DE102007040755A1 - Laser sintering device for producing three-dimensional objects by compacting layers of powdered material, comprises lasers, assembly space with object carrier mechanism, and ten coating devices for applying the layers on the carrier - Google Patents

Abstract

The laser sintering device for producing three-dimensional objects (3) by compacting layers (5) of a powdered material at points corresponding to the respective cross-section of the object by laser radiation (6a), comprises lasers (6), an assembly space (1a) with an object carrier mechanism (2), ten coating devices (8a, 8b) for applying the layers on the carrier mechanism, and a storage chamber for the provision of the powdered material. The coating devices are arranged related to the height of the object in such a manner that layers lying directly with the coating devices are applied. The laser sintering device for producing three-dimensional objects (3) by compacting layers (5) of a powdered material at points corresponding to the respective cross-section of the object using laser radiation (6a), comprises lasers (6), an assembly space (1a) with an object carrier mechanism (2), ten coating devices (8a, 8b) for applying the powdered layers on the carrier mechanism, and a storage chamber for the provision of the powdered material. The coating devices are arranged related to the height of the object in such a manner that layers lying directly with the coating devices are applied. A transport-equipment is intended for the transport of the powdered material from the storage to the assembly space. The two coating devices are formed as transport device. A storage space is intended at the coating devices for the provision of the powdered material and a different material and/or a material is intended with different colors in the storage space. A control-equipment is intended for the laser and is formed in such a manner that the intensity of the radiation of the laser is adaptable to the different powdery materials. The two coating devices are displaceable: from an initial position at an end of the assembly space along an application way via the carrier mechanism of the assembly space away from a final position at an opposite end; along another way into the starting position; to a first reversing position after reaching the final position; from the first reversing position to a second reversing position along a parallel way in a horizontal manner; and from the second reversing position into the starting position in a vertical manner. The number of lasers corresponds to the number of coating devices. An independent claim is included for a method for producing three-dimensional objects by compacting layers of a powdered material.

Description

The The invention relates to a laser sintering apparatus for producing three-dimensional objects by solidifying successive ones Layers of a powdery material to the respective Cross section of the object corresponding points by means of laser radiation. Furthermore, the invention relates to a method for producing three-dimensional Objects by selective laser sintering of powdery Material.

Laser sintering devices for selective laser sintering or corresponding methods are from the State of the art basically known. When selective Laser sintering is a process with which spatial Structures by sintering from a powdery starting material can be produced. It is a generative layer construction process, which was developed at the University of Texas. powder coatings are selectively melted and solidified by laser irradiation. On such a solidified powder layer is a new layer Applied powder and in turn selectively melted and solidified. This process is repeated until the desired object is finished. Thus, with this method almost massive components are produced directly.

The known laser sintering apparatuses for carrying out the selective laser sintering method generally comprise a laser, a construction space with a support means arranged therein, for supporting the object, and a coater for applying powdery layers to the support means. Such a device is, for example, in the DE 102 39 369 A1 disclosed. In this device, a thin layer of powdery material from a storage container or the like is applied to the working plane or the carrier device by means of a coater, which may be formed, for example, as a doctor blade which comprises a sharp blade. The support means generally consists of a plate or the like which lies at the beginning of the manufacturing process in a working plane. To apply the layer, the coater travels from an initial position at one end of the construction space to an end position at the opposite end of the construction space and distributes the powder layer as evenly as possible over the working plane. After application, the coater travels back to its initial position in the same way, and then the points corresponding to the respective cross section of the object to be produced are solidified by means of laser radiation. Thereafter, the support means, which is designed as a lowerable platform and at the same time forms the space floor, down to the space to normally about 50 to 200 to reduced (depending on the particle size and type). Subsequently, a new powder layer is applied by means of the coater and the laser beam in turn melts the powder particles of the second layer together and the second with the first layer. In this way, gradually creates a multi-layered powder cake and in it a component, eg. B. an injection mold or the like.

The Producing an object in such a way increases the layered application and solidification of the powder relative a lot of time. The production of only a few inches large object can take many hours.

task Therefore, it is the object of the present invention to provide a laser sintering apparatus and to provide a method of the type mentioned, with which a three-dimensional object by means of selective laser sintering quickly can be produced.

The The object is achieved by a laser sintering device with the features of claim 1.

