WO2024091198A1

WO2024091198A1 - Continuous additive manufacturing system with rotary spreader

Info

Publication number: WO2024091198A1
Application number: PCT/TR2023/050512
Authority: WO
Inventors: Furkan ÖZER; Hasan Basri KENAR; Serkan Demi̇r
Original assignee: Oezer Furkan; Kenar Hasan Basri; Demir Serkan
Priority date: 2022-10-25
Filing date: 2023-06-02
Publication date: 2024-05-02

Abstract

The present invention relates to a continuous additive manufacturing system with rotary spreader, which ensures that the dead zone formed on the projection of the rotation center on the table (4), in which the heat source (9) cannot impact, changes continuously or when necessary, and which comprises system base (2), body (3), table (4), eccentric table (5), spreader (8), eccentric table motion transmission element (6), spreader motion transmission element (7), vertical motion motor (10), center adjustment motor (11), spreader motor (12), heat source (9), and control unit (17).

Description

CONTINUOUS ADDITIVE MANUFACTURING SYSTEM WITH ROTARY SPREADER

Technical Field

The present invention relates to a powder bed additive manufacturing system.

State of the Art

Additive manufacturing is a production method that allows the production of parts with complex geometries by combining the powder or wire material in layers by subjecting it to heat treatment, unlike conventional material removal methods. The production of parts that cannot be produced with conventional methods can be achieved with this method. The additive manufacturing method, which is carried out using metal materials, has an important place in the production of parts needed especially in the aviation, space, and automotive industries.

In the additive manufacturing method, in which powder is used as raw material, the spreader performs the powder spreading process on the powder bed. While the powder layer formation process is continued during the spreading of the powder, the manufacturing process is prolonged and energy loss occurs since the heat treatment cannot be applied to the powder bed.

The patent document numbered EP2983896B1, which is included in the state of the art, discloses an additive manufacturing system with a rotary mechanism that can provide a solution to the above-mentioned problem. Said system provides continuous production by rotating the powder bed in the axis of the spreader hub, by performing the powder spreading process. However, due to the fixed structure of the spreader shaft and the spreader hub, a dead zone is formed in the center of the table, and it does not allow the production of parts in this region and the production of parts close to the diameter of the table in general.

Objects of the Invention

By means of the embodiment developed with the present invention, the time lost during the spreading of powder layers in powder bed additive manufacturing systems can be minimized. Thus, the amount of product produced per unit time will be increased and the energy consumed per unit product will be reduced. Another object of the present invention is to increase the ratio of the print volume used in the powder bed additive manufacturing process to the volume of the system.

The eccentric table (5) connected to the body (3) is rotated relative to the body (3) axis by the central adjustment motor (11) connected to the body (3), and moves the center of rotation of the spreader (8), which rotates relative to the eccentric table (5), thereby ensuring that the dead zone formed by the projection of the rotation center on the table (4) is moved.

Rotation of the central adjusting motor (11) and the spreader motor (12) contained in the present invention at appropriate speeds provides instantaneous movement of the dead zone in a circle with a radius equal to the eccentricity of the eccentric table (5) centered on the axis of the table (4), thereby ensuring uninterrupted production without getting caught in the dead zone obstacle.

Description of the Figures

Figure- 1 : General View of the System

Figure-2: General Sectional View of the System

Figure-3: Exploded View of Some Components of the System

Figure-4: Sectional View of Some Components of the System

Figure-5: Top View of the System with the Eccentric at 0° and the Spreader at 0°

Figure-6: Top View of the System with the Eccentric at 0° and Spreader at 180°

Figure-7: Top View of the System with the Eccentric at 90° and the Spreader at 0°

Figure-8: Top View of the System with the Eccentric at 90° and the Spreader at 180°

Figure-9: Top View of the System with the Eccentric at 180° and the Spreader at 0°

Figure-10: Top View of the System with the Eccentric at 180° and the Spreader at 180°

Figure-11 : Top View of the System with the Eccentric at 270° and the Spreader at 0°

Figure-12: Top View of the System with the Eccentric at 270° and the Spreader at 180°

