NL2013864B1 - Modular system for producing an object by means of additive manufacturing, as well as an interconnecting module. - Google Patents

Abstract

Modular system for producing an object by means of additive manufacturing, said modular system comprising a control module arranged for controlling said system, and a plurality of adjacently positioned, interconnecting modules, said interconnecting modules comprising at least one additive manufacturing module, comprising a process chamber for receiving a bath of material which can be solidified and a solidifying device for solidifying a selective part of the material for producing said object, an exchange module arranged for exchanging said produced object, wherein each of said interconnecting modules comprise separate, mutually interconnecting guiding elements, said interconnecting guiding elements forming a single guiding rail, wherein said modular system further comprises a handling robot for transporting objects between said interconnecting modules over said single guiding rail.

Description

Title: Modular system for producing an object by means of additive manufacturing, as well as an interconnecting module.

Description

The present invention relates to an apparatus for producing an object by means of additive manufacturing, comprising a process chamber for receiving a bath of material which can be solidified, a support for positioning the object in relation to the surface level of the bath of material, a solidifying device for solidifying a selective part of the material, and a recoating device which can be displaced along the surface of the bath for levelling the surface of the bath. 3D printing or additive manufacturing refers to any of various processes for manufacturing a three-dimensional object. Traditional techniques like injection molding can be less expensive for manufacturing, for example, polymer products in high quantities, but 3D printing or additive manufacturing can be faster, more flexible and less expensive when producing relatively small quantities of three-dimensional objects.

It is anticipated that additive manufacturing becomes more and more important in the future, as the increasing competitive pressure forces companies to not only manufacture more economically with a constant high product quality but also to save time and costs in the area of product development. The life span of products is continuously shortened. In addition to product quality and product costs, the moment of market introduction is becoming increasingly important for the success of a product.

The three-dimensional object may be produced by selectively solidifying, in a layer-like fashion, a powder, paper or sheet material to produce a three-dimensional, 3D, object. In particular, a computer controlled additive manufacturing apparatus may be used which sequentially sinters a plurality of layers to build the desired object in a layer-by-layer fashion. Primarily additive processes are used, in which successive layers of material are laid down under computer control. These objects can be of almost any shape or geometry, and are produced from a 3D model or other electronic data source.

In order to print a three-dimensional object, a printable model is to be created with a computer design package or via a 3D scanner, for example. Usually, the input is a 3D CAD file such as an STL file, a STEP file or an IGS file.

Before printing the object from a CAD file, the file is to be processed by a piece of software, which converts the model into a series of thin subsequent layers. Further, apparatus settings and vectors are generated for controlling the creation of each of the subsequent layers. A laser comprised in the computer controlled additive manufacturing apparatus follows these settings and vectors to solidify successive layers of material to built the 3D object from a series of cross sections. These layers, which correspond to the virtual cross sections from the CAD model, are during this process joined or fused at the same time to create the final 3D object.

To reduce operational costs of the apparatus, it is an object to fully utilize the capacity of the apparatus and, at the same time, make sure that the total production lead time of a three dimensional object is minimized, i.e. the production queue is minimized.

Many different types of apparatuses are available nowadays, ranging from apparatuses capable of producing just a few objects in a day to apparatuses which are specifically tailored to perform mass production of objects. These apparatuses may further be distinguished in their size, some apparatuses are capable of producing objects having a relatively small size and other apparatuses are able to produce objects of a large size. Further, some objects which have been produced may require additional steps before the object is finalized, such as a heat treatment to relieve stresses built up in the produced object or a polishing process to further polish the produced object.

One of the challenges in the manufacturing of three dimensional objects, in particular in additive manufacturing of metal objects, is to provide for an apparatus which is suitable for any of the above mentioned purposes. For example, an apparatus capable of producing small and relatively large sized objects, whether in bulk or just a few samples thereof.

It is therefore an object of the invention to provide for a versatile apparatus for producing an object by means of additive manufacturing.

