Device and method for manufacturing a three-dimensional object by means of an application device for building material in powder form

• US 9,327,450 B2
• Filed: 10/31/2007
• Issued: 05/03/2016
• Est. Priority Date: 11/10/2006
• Status: Active Grant

• Current Assignee: EOS GmbH Electro Optical Systems
• Original Assignee: EOS GmbH Electro Optical Systems
• Inventors: Hein, Peter, Mller, Frank
• Primary Examiner(s): Johnson, Christina
• Assistant Examiner(s): LIU, XUE H
• Application Number:
  US12/311,585
• Publication Number:
  US 20090206522A1
• Time in Patent Office: 3,107 Days
• Field of Search: 425/143, 425/174.4, 264/497, 264/460, 264/488, 264/482, 264/109, 264/112, 264/113, 264/123, 264/125
• US Class Current: 1/1
• CPC Class Codes: B22F 10/28 Powder bed fusion, e.g. selective laser melting [SLM] or electron beam melting [EBM]
• CPC Class Codes: B22F 10/322 of the gas flow, e.g. rate or direction
• CPC Class Codes: B22F 10/34 of powder characteristics, e.g. density, oxidation or flowability
• CPC Class Codes: B22F 10/368 Temperature or temperature gradient, e.g. temperature of the melt pool
• CPC Class Codes: B22F 12/22 Driving means
• CPC Class Codes: B22F 12/38 Housings, e.g. machine housings
• CPC Class Codes: B29C 64/153 using layers of powder being selectively joined, e.g. by selective laser sintering or melting
• CPC Class Codes: B33Y 10/00 Processes of additive manufacturing
• CPC Class Codes: B33Y 40/00 Auxiliary operations or equipment, e.g. for material handling
• CPC Class Codes: B33Y 40/10 Pre-treatment
• CPC Class Codes: Y02P 10/25 Process efficiency

Abstract

A device and a method for manufacturing a three-dimensional object (3) by solidifying layers (25) of a material in powder form at those positions corresponding to the respective cross-section of the object (3) are provided. The device comprises an application device (40) for applying layers of the material in powder form (47) in the building area (5), which can be moved over the building area (5). The application device (40) is formed to have a first longitudinal wall (41a) and a second longitudinal wall (41b) that are connected to one another via two side walls. The application device (40) is provided with a fluidization device for homogenizing the material in powder form (47). This fluidization device comprises at least one hollow body having escape openings in its walls, through which escape opening a gas can flow from the hollow body into the material in powder form (47).

Claims

1. A device for manufacturing three-dimensional object by solidification of layers of a powder material at those positions corresponding to the respective cross-section of the object, said device including:

an application device for applying powder in layers, the application device being movable over a building area and having;

a first longitudinal wall and a second longitudinal wall that are connected to one another via side walls so as to form a supply chamber having a longitudinal direction substantially transverse to a direction of movement of the application device, said first and second longitudinal walls being substantially longer than said side walls,

a device for fluidizing the powder material by means of a fluidizing gas that is fed to the application device, and

a device for an open loop and/or closed loop control of the pressure and/or the flow rate of said fluidizing gas,

the device for manufacturing three-dimensional object further comprising an irradiation device for irradiating powder for solidification of the powder material.

2. The device for manufacturing three-dimensional object according to claim 1, in which the device for fluidizing the powder material comprises at least one hollow body having a wall and gas escape openings in the wall, and gas flows through the hollow body.

3. The device for manufacturing three-dimensional object according to claim 2, in which the hollow body has a pipe shape.

4. The device for manufacturing three-dimensional object according to claim 2, in which the hollow body is arranged close to the lower edge of the first longitudinal wall or of the second longitudinal wall.

5. The device for manufacturing three-dimensional object according to claim 3, in which two parallel pipes are arranged as hollow bodies.

6. The device for manufacturing three-dimensional object according to claim 4, in which two parallel pipes are arranged as hollow bodies.

7. The device for manufacturing three-dimensional object according to claim 1, further having a closed loop temperature control device, by which the temperature of the application device can be controlled.

8. The device for manufacturing three-dimensional object according to claim 2, further having a closed loop temperature control device, by which the temperature of the application device can be controlled.

9. The device for manufacturing three-dimensional object according to claim 3, further having a closed loop temperature control device, by which the temperature of the application device can be controlled.

10. The device for manufacturing three-dimensional object according to claim 4, further having a closed loop temperature control device, by which the temperature of the application device can be controlled.

11. The device for manufacturing three-dimensional object according to claim 5, further having a closed loop temperature control device, by which the temperature of the application device can be controlled.

12. The device for manufacturing three-dimensional object according to claim 6, further having a closed loop temperature control device, by which the temperature of the application device can be controlled.

13. The device for manufacturing three-dimensional object according to claim 1, wherein the irradiation device effects solidification by means of electromagnetic radiation or particle radiation.

15. The device according to claim 1, wherein the supply chamber extends over the entire building area in a direction transverse to said direction of movement of the application device.

14. A device for manufacturing three-dimensional object by solidification of layers of a powder material at those positions corresponding to the respective cross-section of the object, said device including:

an application device for applying powder in layers, the application device being movable over a building area and having;

a first longitudinal wall and a second longitudinal wall that are connected to one another via side walls so as to form a supply chamber having a longitudinal direction substantially transverse to a direction of movement of the application device, said first and second longitudinal walls being substantially longer than said side walls,

a device for fluidizing the powder material by means of a fluidizing gas that is fed to the application device, and

a device for an open loop and/or closed loop control of the pressure and/or the flow rate of said fluidizing gas, wherein the device for an open loop and/or closed loop control is configured to adjust the pressure and/or flow rate of the fluidizing gas based on the position of the application device,

the device for manufacturing three-dimensional object further comprising;

an irradiation device for irradiating powder for solidification of the powder material, and

a dosage device for providing an amount of the powder material for one layer to the device for fluidizing the powder material.