Of the The core idea of the present invention is accordingly to the laser sintering device provide at least two coaters, with each one a powdery layer on the work platform or the carrier device can be applied. Further are the at least two coaters based on the height of the Object so displaceable to each other arranged that with them directly superimposed layers can be applied. Since the working plane or the of the support device provided platform normally aligned horizontally is, the height of the object expands in the vertical direction out. Thus, the at least two coaters are in the vertical direction offset to each other is arranged. With the help of the present invention It is now possible to apply two layers without in between the coater back to the initial position must be moved.

Also the carrier device must only after the application of two Layers are moved down into the building space instead, as usual in the art, already after each shift. This results in a considerable time savings in the production an object.

Accordingly, with the laser sintering device according to the invention, it is possible with a first of the at least two coaters to apply a layer which is solidified at the corresponding points by a laser. The first coater initially remains in the final position. Thereafter, the second of the at least two coaters, by moving from the start to the end position, applies another layer, which in turn adjoins the corresponding one Positions of the laser is solidified. Only then must the at least two coaters be moved back to their initial position and the transport device lowered. Of course, these traverses can be controlled to take place simultaneously, thereby saving further time.

There the layers to be applied are very thin can the at least two coaters expediently also offset in the horizontal direction to each other or one behind the other be both in the initial position and in the final position. hereby It is achieved that they are superimposed layers can apply and still not hinder each other. In principle, however, any other suitable arrangement or training the coater are provided with the guaranteed is that through the at least two coater directly over each other lying layers are applicable.

In a preferred embodiment of the invention, the Lasersintervorrichtung a storage space for storing the powdery Materials on. This storage space is arranged and designed in such a way that from there by means of a transport device, the powdery Material can be transported from the storage room to the installation space. hereby ensures that always enough powdery Material is available. For this is the To dimension the storage room accordingly. Furthermore, it is expediently the storage space designed such that a slight filling the storage room with powdered material by a user becomes possible. After transporting the powder to the installation space or on the working level, the powder by means of the coater be distributed evenly, so that the corresponding Positions can be solidified by the laser.

in principle the transport device can be designed as a separate component be. Preferably, however, the at least two coaters are each designed as a transport device. Thus, the coaters point a dual functionality, on the one hand as a means of transport and second, as a means for applying a uniform layer, on.

alternative can each storage room at each of the at least two coater be provided for storing a powdery material. Thus, the storage rooms and the coater form a unit and there is no extra transport device between storage or Storage space and space to be provided. Rather, the coater points a kind of dosage device, with which he when driving over the working plane a uniform powder layer applying. The storage rooms of the coater can either formed directly fillable by a user be filled or via a filling system which in turn can be filled centrally by the user with powder material is.

In a preferred embodiment is in this alternative in the storage rooms of the at least two coater each a different powder material and / or a material with different Color provided. This can be achieved that different Materials or materials with different colors for the production of Object can be used. Accordingly, it is possible that another material can be used per shift. As materials come in principle all suitable and Materials known from the prior art, in particular metal powder, Plastic powder and the like in question. When using Materials of different colors is thus solely due to the choice of materials the coloring of the individual layers can be influenced. To have to however, no longer, as known from the prior art, for application from color with color inks and the like populated printheads be provided, the extra on the layer for colorization drive over and complete the production of the object delay further.

Should the laser sintering device be designed such that different Materials for making an object are usable is it is expedient that a control device for the laser is provided, with the help of which the intensity the radiation of the laser to the respective materials adaptable is. This ensures that for every material always the optimum solidification temperature is selected.

According to one Another preferred embodiment of the invention are 3 to 15 coater, preferably 7 to 12 coaters, more preferably 10 coaters provided on the laser sintering device.

For application of the powder layer, the at least two coaters are expediently moved in such a way that they can each be moved from a starting position at one end of the installation space along an application path over the support device or working plane of the installation space to an end position at an opposite end region of the installation space. This ensures that the entire work plane can be covered and an evenly distributed layer can be applied over the entire level. Furthermore, the at least two coaters are designed such that they can be moved from the end position along another path, different from the application path, back into the initial position. In particular, this way back to the An fangsposition be designed such that the first coater, which is located on the way back, the second coater, which is located on the application path, not hindered in the process. As a result, it is possible that the first coater is already on the way back, while the second coater is still on the application path. In this way, therefore, the time until the first coater is back in the starting position and again can start a new cycle, or can apply a new layer, be significantly shortened. In particular, a kind of continuous circulation is possible in which the individual coaters are constantly in motion and do not have to wait until all of the at least two coaters have arrived in the final position, in order then to move all coaters simultaneously or in succession back to the application path back to the start position.

