阅读说明：本技术 用于增材制造三维物体的装置 (Device for additive manufacturing of three-dimensional objects ) 是由 尤尔根·沃纳 于 2019-07-24 设计创作，主要内容包括：一种用于借助于构建材料(3)的层的连续分层选择性照射和固结来增材制造三维物体(2)的装置(1),构建材料(3)的层能够借助于经由照射设备(4)产生的能量束(6,6’)固结,其中,照射设备(4)包含适配成引导能量束(6,6’)越过构建平面(9)的至少一个射束引导单元(7,7’),构建材料(3)施加在构建平面(9)中以被照射,其中,至少一个射束引导单元(7,7’)相对于在构建平面(9)上流动的气体流(13)的流动方向(16),布置在构建平面(9)中的能量束(6,6’)的作用点(20)(特别地,所有可能的作用点(20))后面。(An apparatus (1) for additive manufacturing of a three-dimensional object (2) by means of successive layered selective irradiation and consolidation of layers of a build material (3), the layers of the build material (3) being capable of being consolidated by means of an energy beam (6, 6') generated via an irradiation device (4), wherein the irradiation device (4) comprises at least one beam guiding unit (7, 7 ') adapted to guide an energy beam (6, 6') across a build plane (9), the build material (3) being applied in the build plane (9) to be irradiated, wherein the at least one beam directing unit (7, 7 ') is arranged behind an action point (20) (in particular all possible action points (20)) of the energy beam (6, 6') in the building plane (9) with respect to a flow direction (16) of the gas flow (13) flowing on the building plane (9).)

1. An apparatus (1) for additive manufacturing of a three-dimensional object (2) by means of successive layered selective irradiation and consolidation of layers of build material (3), which layers of build material (3) can be consolidated by means of an energy beam (6, 6 ') generated via an irradiation device (4), wherein the irradiation device (4) comprises at least one beam guiding unit (7, 7 ') adapted to guide the energy beam (6, 6 ') across a build plane (9), in which build material (3) is applied to be irradiated, characterized in that the at least one beam guiding unit (7, 7 ') is arranged behind an action point (20) of the energy beam (6, 6 ') in the build plane (9) with respect to a flow direction (16) of a gas flow (13) flowing on the build plane (9), in particular, behind all possible points of action (20).

2. The apparatus according to claim 1, characterized in that the at least one beam directing unit (7, 7') is arranged on at least one section (22-25) of the building plane (9) or a processing plane (21) containing the building plane (9) depending on the flow direction (16) of the gas flow (13).

3. The apparatus according to claim 2, characterized in that the at least one beam directing unit (7, 7') is arranged on a part (22-25) of the building plane (9) or a part (22-25) of the process plane (21) facing a side (17) of a process chamber (11), wherein the gas stream (13) is fed into the process chamber (11) or flows over the building plane (9) at the side (17) of the process chamber (11).

4. The apparatus according to any of the preceding claims, characterized in that the at least one beam guiding unit (7, 7 ') is arranged eccentrically with respect to the center of at least one section (22-25) of the building plane (9) to which the at least one beam guiding unit (7, 7') is assigned.

5. An apparatus according to any one of the preceding claims, characterized in that the irradiation device (4) is adapted to direct the energy beam (6, 6 ') across the build plane (9), wherein the energy beam (6, 6') is incident on the build plane (9) from a side (17) of the process chamber (11), and the gas flow (13) flows on the build plane (9) at the side (17) of the process chamber (11) with respect to the center of the part (22-25) of the build plane (9) to be irradiated.

6. The apparatus according to any of the preceding claims, characterized in that the irradiation device (4), in particular the at least one beam guiding unit (7, 7 '), is adapted to adjust an angle of incidence (19) of the energy beam (6, 6') on the build plane (9) in dependence on at least one parameter of the gas flow (13), preferably in dependence on a flow direction (16) and/or a flow velocity.