Figure-13: Another Embodiment of Motion Drive of the Invention Figure-14: Spiral Continuous Layer Sample

Figure-15: Cylindrical Layer Sample

Figure-16: Fused Layer Sample

Figure- 17: Part Sample

Description of the References Included in Figures

(1) Additive Manufacturing System

(2) System Base

(3) Body

(4) Table

(5) Eccentric Table

(6) Eccentric Table Motion Drive Element

(7) Spreader Motion Drive Element

(8) Spreader

(9) Heat Source

(10) V erti cal Moti on Motor

(11) Center Adj ustment Motor

(12) Spreader Motor

(13) Alternative Center Adj ustment Motor

(14) Center Adjustment Belt

(15) Alternative Spreader Motor

(16) Moti on Drive B elt

(17) Control Unit

(18) Powder to be Spread

(19) Powder Bed

(20) Part

(21) Table Center

(22) Eccentricity Center

(23) Vertical Movement

(24) First Rotational Movement

(25) Second Rotational Movement

(26) Spiral Continuous Layer (27) Cylindrical Layer

(28) Fused Layer

Description of the Invention

A powder bed additive manufacturing system (1) comprising system base (2), body (3) on which the system is built, at least one table (4) that is supported by the body (3), that can perform vertical movement (23), and allows for spreading the powder to be spread (18) thereon, at least one spreader (8), which ensures that the powder to be spread (18) is spread on the table (4), at least one heat source (9) that provides the fusing of the powders spread on the table (4), at least one control unit (17) that regulates the operation of the system, said designed powder bed additive manufacturing system (1) characterized by comprising; at least one eccentric table (5), which allows the dead zone formed in the projection of the rotation center on the table (4), on which the heat source (9) cannot impact, to change continuously when necessary, at least one center adjustment motor (11) and at least one eccentric table motion drive element (6) that enable the eccentric table (5) to rotate. The eccentric table motion drive element (6) and eccentric table (5) can be produced in single piece. The spreader motion drive element (7) and the spreader (8) can be produced in single piece.

The first claim and the dependent claims made to achieve the object of the present invention comprises a body (3), a table (4) that can perform vertical movement (23) connected to the body (3) and allows powder to be spread thereon with the spreader (8), a powder bed (19) located on the table (4), a part (20) produced by sintering or fusing the powders spread on the powder bed (19) and fusing them by using the additive manufacturing method, an eccentric table (5) that can rotate eccentrically in both directions relative to the table (4) and the body (3), a spreader (8), which can rotate in the same direction or in the opposite direction with respect to the eccentric table (5), at least one heat source (9) that heats the powders on the powder bed (19), and at least one control unit (17).

The eccentric table (5) connected to the body (3) is rotated relative to the body (3) axis by the central adjustment motor (11) connected to the body (3) and moves the center of rotation of the spreader (8), which rotates relative to the eccentric table (5), thereby ensuring that the dead zone formed by the projection of the rotation center on the table (4) is moved.

Rotation of the central adjusting motor (11) and the spreader motor (12) contained in the present invention at appropriate speeds provides instantaneous movement of the dead zone in a circle with a radius equal to the eccentricity of the eccentric table (5) centered on the axis of the table (4), thereby ensuring continuous production without being affected by the dead zone.