In In a further preferred embodiment, this is achieved Achieved that the individual coater in the manner of a chain drive a caterpillar or the like at the end of the application path, which runs horizontally across the working plane, move vertically up or down to a first turning point and from there horizontally and parallel to the path of application to a second turning point, which along a vertical axis over or below the starting position. From the second turning point the coater again vertically to the initial position method. This results in a continuous chain of coaters. Depending on the configuration of the laser sintering device are also laterally from the working surface running return paths, the For example, always run in the plane of the working level, conceivable. Important Here is that the returning coaters the running Do not obstruct coaters that apply a powder layer.

There Several coaters are provided, it may be appropriate be to provide also several lasers. In particular, this is advantageous because under certain circumstances, several coaters at the same time above the working level or the carrier device and thus those digits of a first layer, already from covered by the second layer, before covering by the second layer must already be solidified. This means, The laser or the laser must be between the places to be processed work the coaters so fast that a to be solidified Do not cover before solidification by another layer becomes.

In In this sense, it is particularly advantageous if at each coater a laser is provided, each for solidifying the applied layers its respective coater is formed. So everyone is Coater associated with a laser.

Further The object described above is achieved by a method according to claim 12 solved. After that, a first coater is going along a path of application from an initial position in an end region a space in an end position on an opposite Processed end of a space, the first coater during the process a first layer of powder a arranged in the space object slide device or on the working plane formed by this. In a second step will be the respective cross section of the to be created object corresponding points by means of laser radiation solidified. Further, a second coater becomes from the initial position in the final position along a second path of application, parallel to the first application path, proceed, the Traversing process of the second coater is started even before the first coater has reached the end position and wherein the second coater during the process a second layer powdery material on the first layer of the coater applying. The second application path is accordingly parallel to and just above the first path of application, so that through the second coater a second layer directly can be applied on the first layer. It is also important that the second coater leaves the initial position, even while the first coater on the application because it significantly speeds up the manufacturing process can be. In a further step, the second layer is on the corresponding to the respective cross section of the object bodies solidified by laser radiation. Care should be taken that the areas of the first layer to which the second layer is applied is already solidified in the appropriate places of the object are. For this purpose, the laser by means of the laser radiation is generated accordingly. Should more coater be provided, the specified steps can be analog be repeated. For example. would be a third coater along the order path, as long as the second coater is still on this and a third layer right on Apply the second coat. Furthermore, the individual coaters move back to the initial positions and the previous ones repeated steps until the object is finished is placed.

By Such a procedure can be the time to make the objects be significantly reduced, since no longer just a coater the Applies layers, but at least two and these layers at least partially applied at the same time.

The process may be carried out by waiting until all the coats settle in are the end position and then they are simultaneously moved back to the starting position, either one above the other or directly behind each other.

alternative the coaters can each be on a different, by application different way back from the final position be moved to the initial position. It is important to ensure that the reciprocating coaters are not mutually exclusive hinder. This ensures that you do not wait must, until all coaters are in the final position, but already the first coater arriving there on the way back can be moved back to the initial position, while other coaters are still on the application path are located. As a result, a circulating circulation of the coater achieved and the time for the production of the object further reduced.

Especially is it useful in this form of training, that the individual coaters throughout the manufacturing process of the object continuously, in particular continuously, proceed become. This ensures that the coaters never stand still and the time of manufacture is thus further reduced. In a Particularly preferred embodiment, the individual Coater in the manner of a chain drive of a tracked vehicle or the like from the end position to a first turning position Continue to a second turning position and finally back to Move the initial position.

in the The invention will be explained below with reference to an embodiment shown in the drawing Embodiment described in more detail. It shows schematically:

1 a laser sintering device with three coaters.