7. The apparatus according to any of the preceding claims, characterized in that the irradiation device (4), in particular the at least one beam guiding unit (7, 7 '), is adapted to adjust the angle of incidence (19) such that the beam guiding path along which the energy beam (6, 6') is guided extends only through a first region of the process chamber (11), in particular above the build plane (9), wherein residues (10) resulting from irradiating the build material (3) are only produced in a second region different from the first region.

8. The apparatus according to any of the preceding claims, characterized by at least two beam guiding units (7, 7 '), wherein at least one first part (22-25) of the build plane (9) is assigned to a first beam guiding unit (7, 7 '), and at least one second part (22-25) of the build plane (9) is assigned to a second beam guiding unit (7, 7 ').

9. The device according to any of the preceding claims, characterized in that the at least two beam guiding units (7, 7') are arranged in series or in parallel with respect to the flow direction (16) of the gas flow (13).

10. The apparatus according to any of the preceding claims, characterized in that at least one beam guiding unit (7, 7 ') is movable relative to the build plane (9), wherein the apparatus (1), in particular the irradiation device (4), is adapted to move the at least one beam guiding unit (7, 7 ') to at least a part (22-25) of the build plane (9) to be irradiated, wherein the apparatus (1) is adapted to position the beam guiding unit (7, 7 ') eccentrically relative to a center of the part (22-25) of the build plane (9).

Technical Field

The present invention relates to an apparatus for additive manufacturing of a three-dimensional object by means of successive layered selective irradiation and consolidation of layers of build material which can be consolidated by means of an energy beam generated via an irradiation device, wherein the irradiation device comprises at least one beam guiding unit adapted to guide the energy beam across a build plane in which the build material is applied to be irradiated.

Background

Apparatuses for additive manufacturing of three-dimensional objects, e.g. via selective irradiation of layers of applied build material, are generally known from the prior art. In general, there is provided an irradiation apparatus adapted to generate and direct an energy beam onto a build plane via at least one beam directing unit, a current layer of build material being applied in the build plane to be irradiated.

Further, it is known from the prior art, for example, that irradiation of the build material generates residues (such as soot, smoke, or smoldering smoke) that can be conveyed out of a process chamber (i.e., a chamber performing an additive manufacturing process) via a gas flow generated by a flow generating unit. It is also possible that as the residue, which may be filled with a gas stream, is transported through the process chamber, the energy beam is incident in an area of the build plane on which the residue is present, e.g. an area on which the residue "cloud" is currently located. The quality of the additive manufacturing process (in particular, the quality of the irradiation process) may be negatively affected due to interaction of the energy beam with the residue (e.g., scattering of at least one portion of the energy beam at smoke particles or other types of residues).

Disclosure of Invention

It is an object of the present invention to provide an apparatus for additive manufacturing of a three-dimensional object, wherein the irradiation of the build material is improved, in particular, the interaction of the energy beam with residues present in the process chamber is reduced.

This object is inventively achieved by a device according to claim 1. Advantageous embodiments of the invention are dependent on the dependent claims.

The apparatus described herein is an apparatus for additive manufacturing of three-dimensional objects (e.g., technical components) by means of successive selective layered consolidation of layers of powdered build material ("build material"), which may be consolidated by means of an energy beam, in particular a laser beam or an electron beam. The corresponding build material may be a metal, ceramic or polymer powder. The respective energy beam may be a laser beam or an electron beam. For example, the respective devices may be devices in which application of the build material and consolidation of the build material are performed separately, such as selective laser sintering devices, selective laser melting devices, or selective electron beam melting devices.

The device may contain several functional units that are used during its operation. As previously mentioned, exemplary functional units are a process chamber, an illumination device adapted to selectively illuminate a layer of build material disposed in the process chamber with at least one energy beam, and a flow generating unit adapted to generate a flow of gaseous fluid having given flow properties (e.g., a given flow profile, flow velocity, etc.) and flowing at least partially through the process chamber. The gaseous fluid stream can be charged with unconsolidated particulate build material (particularly, smoke or smoke residue generated during operation of the apparatus) while flowing through the process chamber. The gaseous fluid stream is generally inert, i.e., generally a stream of an inert gas (e.g., argon, nitrogen, carbon dioxide, etc.).