To this end, the invention provides, in a first aspect thereof, in a modular system for producing an object by means of additive manufacturing, said modular system comprising a control module arranged for controlling said system, and a plurality of adjacently positioned, interconnecting modules, said interconnecting modules comprising: at least one additive manufacturing module, comprising: a process chamber for receiving a bath of material which can be solidified; a solidifying device for solidifying a selective part of the material for producing said object; and at least one of: an exchange module arranged for exchanging said produced object, a heat treatment module arranged for providing a thermal process to relieve stresses built up in produced objects, and a storage module arranged for storing produced objects.

The invention is characterized in that each of said interconnecting modules comprise separate, mutually interconnecting guiding elements, said interconnecting guiding elements forming a single guiding rail, wherein said modular system further comprises a handling robot for transporting objects between said interconnecting modules over said single guiding rail.

It was the insight of the inventors that, in order to obtain a versatile apparatus for producing an object by means of additive manufacturing, a modular system may be provided, wherein the modular system may comprise a plurality of suitable modules adjacently positioned and connected to each other. The advantage hereof is that the system may be build up with different types of modules resulting in a system which is tailored to the needs of the customer. For example, a plurality of additive manufacturing modules may be used within a system in case the system should be suitable for mass production.

Another advantage of the present invention is that the system may be expanded, i.e. upgraded, over time with more modules. In case the need for producing objects changes over time, it may be decided to replace existing modules with other modules more suitable to meet that need.

The inventors noted that, in order to provide for a modular system as described above, each of the modules is to be equipped with interconnecting guiding elements, such that, when connected, the interconnecting guiding element form a single guiding rail over which the handling robot is able to be moved. In such a case, it is not necessary to provide for a new guiding rail each time a module is replaced.

According to the present invention, the handling robot is able to move over the single guiding rail. The exact movement of the robot may be controlled by the control module. As such, a data connection between the control module and the handling robot is to be provided. The data connection may, for example, be comprised by a cable connected to the handling robot and to the control module. In another example, the data connection is provided by data lines provided in, or provided by the single guiding rail. A single guiding rail in the form a railroad track is, for example, suitable as a means for guiding the handling robot between the different interconnecting modules and, at the same time, provide for data exchange between the handling robot and the control module for controlling the handling robot.

The handling robot may also require power for driving itself over the single guiding rail. According to the invention, the power may be provided by the control module, again over separate cables between the handling robot and the control module, or incorporated in the singe guiding rail.

According to the present invention, the exchange module is arranged for exchanging the produced object. This means that the produced object may be safely taken from the module, by, for example, a person, such that the object can be transported to its destination. As such, the exchange module may be regarded as a temporary storage location wherein produced objects are to be stored before they are processed by a shipping service, or the like.

In stead of replacing modules present in the system, it may also be decided to add new modules such as at least one heat treatment module arranged for providing a thermal process to relieve stresses built up in produced objects, or at least one storage module arranged for storing produced objects.

In an example, an order of said modules is said control module, followed by said at least one additive manufacturing module, followed by a remainder of said interconnecting modules, and ending with said exchange module.

The inventors noted that, in order to gain efficiency in producing the objects, the at least one additive manufacturing modules should be placed adjacently to each other. This is especially beneficially in situations wherein the control module further provides for utilities like cooling, gas provisioning, etc., such that these utilities do not need to be distributed over all the modules of the system. These

Utilities are, for example, only required by the additive manufacturing modules such that these modules are placed adjacently to each other.

In another example, a first side of an interconnecting module is connected to a second side of another interconnecting module, wherein the interconnecting guiding elements of said interconnecting modules extend between said first side and said second side of said interconnecting modules.

The guiding elements may also be extendable in towards the first side and the second side of the interconnecting module such that the guiding elements may be connected to each other once the modules are already placed adjacently to each other.