1 shows a laser sintering apparatus, which is a process chamber 12 includes. Within this process chamber 12 is a container 1 arranged, the interior of which is a construction space 1a Are defined. The container 1 is designed to be open at the top. In the container 1 is a carrier device 2 for carrying objects to be produced 3 provided as vertical within the container 1 movable, horizontally oriented platform is formed. This up and down movement in the vertical direction A is by means of a drive 4 allows. On the carrier device 2 be by means of coaters 8a . 8b . 8c layers 5 applied from powdered material. At the respective sections of the layers corresponding to the respective cross section of the object to be produced 5 the powder is made by laser radiation 6a a laser 6 solidified. The laser 6 is above the installation space 1a or the container 1 arranged and has one to the laser 6 connected deflection device 7 by means of which the direction of the laser radiation 6a can be influenced or specified. laser 6 and deflector 7 be from a controller 9 controlled, thereby ensuring that always the right spots of each layer 5 be hit by the laser radiation, or the intensity of the radiation 6a can be adjusted.

The laser sintering device 100 includes a first coater 8a , a second coater 8b and a third coater 8c , which are each arranged offset from one another in the vertical direction. The first coater 8a is right on a work plane 13 placed on top of the container 1 is formed. Viewed in the vertical direction is the second coater 8b a layer thickness over the coater and the coater 8c another layer thickness over the coater 8b arranged. In the example shown here is with the coater 8a just a first shift 5a , with the second coater 8b a second layer 5b and with the third coater 8c a third layer 5c applied. The layers 5a . 5b and 5c lie on further, already created layers 5 on, in which the respective cross-section of the object corresponding locations are already attached. The coater 8a . 8b . 8c are by means of a schematically indicated by the arrows B to drive on the working plane 13 or to this parallel working levels in the horizontal direction back and forth movable. The first shift 5a is already almost completely applied and the points corresponding to the object are already using the laser radiation 6a the laser 6 solidified. The coater 8a is located at the end of the installation space 1a and has his shift 5a applied almost completely. On the shift 5a carries the coater 8b a second layer 5b on, which is already created to about 2/3. It is essential that the points to be consolidated on the layer 5a already solidified where the layer 5b is applied. Also in the shift 5b are the sites to be solidified already by the laser radiation 6a the laser 6 solidified. On the second layer 5b in turn wears the third coater 8c a third layer 5c on. Thus, all three coater are at the time shown 8a . 8b . 8c at least partially above the container 1 ,

Through two powder reservoirs 10 , which are left and right of the installation space 1a or container 1 are the coaters 8a . 8b . 8c fed. Further, left and right of the container 1 two overflow tanks 11 provided that can absorb the excess powder arising during coating. Through the process chamber 12 is the laser sintering device 100 Completed by the external environment, causing harmful effects of the environment on the device or the Materia Lien (eg. Oxidation of the powder) can be prevented.

100

Laser sintering device

1

container

1a

space

2

support means

3

object

4

drive

5

layer

6

laser

6a

laser radiation

7

deflector

8th

coaters

9

control device

10

Powder reservoir

11

Overflow tank

12

process chamber

13

working level

QUOTES INCLUDE IN THE DESCRIPTION

This list The documents listed by the applicant have been automated generated and is solely for better information recorded by the reader. The list is not part of the German Patent or utility model application. The DPMA takes over no liability for any errors or omissions.

Cited patent literature

• - DE 10239369 A1 [0003]

Claims (20)