The invention is based on the following idea: the at least one beam directing unit is arranged behind the point of action (in particular all possible points of action) of the energy beam in the build plane with respect to the flow direction of the gas stream flowing on the build plane. Thus, the flow direction of the gas stream flowing on the build plane of the inventive apparatus defines an arrangement of at least one beam directing unit, wherein the beam directing unit may advantageously be arranged such that residues generated in the additive manufacturing process (e.g. in an irradiation step of the additive manufacturing process) are transported or transported on the build plane via the gas stream such that the energy beam does not interact with the residues transported via the gas stream.

The flow direction of the gas flow may then be added to the calculation, wherein the gas flow (in particular the flow direction of the gas flow) defines a direction or path along which residues generated in the additive manufacturing process are transported and transported out of the build chamber on the build plane. Thus, the flow path of the resulting residue (e.g., due to irradiation of the build material) may be determined. In determining the flow path or flow pattern of the residue, the build material may be irradiated only in the area of the build plane, wherein the residue is (currently) not present.

The beam guiding unit is arranged such that the energy beam is incident on a build plane "behind" a residue generated via the energy beam, wherein the term "behind" is defined with respect to a moving direction of the residue (i.e. a flow direction of the gas stream). The term later is to be understood as upstream with respect to the flow direction of the gas stream. The beam directing unit may then be arranged (in the vertical direction) above the build plane behind the action point.

According to the inventive device, the beam directing unit is arranged behind the point of action (in particular, all possible points of action) of the energy beam in the build plane with respect to the flow direction of the gas stream flowing on the build plane. In a general additive manufacturing apparatus, as known from the prior art, the beam guiding unit is typically arranged above the build plane (in particular, above the center of the build plane). In this prior art arrangement, the energy beam is likely to interact with residues resulting from irradiation of the build material with the energy beam, as build material irradiated "against" the flow direction of the gas stream (relative to the arrangement of the beam directing unit) produces residues that are transported via the gas stream towards a portion of the build plane on which the beam directing unit is arranged. Thus, in such a region of the build plane, the energy beam may interact with residues that have been generated as a result of irradiating the build material with the energy beam.

The beam directing unit is therefore arranged behind ("upstream") the point of action of the energy beam with respect to the flow direction of the gas stream. Advantageously, this arrangement allows for the irradiation of the build material, wherein residue resulting from the irradiation of the build material is transported/conveyed via the gas stream, wherein the point of action of the energy beam is "behind" the residue generated and transported via the gas stream. Due to the arrangement of the beam guiding unit "behind the point of action" of the energy beam, it may be that the energy beam is incident on the build plane without passing through the space inside the process chamber, in which residues resulting from irradiating the build material are present. In other words, the energy beam may be directed onto the build plane without interacting with residues generated in the irradiation process with the same energy beam.

In particular, it is preferred that the beam directing unit can be arranged in the inventive device such that the beam directing unit is arranged behind all possible points of action of the energy beam in the build plane. For example, the beam guiding unit may be arranged above an edge of the build plane ("outside of the build plane"), wherein the energy beam directed onto the build plane will have an action point arranged before ("downstream") the position of the beam guiding unit with respect to the flow direction of the gas stream. Thus, the energy beam may be guided via the beam guiding unit such that the point of action is "behind" the residue generated via the energy beam. Thus, interaction of the energy beam with the generated residues in the additive manufacturing process is reduced or entirely avoided.