In a further example, said interconnecting guiding elements comprise mutually complementing shapes at said first and second side of their interconnecting modules, respectively, thereby resulting in a mating connection between said interconnecting modules.

In yet another example, the interconnecting guiding elements are mounted to a back side of said interconnecting modules.

In a further example, the interconnecting modules are connected to each other such that said modular system is dust tight.

In an example, the control module is arranged for providing utilities comprising at least one of gas, power supply, cooling, data communication, to said interconnecting modules.

Here, each of said interconnecting guiding elements may comprise interconnecting distributing elements, said distributing elements forming a single distributing rail, wherein said utilities are being distributed over said modular system using said distributing rail.

The interconnecting distributing elements may further be arranged for data communication, and wherein each of the interconnecting modules comprise an electronic identification, and wherein said interconnecting modules are arranged for communicating said electronic identifications over said distributing elements to said control module for indicating a type of module and an order of adjacent positioned interconnecting modules, wherein said control module is arranged for controlling said handling robot based on said received identifications.

In another example, each module may be arranged with detection means for detecting the presence of the handling robot at its corresponding interconnecting guiding element. The detection means may be arranged, for example, as an optical gate, wherein an optical path of the gate is being interrupted every time the handling robot passes the detection means.

The mechanical location of the detection means at each of the modules may be used, by the control module, to control the handling robot. For example, the control module may use this information to calibrate the position of the handling robot at the single guiding rail.

One of the advantageous hereof is that adding or replacing modules have the beneficial effect that the control module does not need to be updated. The control module is able to use the information of the detection means to calibrate and/or control the handling robot over the single guiding rail.

The expressions, i.e. the wording, of the different aspects comprised by the system according to the present invention should not be taken literally. The wording of the aspects is merely chosen to accurately express the rationale behind the actual function of the aspects.

In accordance with the present invention, different aspects applicable to the above mentioned examples of the system, including the advantages thereof, correspond to the aspects which are applicable to the interconnecting module, according to the present invention.

The invention provides, in a second aspect thereof, in an interconnecting module arranged for operation in a modular system for producing an object by means of additive manufacturing according to any of the previous claims, said interconnecting module being any of: an additive manufacturing module, comprising: a process chamber for receiving a bath of material which can be solidified; a solidifying device for solidifying a selective part of the material for producing said object; an exchange module arranged for exchanging said produced object, said interconnecting modules further comprise: a heat treatment module arranged for providing a thermal process to relieve stresses built up in produced objects. a storage module arranged for storing produced objects. said interconnecting module comprises separate, mutually interconnecting guiding elements such that said interconnecting module may be connected to a further interconnecting module, where said interconnecting guiding elements forming a single guiding rail when said modules are connected such that a handling robot is able to transport objects between said interconnecting modules, when connected, over said single guiding rail.

The above-mentioned and other features and advantages of the invention will be best understood from the following description referring to the attached drawings. In the drawings, like reference numerals denote identical parts or parts performing an identical or comparable function or operation.

The invention is not limited to the particular examples disclosed below in connection with a particular type of computer system for producing object by means of additive manufacturing.

Figure 1 is an overview of an apparatus for additive manufacturing an object.

Figure 2a is an overview of a modular system for producing an object by means of additive manufacturing, according to the present invention.

Figure 2b is a cross sectional view of the modular system, showing the handling robot according to the present invention.

Figure 3 is an example showing the handling robot and the single guiding rail, according to the present invention.

Figure 4 discloses different types of examples of modular systems for producing an object, according to the present invention.

Figure 5 discloses an example of a specific interconnecting guiding element, as well as interconnecting guiding elements forming a single guiding rail.