Laser sintering device ( 100 ) for producing three-dimensional objects ( 3 ) by solidifying successive layers ( 5 ) of a powdery material at the respective cross-section of the object ( 3 ) corresponding points by means of laser radiation ( 6a ), with a laser ( 6 ), a space ( 1a ) with a carrier device ( 2 ) for carrying the object ( 3 ), and a coater ( 8th ) for applying powdery layers ( 5 ) on the support device ( 2 ), characterized in that the laser sintering device ( 100 ) at least two coaters ( 8a . 8b ) related to the height of the object ( 3 ) are arranged offset to one another in such a way that with the at least two coaters ( 8a . 8b ) directly superimposed layers ( 5a . 5b ) are orderable. Laser sintering device according to claim 1, characterized in that the laser sintering device ( 100 ) a storeroom ( 10 ) for storing the powdery material, wherein a transport device for transporting the powdery material from the storage space ( 10 ) to the installation space ( 1a ) is provided. Laser sintering device according to claim 2, characterized in that each of the at least two coaters ( 8a . 8b ) is designed as a transport device. Laser sintering apparatus according to claim 1, characterized in that on each of the at least two coaters ( 8a . 8b ) is provided in each case a storage space for storing the powdery material. Laser sintering device according to claim 4, characterized in that in each of the storage spaces of the at least two coaters ( 8a . 8b ) is provided a different material and / or a material with different colors. Laser sintering device according to claim 5, characterized in that a control device ( 9 ) for the laser ( 6 ) is provided, which is designed such that through them the intensity of the radiation ( 6a ) of the laser ( 6 ) is adaptable to the different powdery materials. Laser sintering device according to one of the preceding claims, characterized in that 3 to 15, preferably 7 to 12, particularly preferably 10 coater ( 8th ) are provided. Laser sintering device according to one of the preceding claims, characterized in that the at least 2 coaters ( 8a . 8b ) each from a start position at one end of the installation space ( 1a ) along a path of application via the carrier device ( 2 ) of the installation space ( 1a ) to an end position at an opposite end region of the installation space ( 1a ), wherein the at least two coaters ( 8a . 8b ) are each movable along another path back to the initial position. Laser sintering device according to claim 8, characterized in that the at least two coaters ( 8a . 8b ) are each vertically movable after reaching the end position to a first turning position, from the first to a second turning position along a parallel path to the application path are horizontally movable and from the second turning position vertically movable to the initial position. Laser sintering device according to one of the preceding claims, characterized in that a plurality of lasers ( 6 ), in particular a number of lasers ( 6 ), the number of coaters ( 8th ), are provided. Laser sintering device according to claim 10, characterized in that on each coater ( 8th ) a laser ( 6 ), each laser ( 6 ) for solidifying the applied layers ( 5 ) of its respective coater ( 8th ) is trained. Method for producing three-dimensional objects ( 3 ) by selective laser sintering of powdery material, characterized by the following steps: a) process of a first coater ( 8th ) from an initial position in an end region of a construction space ( 1a ) along an application path to an end position in an opposite end region of the construction space ( 1a ), wherein the first coater ( 8a ) during the movement a first layer ( 5a ) Powder on one in the installation space ( 1a ) ( 2 b) solidifying the first layer ( 5a ) at the respective cross-section of the object ( 3 ) corresponding points by means of laser radiation ( 6a ), c) process of a second coater ( 8b ) from the initial position to the end position along a second application path, which runs parallel to the first application path, wherein the movement process of the second coater ( 8b ) is started even before the first coater ( 8a ) has reached the end position, and wherein the second coater ( 8b ) during the movement a second layer ( 5b ) powdery material on the first layer ( 5a ) of the first coater ( 8a d) solidifying the second layer ( 5b ) at the respective cross-section of the object ( 3 ) corresponding points by means of laser radiation ( 6a ) e) if appropriate, analogous repetition of steps c) and d) in each case with further coaters ( 8th ), and f) process of the coater ( 8th ) back to the starting position and, if necessary, repeat the previous steps. Process according to claim 12, characterized in that all coaters ( 8th ) are moved simultaneously from the end position back to the starting position. Process according to claim 12, characterized in that the coaters ( 8th ) are each moved in a different way back from the end position to the starting position. Process according to claim 14, characterized in that the individual coaters ( 8th ) during the entire manufacturing process of the object ( 3 ) are each continuously, in particular continuously, proceed. Method according to claim 14 or 15, characterized in that the individual coaters ( 8th ) are each first moved from the end position vertically to a first turning position, then horizontally along a path parallel to the application path to a second turning position and finally vertically back to the initial position. Method according to one of claims 12 to 16, characterized in that in each case 3 to 15, preferably 7 to 12, particularly preferably 10 coater (between the initial and the final position at a given time during the production process) ( 8th ) at the same time. Process according to claims 12 to 17, characterized in that a plurality of lasers ( 6 ), in particular a number of lasers ( 6 ) the number of intended coaters ( 8th ), are provided. Method according to claim 18, characterized in that on each coater ( 8th ) one laser each ( 6 ), each laser ( 6 ) for solidifying the layers ( 5 ) of its respective coater ( 8th ) is trained. Process according to claims 12 to 19, characterized in that with each coater ( 8th ) a different powdered material and / or a material with a different color is applied.