The inventive device can be further developed in that at least one beam directing unit can be arranged on at least one part of the build plane or on a processing plane containing the build plane, depending on the flow direction of the gas flow. As previously mentioned, the flow direction of the gas flow may be added to the calculation as one of a number of possible parameters of the gas flow generated in the additive manufacturing process, for example inside the process chamber, to remove residues generated in the additive manufacturing process. By adding the direction of flow of the gas stream to the calculation, the movement pattern or movement path along which the residues will move through and out of the process chamber can be determined. Thus, the position of the residue generated via the energy beam can be predicted, thus avoiding the energy beam to be incident on/interact with such residue.

Preferably, the beam directing unit is arranged on one side of the build plane (or on an area of one side of the build plane) facing opposite to the flow direction. Thus, the residue created by directing the energy beam onto the build plane will move in the direction of flow, thus allowing the energy beam to be directed "behind" the residue. According to this embodiment, the at least one beam guiding unit may be arranged on a part of the build plane or a part of the process plane of the side of the process chamber where the gas stream is fed into the process chamber or flows over the build plane. In other words, at least two sides of a build plane may be defined, wherein the gas flow starts on the build plane from a side facing "opposite to the flow direction" (i.e. a side of the build plane facing the side of the process chamber from which the gas flow is fed into the process chamber). As such, the other side of the build plane faces in the flow direction, i.e., the side of the process chamber where the gas flow is removed from the process chamber. The sides "facing opposite/in the flow direction" can also be regarded as inlet and outlet sides or gas inlet and gas outlet, respectively.

The arrangement of the beam guiding units on a part of the build plane may also be understood as a separation of the entire available build plane into several parts, wherein at least one beam guiding unit may be assigned to each part of the build plane. For example, there may be a plurality of portions of the build plane, wherein each portion of the build plane is irradiated with a separate energy beam guided via the beam guiding unit.

Further, the at least one beam directing unit may be arranged eccentrically with respect to a center of the at least one portion of the build plane to which the at least one beam directing unit is assigned. Thus, unlike additive manufacturing devices known from the prior art, the beam guiding unit does not have to be arranged over the center of the build plane or a respective part of the build plane to which the beam guiding unit is assigned, but the beam guiding unit may be arranged eccentrically to the respective center of a part of the build plane to which the beam guiding unit is assigned. As previously mentioned, it is advantageous to arrange the beam guiding unit in a region where a part of the build plane of the beam guiding unit is allocated, which region faces a side of the process chamber where the gas flow is fed into the process chamber (i.e. a side of a part of the build plane facing the gas inlet).

According to a further preferred embodiment of the apparatus according to the invention, the irradiation device may be adapted to direct the energy beam across the build plane, wherein the energy beam is incident on the build plane from a side of the process chamber with respect to a center of a portion of the build plane to be irradiated, wherein the gas stream flows over the build plane in the process chamber. Thus, as previously mentioned, the beam guiding unit, which may be considered as a functional component of the illumination apparatus, may be arranged such that the energy beam guided via the beam guiding element (e.g. a movable mirror) of the beam guiding unit is guided from one side of the process chamber (from which the gas flows) to the other side of the process chamber with respect to the center of the part of the build plane to which the beam guiding unit is assigned. As previously mentioned, the gas inlet and the gas outlet may be arranged at two different sides of the process chamber, wherein the beam guiding unit for guiding the energy beam across the build plane is arranged at the side of the process chamber facing the gas inlet. The beam guide unit is then not arranged centrally on the part of the building plane to which it is assigned, but on the part of the building plane facing the gas inlet.

The inventive device may be further improved in that the at least one beam directing unit may be adapted to adjust the angle of incidence of the energy beam on the build plane in dependence on at least one parameter of the gas flow, preferably the flow direction and/or the flow velocity of the gas flow. Thus, the angle of incidence of the energy beam on the build plane may be adjusted depending on the flow direction and/or flow velocity of the gas stream. The generation of the residue (and its current position) may then be added to the calculation and the angle of incidence of the energy beam on the portion of the build plane to which the at least one beam guiding unit is assigned may be adjusted.