Figure 1 shows an overview of an apparatus 1 for producing an object 2 by means of additive manufacturing. The apparatus 1 is built from several frame parts 11, 12, 13. The apparatus comprises a process chamber 3 for receiving a bath of material 4 which can be solidified. In a lower frame part 11, a shaft is formed, wherein a support 5 is provided for positioning the object 2 in relation to the surface level L of the bath of material 4. The support 5 is movably provided in the shaft, such that after solidifying a layer, the support 5 may be lowered, and a further layer of material may be solidified on top of the part of the object 2 already formed.

In a top part 13 of the apparatus 1, a solidifying device 7 is provided for solidifying a selective part of the material. In the embodiment shown, the solidifying device 7 is a laser device, which is arranged for producing electromagnetic radiation in the form of laser light, in order to melt a powdered material provided on the support, which then, after cooling forms a solidified part of the object to be produced. However, the invention is not limited to the type of solidifying device. As can be seen, the electromagnetic radiation 71 emitted by the laser device 7 is deflected by means of a deflector unit 74, which uses a rotatable optical element 75 to direct the emitted radiation 71 towards the surface L of the layer of material 4. Depending on the position of the deflector unit 74, radiation may be emitted, as an example, according to rays 72, 73.

Figures 2a 2b show the modular system 101 for producing an object by means of additive manufacturing from different angles. The modular system 101 comprises a control module 102, two adjacently placed and connected additive manufacturing modules 103, 104, a heat treatment module 105 and an exchange module 106.

The additive manufacturing modules 103, 104 comprise a process chamber for receiving a bath of material which can be solidified and a solidifying device for solidifying a selective part of the material for producing said object.

The control module 102 may be equipped with a user interface 109 for inputting various data relating to the process of producing the object. Such data may, for example, be the models of the objects to be produced, the specific order and the type of modules provided in the modular system 101, etc.

Further, each of the modules 102, 103, 104, 105, 106 may be provided with a frame 107, which frame 107 is used for connecting the modules to each other.

In figure 2b, the handling robot 108 is shown, which is guided over the single guiding rail which is placed, or mounted, at the back side 110 of the modules 102, 103, 104, 105, 106.

Figure 3 is an example showing the handling robot 201 and the single guiding rail 202, 203, according to the present invention.

Here, the single guiding rail comprises two different parts, i.e. referred to with reference numeral 202 and 203, such that data communication and the provisioning of power from the control module to the handling robot 201 is made possible. The data communication and the provisioning of power may then be transported over these two parts 202, 203.

Figure 4 discloses different types of examples of modular systems for producing an object, according to the present invention.

In the top example, a control module 102 is adjacently positioned to an additive manufacturing module 103, which is then connected to the exchange module 106. This setup is considered to be the minimal setup of the system to function properly.

In more advanced setups, i.e. the 2nd setup from the top, the control module 102 is connected to two adjacently positioned additive manufacturing modules 103, which are subsequently connected to a storage module 121, and finally ending with an exchange module 106.

An even more detailed setup is shown in the 3rd setup from the top, where a single control module 102 is connected to two adjacently positioned additive manufacturing modules 103, which are connected to a heat treatment module 105, a storage module 121 and an exchange module 106.

Finally, a very detailed and extended setup is shown in the 4th setup from the top, in which a monitoring module 122 is connected to a control module, which is connected to three adjacently positioned additive manufacturing modules 103, which are connected to two storage modules 121, which are connected to two heat treatment modules 105, which are finally connected to an exchange module 106. This setup may, for example, be used for mass production of objects.

Figure 5 discloses an example of a specific interconnecting guiding element 301, as well as interconnecting guiding elements forming a single guiding rail.

In the present example, the interconnecting guiding element 301 comprises, at a first end thereof, a dowel pin 302 and, at a second end thereof, a corresponding hole 303.

The dowel pin 202 may have a smaller diameter than its corresponding hole 303 such that it can freely slip in, or may have a larger diameter so that it must be pressed into its hole 303.

