included.
- the simulation results show a significant improvement in the flow distribution in a process chamber of a device according to the invention or when using a method according to the invention.
- Figure 5 Flow distribution on the horizontal plane at a distance of 20 mm from the powder bed after optimization shows a velocity distribution on a horizontal plane 20 mm above the powder bed, and the flow has a fairly uniform distribution over the distributor as well as the individual nozzles. The deflection of the flow to the left of the powder bed is compensated by the extended length of the nozzles against the powder bed (Figure 5).
- the liquid flow distribution in the direction perpendicular to the powder bed was plotted both as a side view of the volumetric distribution and in the center plane along the powder bed as in Figure 4 (side view of volumetric flow distribution along powder bed).
- the volumetric plot has the advantage of representing the overall flow trend with a lighter color, whereas a single plane might misrepresent the entire velocity profile along the length as a single sample.
- the single plane ( Figure 4 right) better represents the interaction of the flows from the nozzles. It can be seen that the flow from the lower nozzles (first nozzle setup) is squeezed as it moves along the powder bed, while the flow from the middle and upper nozzles (second and third nozzle setup) prevents the flow from separating.
- the device is able to prevent recirculation of the weld plume within the process chamber and flow over the outlet nozzle due to the shape of the outlet nozzle and the diversion by the flow from the upper nozzle.
- This is evident from Figures 5 and 4, as there are areas of very low velocities only in the rear area of the outlet nozzle, which means that most of the by-products should be effectively captured. It can also be seen that by using a double plenum design in combination with a perforated plate inside the nozzles and the asymmetric design of the outlet, the common problem of uneven distribution over the nozzle length can be overcome.
- the upper, middle and lower mass flow rates obtained from the surface behavior based optimization were 0.040506 kg/s, 0.076561 kg/s and 0.12092 kg/s respectively.
- the optimization results were verified by simulation and the results for the flow distribution 20 mm above the powder bed are shown in Figure 5.
- the uniformity of the flow in the considered horizontal and vertical planes was found to be 0.92665 and 0.89637. It can also be seen that the low velocity region at the lower left side of the powder bed has been further improved and now covers the entire area of the powder bed. This also shows how important it is to optimize the flow in LPBF systems with multiple inlets.
- the velocities in the desired range are almost identical at around 1.5 m/s to 2.5 m/s, which suggests a uniform flow along different sections.
- the lower limit of this velocity is clearly close to 1.5 m/s, which was chosen as the minimum velocity when designing the outlet nozzle.
- the laser arms were omitted from the CAD model for simplicity, and also because of the dynamic nature of the laser position, it would be difficult to predict the most flow-disrupting configuration of eight lasers. Since the laser arms directly impede the flow from the upper nozzles, a configuration was chosen where the laser arms are rotated to have a greater length to disrupt the flow.
- the flow uniformity in the horizontal plane does not change significantly even after including the laser arms as in the model, because at 20 mm above the powder bed it is more influenced by the flows from the lower and middle nozzles, and these two flows are free of obstructions in any laser configuration.
- the flow separation is less due to the Coanda effect on the curved surface of the laser arm, as can be seen in Figure 59.
- the powder bed is heated to a nominal temperature of 200° Celsius.
- This preheating allows the microstructure to be adjusted and the mechanical properties of the product to be improved by enhancing the thermal field generated by the cyclic laser heating. Since this heating can have an impact on the fluid properties such as density and kinematic viscosity and thus on the fluid properties and related effects such as buoyancy, a simulation was carried out with a powder bed heated to 200 °C.
- the average internal temperature of the chamber is approximately 80 °C. There seems to be no significant change in the velocity distribution compared to the case without heating.
- the shielding gas flow system for the high volume LPBF system was designed.
- the desired flow behavior was quantified in terms of average velocity, flow uniformity, and flow distribution in the chamber.
- the shielding gas flow system design was developed from scratch using the device according to the invention.
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Abstract
L'invention concerne un dispositif d'alimentation dirigée en gaz d'un espace de construction pour la fabrication additive. Ce dispositif comprend : une chambre de traitement délimitant un espace de construction comprenant une plate-forme de construction s'étendant dans un plan X/Y, une première zone de bord de la plate-forme de construction s'étendant dans la direction Y formant un côté d'alimentation en gaz, et une deuxième zone d'extrémité de la plate-forme de construction opposée au côté d'alimentation en gaz dans la direction X et s'étendant dans la direction Y formant un côté d'évacuation de gaz, un premier ensemble buse, qui est disposé sur le côté d'alimentation en gaz, directement à proximité de la plate-forme de construction, et qui est conçu pour délivrer un premier flux de gaz horizontal, s'écoulant approximativement de manière parallèle à la surface de la plateforme de construction dans la direction X, et un troisième ensemble buse, qui est disposé dans une direction Z verticale perpendiculaire au plan X/Y au-dessus de la plate-forme de construction et de manière décalée horizontalement dans la direction X par rapport au premier ensemble buse, et qui est dirigé vers la plate-forme de construction, et qui est conçu pour délivrer un troisième flux de gaz s'écoulant en direction de la plate-forme de construction, le premier et le troisième ensemble buse étant conçus de sorte que le premier et le troisième flux de gaz forment un flux de gaz total qui, dans la zone de la plate-forme de construction, génère un flux sensiblement laminaire du côté de l'alimentation en gaz vers le côté de l'évacuation de gaz.
Priority Applications (1)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| CN202480027622.5A CN121001841A (zh) | 2023-04-24 | 2024-04-23 | 用于增材制造的定向施加气体至成型空间的装置和方法 |
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| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| DE102023110357.1 | 2023-04-24 | ||
| DE102023110357.1A DE102023110357A1 (de) | 2023-04-24 | 2023-04-24 | Vorrichtung und Verfahren zur gerichteten Gasbeaufschlagung eines Bauraums zur additiven Fertigung |
Publications (1)
| Publication Number | Publication Date |
|---|---|
| WO2024223592A1 true WO2024223592A1 (fr) | 2024-10-31 |
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Family Applications (1)
| Application Number | Title | Priority Date | Filing Date |
|---|---|---|---|
| PCT/EP2024/061131 Pending WO2024223592A1 (fr) | 2023-04-24 | 2024-04-23 | Dispositif et procédé d'alimentation dirigée en gaz d'un espace de construction pour la fabrication additive |
Country Status (3)
| Country | Link |
|---|---|
| CN (1) | CN121001841A (fr) |
| DE (1) | DE102023110357A1 (fr) |
| WO (1) | WO2024223592A1 (fr) |
Cited By (1)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| CN120734359A (zh) * | 2025-09-02 | 2025-10-03 | 上海毅速激光科技有限公司 | 一种增材制造大幅面成型平台用气流均匀分布的风场系统 |
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Also Published As
| Publication number | Publication date |
|---|---|
| DE102023110357A1 (de) | 2024-10-24 |
| CN121001841A (zh) | 2025-11-21 |
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