Machine and method for powder-based additive manufacturing

• US 10,413,968 B2
• Filed: 07/31/2013
• Issued: 09/17/2019
• Est. Priority Date: 07/31/2012
• Status: Active Grant

• Current Assignee: Compagnie Generale DES Etablissements Michelin SCA, Michelin Recherche et Technique SA (Compagnie Generale DES Etablissements Michelin SCA)
• Original Assignee: Compagnie Generale DES Etablissements Michelin SCA
• Inventors: Pialot, Frederic, Torres-Catellano, Miguel, Walrand, Gilles, Pourcher, Benoit
• Primary Examiner(s): Dunn, Colleen P
• Assistant Examiner(s): Wang, Nicholas A
• Application Number:
  US14/418,644
• Publication Number:
  US 20150202687A1
• Time in Patent Office: 2,239 Days
• CPC Class Codes: B22F 10/28 Powder bed fusion, e.g. selective laser melting [SLM] or electron beam melting [EBM]
• CPC Class Codes: B22F 10/73 of powder
• CPC Class Codes: B22F 12/222 for motion along a direction orthogonal to the plane of a layer
• CPC Class Codes: B22F 12/49 Scanners
• CPC Class Codes: B22F 12/52 Hoppers
• CPC Class Codes: B22F 12/63 Rollers
• CPC Class Codes: B22F 3/003 Apparatus, e.g. furnaces in general F27B
• CPC Class Codes: B23K 15/0086 welding for purposes other than joining, e.g. built-up welding
• CPC Class Codes: B23K 26/342 Build-up welding
• CPC Class Codes: B28B 1/001 Rapid manufacturing of 3D objects by additive depositing, agglomerating or laminating of material selective deposition modelling of metallic powder B22F10/00; rapid manufacturing of 3D objects in general and in particular of plastics B29C64/00
• 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 64/232 for motion along the axis orthogonal to the plane of a layer
• CPC Class Codes: B29C 64/245 Platforms or substrates support structures intended to be sacrificed after manufacture B29C64/40
• CPC Class Codes: B29C 64/25 Housings, e.g. machine housings
• 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: Y02P 10/25 Process efficiency

Abstract

The machine presents a working zone that is defined in an upper part of a build sleeve which is fixedly mounted in a chassis. Within the working zone, the object is supported by a build plate which slides inside the build sleeve when driven in vertical translation by the head of an actuating cylinder which is placed along a central axis of the sleeve. The build plate is positioned inside a transport container which is arranged removably between the sleeve and the actuating cylinder. The machine also includes a means for moving the transport container vertically into contact with the build sleeve. The container is open at its top and at its bottom so that, when the actuating cylinder is actuated, the head thereof can transfer the plate between the transport container and the build sleeve which forms a build envelope around the plate.

Claims

1. A machine for the additive manufacture of a three-dimensional object by sintering or melting powder using a beam of energy acting on a layer of powder comprising:

a working zone, wherein the working zone is defined in an upper part of a build sleeve in which the three-dimensional object is manufactured, wherein the build sleeve has a height which defines a maximum height for the three-dimensional object to be manufactured such that the entire three-dimensional object remains in the build sleeve during manufacturing;

a chassis, in which the build sleeve is fixedly mounted;

a build plate which supports the three-dimensional object, and which slides inside the build sleeve when driven in vertical translation;

a head of an actuating cylinder placed along the central axis of the build sleeve, and which drives the build plate in vertical translation;

wherein the build plate is positioned inside a transport container which is made as a separate piece from the sleeve and which is arranged removably below a lower edge of the build sleeve and above the actuating cylinder;

a raising device that is configured to move the transport container vertically upwardly into contact with the build sleeve; and

wherein the transport container is open at its top and at its bottom so that, when the actuating cylinder is actuated, the head transfers the plate from the transport container to the build sleeve, which forms a build envelope around the build plate, and so that the head of the actuating cylinder are retractable out of the bottom of the transport container such that the transport container with the build plate and the three-dimensional object can be transported away from the build sleeve and away from the actuating cylinder.

2. The machine according to claim 1, wherein the central axis of the actuating-cylinder head is aligned with the central axis of the build sleeve, and further comprising an indexing means for orienting the transport container relative to the chassis of the machine, and a centering means for centering between the build plate relative to the head of the actuating cylinder.

3. The machine according to claim 2, wherein the raising device comprises push rods belonging to a box fixedly mounted on the chassis and which collaborate with orifices made in the bottom part of the transport container.

4. The machine according to claim 2, wherein the indexing means comprises studs made on a bottom rim of the build sleeve and collaborating with openings made on a top rim of the transport container.

5. The machine according to claim 2, wherein the centering means comprises two diametrically opposite orifices on a bottom face of the build plate which collaborate with protuberances situated on a frontal face of the head of the actuating cylinder.

6. The machine according to claim 1, wherein the build plate slides freely inside the build sleeve and inside the transport container.

7. The machine according to claim 1, wherein a sliding clearance for sliding of the build plate inside the transport container is greater than a sliding clearance for sliding of the build plate inside the build sleeve.

8. The machine according to claim 1, wherein the transport container comprises a sealed flexible bellows arranged between the build plate and its bottom wall.

9. The machine according to claim 1, wherein the build sleeve comprises a periphery having lateral openings outside of the working zone which are made to communicate with a transport container when it is placed underneath.

10. The machine according to claim 9, wherein the transport container comprises an internal chamber for accepting the build plate, which internal chamber is surrounded by a peripheral corridor communicating at its top with the said lateral openings of the build sleeve.

11. The machine according to claim 1, wherein the actuating cylinder drives the build plate via an intermediate plate.

12. The machine according to claim 1, wherein the raising device includes a frame actuated in a horizontal translational movement.

13. A method for the additive manufacture of a three-dimensional object by sintering or melting powder using a beam of energy acting on a layer of powder in a working zone of a machine according to claim 1, wherein the working zone is defined in the upper part

of the fixed build sleeve in which the object is manufactured, the object being supported by

a build plate which slides inside the build sleeve when driven in vertical translation by

the head of the actuating cylinder placed along the central axis of the build sleeve, comprising:

positioning the plate inside the transport container, which is open at its top and at its bottom;

removably arranging the transport container between the build sleeve and the actuating cylinder

vertically moving the transport container until it comes into contact with the build sleeve; and

transferring the build plate between the transport container and the build sleeve which forms a build envelope around the build plate using the actuating cylinder.

14. The method according to claim 13, comprising successively:

bringing the build plate to the top of the build sleeve,

depositing a layer of powder on the build plate,

melting the powder particles using a pre-established melting strategy,

repeating the depositing and melting steps layer by layer while at the same time progressively lowering the build plate down inside the build sleeve until the object is obtained,

lowering the build plate and with the object out of the build sleeve and into the transport container only after the depositing and melting steps are completed,

lowering the build plate to the bottom of the transport container,

moving the actuating cylinder until it is detached from the build plate, and

removing the transport container from the machine with the unmelted and previously melted powder particles inside the transport container.