The additive manufacturing system (1), which is the subject of the present invention, comprises a body (3) that is fixedly attached to the immobile system base (2). There is a table (4) that can only make vertical movement (23) on the inner surface of the body (3). The vertical movement (23) of the table (4) is provided by the vertical movement motor (10). The powders spread in the space formed by the vertical movement (23) of the table (4) form the powder bed (19). The fusion or sintering of the powders is provided by the energy sent from the heat source (9) to the areas that need to be fused or sintered on the upper surface of the powder bed (19). The powder to be spread (18) in the spreader (8) forms the powder bed (19) by being spread on the table (4) by making the second rotational movement (25) of the spreader (8) and the vertical movement (23) of the table (4). Cylindrical layer (27) manufacturing can be performed by making the second rotational movement (25) and vertical movement (23) one after the other, and spiral continuous layer (26) manufacturing can be performed by making the second rotational movement (25) and vertical movement (23) simultaneously. The part (20) is produced by combining the regions that are fused or sintered in cylindrical layers (27) or spiral continuous layers (26) with the energy sent from the heat source (9). There is an eccentric table (5) that can only make the first rotational movement (24) around the body (3). The eccentric table (5) performs its first rotational movement (24) by the central adjustment motor (11) fixed to the body (3) driving the eccentric table motion drive element (6) fixed to the eccentric table (5). The eccentric table (5) and the eccentric table motion drive element (6) can also be manufactured as single piece. Spreader (8) performs its second rotational movement (25) by the spreader motor (12) fixed to the eccentric table (5) driving the spreader motion drive element (7) fixed to the spreader (8). Spreader (8) and spreader motion drive element (7) can also be manufactured as single piece. Coordination of the coordinates of the energy sent by the heat source (9), the first rotational movement (24), the second rotational movement (25), and the vertical movement (23) is performed by the control unit (17). In another embodiment of the present invention, the eccentric table (5) performs its first rotational movement (24) by the alternative center adjustment motor (13) fixed to the body (3) driving the motion of the eccentric table motion drive element (6) fixed to the eccentric table (5) through the center adjustment belt (14). In another embodiment of the present invention, the spreader (8) performs its second rotational movement (25) by the alternative spreader motor (15) fixed to the eccentric table (5), driving the motion of the spreader motion drive element (7) fixed to the spreader (8) through the motion drive belt (16).

Between Figure-5 and Figure-12, there are views of the eccentric table (5) and the spreader (8) at different angles. The eccentricity center (22) performs the same movement around the center of the table (21) by the eccentric table (5) making the first rotational movement (24). The center of rotation of the spreader (8) becomes the eccentricity center (22), when the eccentric table (5) does not make the first rotational movement (24). The dead zone, which is formed due to the spreader (8) covering the center of rotation, is prevented from being in the same position all the time by the eccentric table (5) making its first rotational movement (24). In case the first rotational movement (24) and the second rotational movement (25) are in the same direction and speed, the center of rotation of the spreader (8) becomes the center of the table (21). In this case, the dead zone is formed in the center of the table (21). This combination of motion is used in cases where it is not necessary to send energy from the heat source (9) to the center of the table (21). In case the first rotation (24) and the second rotation (25) are at different speeds and in the same or different direction, or in the same speed and different direction, the center of rotation of the spreader (8) is not fixed but movable. Thus, the position of the dead zone, which coincides with the center of rotation of the spreader (8) can be moved to the regions of the fused layer (28) according to the manufactured part, where it is not necessary to send energy by the heat source (9).

The powder to be spread (18) in the spreader (8) can be in the amount that can completely feed the powder bed (19) or it can be refilled during production with a feeder.

Industrial Applicability of the Invention

The present invention can be used in powder bed additive manufacturing machines that allow the production of parts with complex geometries by combining the powder or wire material in layers by subjecting it to heat treatment, unlike conventional material removal methods.

Claims

1. A powder bed additive manufacturing system (1) comprising system base (2), body (3) on which the system is built, at least one table (4) that is supported by the body (3), that can perform vertical movement (23), and allows for spreading the powder to be spread (18) thereon, at least one spreader (8), which ensures that the powder to be spread (18) is spread on the table (4), at least one heat source (9) that provides the fusing of the powders spread on the table (4), at least one control unit (17) that regulates the operation of the system, said designed powder bed additive manufacturing system (1) characterized by comprising; • At least one eccentric table (5), which allows the dead zone formed in the projection of the rotation center on the table (4), on which the heat source (9) cannot impact, to change continuously or when necessary,

• At least one center adjustment motor (11) and at least one eccentric table (5) motion drive element (6) that enable the eccentric table to rotate.

2. A powder bed additive manufacturing system (1) according to Claim 1, characterized in that, the eccentric table motion drive element (6) and the eccentric table (5) can be produced in single piece.

3. A powder bed additive manufacturing system (1) according to Claim 1, characterized in that, the spreader motion drive element (7) and the spreader (8) can be produced in single piece.