Method and device for layer-wise production of patterns

• US 10,099,426 B2
• Filed: 10/17/2016
• Issued: 10/16/2018
• Est. Priority Date: 10/21/2007
• Status: Active Grant

• Current Assignee: Voxeljet AG
• Original Assignee: Voxeljet AG
• Inventors: Ederer, Ingo, Hartmann, Andreas
• Primary Examiner(s): Dillon, Jr., Joseph A
• Application Number:
  US15/295,122
• Publication Number:
  US 20170028630A1
• Time in Patent Office: 729 Days
• Field of Search: 264113, 425375, 406 53, 406106
• CPC Class Codes: B05C 19/06 Storage, supply or control of the application of particulate material; Recovery of excess particulate material
• CPC Class Codes: B22F 10/10 Formation of a green body
• CPC Class Codes: B22F 10/73 of powder
• CPC Class Codes: B22F 12/60 Planarisation devices; Compression devices
• CPC Class Codes: B22F 2998/00 Supplementary information concerning processes or compositions relating to powder metallurgy
• CPC Class Codes: B22F 2998/10 Processes characterised by the sequence of their steps
• CPC Class Codes: B22F 3/003 Apparatus, e.g. furnaces in general F27B
• CPC Class Codes: B29C 64/141 using only solid materials
• CPC Class Codes: B29C 64/153 using layers of powder being selectively joined, e.g. by selective laser sintering or melting
• CPC Class Codes: B29C 64/165 using a combination of solid and fluid materials, e.g. a powder selectively bound by a liquid binder, catalyst, inhibitor or energy absorber
• CPC Class Codes: B29C 64/35 Cleaning
• CPC Class Codes: B29C 64/357 Recycling
• CPC Class Codes: B29K 2105/251 Particles, powder or granules expandable particles B29K2105/046
• CPC Class Codes: B33Y 10/00 Processes of additive manufacturing
• CPC Class Codes: B33Y 30/00 Apparatus for additive manufacturing; Details thereof or accessories therefor
• CPC Class Codes: B33Y 40/00 Auxiliary operations or equipment, e.g. for material handling
• CPC Class Codes: Y02P 10/25 Process efficiency

Abstract

The present invention relates to apparatus, devices and methods for conveying particulate material during the manufacture of patterns in layers, wherein powder is conveyed out of a reservoir into a spreader unit having an ejection system.

Claims

1. An apparatus for the manufacture of a three-dimensional object in layers comprising

i) a device for conveying a particulate material during the manufacture of the object in layers, wherein the devise comprises

a) a reservoir,

b) a spreader unit,

c) a particulate material conveying component, and

d) a build platform on which the object is built;

wherein

the particulate material conveying component conveys the particulate material from the reservoir to the spreader unit;

the spreader unit is adapted for spreading the particulate material onto the build platform as a layer of the particulate material, and

the device includes an ejection system for filling the spreader unit with the particulate material, the ejection system including a first component having a pattern of openings and a second component having the same pattern of openings, wherein the first component moves relative to the second component for shifting the patterns of openings between an aligned configuration and a sealed configuration.

3. The apparatus of claim 1, wherein the particulate material conveying component includes a screw conveyor.

4. The apparatus of claim 3, wherein the screw conveyor runs horizontally above the spreader unit.

5. The apparatus of claim 4, wherein the screw conveyor extends the length of the spreader unit.

6. The apparatus of claim 1, wherein the reservoir is arranged below the spreader unit in a vertical direction, at least during a filling process.

7. The apparatus of claim 1, wherein the apparatus includes a recirculation system for reintroducing particulate material back into the spreader after being ejected from the ejection system.

8. The apparatus according to claim 7, wherein provision is furthermore made for a junction for introducing new particulate material into the reservoir.

13. The apparatus of claim 1, wherein the pattern of openings includes a plurality of openings.

14. The apparatus of claim 13, wherein gravity forces the particulate material through the plurality of openings.

19. The apparatus of claim 6, wherein

the reservoir is arranged below the spreader unit in a vertical direction, at least during a filling process;

and

the apparatus includes a recirculation system for reintroducing particulate material back into the spreader after being ejected from the ejection system, wherein provision is furthermore made for a junction for introducing new particulate material into the reservoir.

2. An apparatus for the manufacture of a three-dimensional object in layers comprising:

i) a device for conveying a particulate material during the manufacture of the object in layers, wherein the devise comprises

a) a reservoir,

b) a spreader unit,

c) a particulate material conveying component, and

d) a build platform on which the object is built;

wherein

the particulate material conveying component conveys the particulate material from the reservoir to the spreader unit;

the spreader unit is adapted for spreading the particulate material onto the build platform and

the device includes an ejection system for filling the spreader unit with the particulate material, the ejection system including a first component having a pattern of openings and a second component having the same pattern of openings, wherein the first component moves relative to the second component for shifting the patterns of openings between an aligned configuration and a sealed configuration;

wherein the first component and the second component are tubes having spaced apart openings along a bottom length of the tubes.

15. The apparatus of claim 2, wherein the particulate material conveying component includes a screw conveyor.

16. The apparatus of claim 15, wherein the screw conveyor runs horizontally above the spreader unit and extends the length of the spreader unit.

17. The apparatus of claim 16, wherein the reservoir is arranged below the spreader unit in a vertical direction, at least during a filling process.

18. The apparatus of claim 17, wherein the apparatus includes a recirculation system for reintroducing particulate material back into the spreader after being ejected from the ejection system, wherein provision is furthermore made for a junction for introducing new particulate material into the reservoir.

9. A method of constructing a three-dimensional article in layers with a device for conveying a particulate material during the manufacture of the article in layers, wherein the devise includes a reservoir, a spreader unit, a particulate material conveying component, and a build platform on which the object is built;

the method comprising the following steps;

conveying a particulate material from the reservoir to the spreader unit with the particulate material conveying component;

filling the spreader unit with the particulate material using an ejection system; and

spreading the particulate material onto the build platform as a layer of the particulate material with the spreader unit;

wherein the ejection system includes a first component having a pattern of openings and a second component having the same pattern of openings, wherein the first component moves relative to the second component for shifting the patterns of openings between an aligned configuration and a sealed configuration.

10. The method of claim 9, wherein the particulate material conveying component includes a screw conveyor and the method includes moving the first and/or the second component of the ejection system for sealing a bottom of the ejection system;

and rotating the screw conveyor for filling the spreader while the bottom of the ejection system is sealed.

11. The method of claim 9, wherein the method includes opening a bottom of the ejection system only after the particulate material is distributed throughout an entire length of the spreader.

12. The method of claim 9, wherein the first component and the second component are tubes having spaced apart openings along a bottom length of the tubes, and the method includes rotating one of the tubes for aligning the openings.