Two modules 304, 305, may then be connected to each other by aligned the modules next to each other such that the dowel pin 302 of the first module 304 is aligned with the hole 303 of the second module 305. By connecting the first module 304 with the second module 305, a single guiding rail is formed as the guiding elements of the first module 304 and the second module 305 are connected, i.e. the dowel pin 202 is pushed into its corresponding hole (or vice versa).

The inventors noted that the use of dowel pins 202 in combination with holes 303 may serve as solid reference points to control the positioning of the modules adjacent to each other. The use of dowel pins 202 in combination with their mating holes 303 may result in less mechanical play between two adjacently placed modules 304, 305.

Control of the handling robot, by the control module, may be achieved via data and/or power connections integrated in the interconnecting guiding element 301 or via separate cables connected between the handling robot and the control module.

It will be clear to those skilled in the art, that the invention is described above by means of several embodiments. However, the invention is not limited to these embodiments. The desired protection is defined by the appended claims.

Claims (10)

A modular system for manufacturing an object by means of additive manufacturing, wherein the modular system comprises a control module adapted to control the system, and a plurality of juxtaposed, interconnected modules, the interconnected modules comprising: at least one additive manufacturing module, comprising: - a process chamber for receiving a bath of material that can be solidified; - a solidifying device for solidifying a selective part of the material for manufacturing the object; and at least one of: an exchange module adapted for exchanging the produced object, a heat treatment module adapted to provide a heating process for relieving stresses built up in the manufactured objects, and - a storage module adapted for storing manufactured objects, wherein the modular system is characterized in that each of the modules connected to each other comprises separate, mutually connected guide elements, wherein the mutually connected articulation elements form a single guide rail, wherein the modular system further comprises a processing robot for transporting objects between the connected modules over the single guide rail. A modular system according to any of the preceding claims, wherein a sequence of the modules is the control module, followed by the at least one additive manufacturing module, followed by a remainder of the interconnected modules, and ending with the exchange module. 3. Modular system as claimed in any of the foregoing claims, wherein a first side of an interconnected module is connected to a second side of another interconnected module, wherein the interconnected guide elements of the interconnected modules extend between the first side and the second side of the modules connected to each other. The modular system of claim 3, wherein the interconnected guide elements comprise mutually complementary shapes at the first and second sides of the interconnected modules, respectively, thereby resulting in a mating connection between the interconnected modules. Modular system according to one of the preceding claims, wherein the mutually connected guide elements are mounted on a rear side of the mutually connected modules. Modular system according to one of the preceding claims, wherein the modules connected to each other are connected to each other such that the modular system is dust-tight. A modular system according to any of the preceding claims, wherein the control module is adapted to provide utilities comprising at least one of gas, power supply, cooling, data communication, to the modules connected to each other. A modular system according to claim 7, wherein each of the guide elements connected to each other comprises distribution elements connected to each other, the distribution elements forming a single distribution rail, wherein the utilities are distributed over the modular system using the distribution rail. The modular system of claim 8, wherein the interconnected distribution elements are adapted for data communication, and wherein each of the interconnected modules comprises an electronic identification, and wherein the interconnected modules are adapted to communicate the electronic identifications over the distributing elements to the control module for indicating a type of module and a sequence of modules positioned adjacent to each other, wherein the control module is adapted to control the processing robot based on the received identifications. A module adapted to operate in a modular system for manufacturing an object by means of additive manufacturing according to one of the preceding claims, wherein the module is one of: an additive manufacturing module, comprising: - a process chamber for receiving of a bath of material that can be solidified; - a stable device for solidifying a selective part of the material for manufacturing the object; - an exchange module adapted to exchange the manufactured object, - a heat treatment module adapted to provide a heating process for relieving stresses built up in manufactured objects; - a storage module adapted for storing manufactured objects, wherein the module comprises separate guide elements to be mutually connected, such that module can be connected to a module, in which the guide elements to be connected to each other form a single guide rail when the modules are connected such that the processing robot is capable of transporting objects between the modules connected to each other, when connected, over the single guide rail.