According to a further embodiment of the apparatus according to the invention, the irradiation device (in particular, the at least one beam guiding unit) may be adapted to adjust the angle of incidence such that the beam guiding path along which the energy beam is guided extends only through a first region (in particular, above the build plane) of the process chamber, wherein residues resulting from the irradiation of the build material are only generated in a second region different from the first region. Thus, the energy beam may be directed along a beam guiding path, e.g. from a beam source (such as a laser beam source) through an optical link onto the build plane. The energy beam directed along the beam guide path passes only through a first region of the process chamber, wherein residues are generated/present only in a second region of the process chamber. In other words, the energy beam is directed along a beam guide path, wherein a first region through which the beam guide path extends or through which the energy beam is directed is free of residue resulting from irradiating the build material as the residue moves through a second region of the processing chamber.

Of course, the first and second zones are not fixed in position and may differ depending on the adjusted angle of incidence and the position of the residue conveyed or transported via the gas flow respectively.

Further, the irradiation apparatus (in particular, the at least one beam directing unit) may be adapted to direct the energy beam across the build plane behind a residue loaded in the gas stream with respect to the flow direction of the gas stream, wherein the residue is generated in the irradiation process of the build material using the energy beam. In other words, the residues generated in the irradiation process are transported via the gas stream, i.e. the gas stream is loaded with the residues generated in the irradiation process. By directing an energy beam behind the residue generated and moved via the gas stream, the energy beam may be directed through the processing chamber without interacting with the residue resulting from irradiating the build material. Thus, the beam guiding unit may be adapted to add the position and the movement path of the generated residue to the calculation, in particular taking into account the flow direction and/or the flow velocity of the gas flow. Thus, the interaction of the energy beam with the generated residue can be avoided, thus improving the irradiation process.

The inventive device can be further improved in that at least two beam guidance elements can be provided, wherein at least one first part of the build plane can be assigned to a first beam guidance element and at least one second part of the build plane can be assigned to a second beam guidance element. According to this embodiment, the available build plane may be subdivided into at least two parts, namely a first part of the build plane and a second part of the build plane. Of course, the available build plane may be divided into any number of portions, wherein a corresponding number of beam guiding units may be used to irradiate build material arranged or applied in respective portions of the build plane. As previously mentioned, each of the at least two beam directing units may be arranged in dependence of at least one parameter of the gas flow flowing over a corresponding portion of the build plane, in particular in dependence of the flow direction of the gas flow. Advantageously, the at least two beam directing units are arranged such that residue produced via irradiation of the build material by the energy beam is not interfered with the irradiation process performed via the second energy beam, the energy beam being directed via the first beam directing unit and the second energy beam being directed via the second beam directing unit, and vice versa.

For example, it may be that at least two beam directing units may be arranged in series or in parallel with respect to the flow direction of the gas stream. Thus, it may be that the build plane is divided into at least two sections arranged in series or in parallel with respect to the flow direction of the gas stream. Of course, by subdividing the available building plane into a plurality of sections, it is also possible to combine the arrangement of different sections arranged in series and/or in parallel with respect to the flow direction of the gas stream. The arrangement of at least two beam directing units assigned to respective parts of a build plane allows for illumination of build material arranged in a larger available build plane which allows for illumination of a larger part and/or parts to be built simultaneously. Further, by using more than one beam directing unit, each beam directing unit may be arranged such that a corresponding portion of the build plane to which the beam directing unit is assigned may be irradiated without interfering with residues generated in the irradiation process.

The at least one beam guiding unit (or at least one of the beam guiding units) may be movable relative to the build plane, wherein the apparatus (in particular the irradiation device) may be adapted to move the at least one beam guiding unit to at least a part of the build plane to be irradiated, wherein the apparatus is adapted to position the beam guiding unit eccentrically relative to a center of the part of the build plane. According to this embodiment, the at least one beam guiding unit may be moved relative to a build plane, wherein the build plane may for example be subdivided into a plurality of sections. Thus, build material applied in available build planes may be irradiated via one beam guiding unit that is movable to different positions, from which different parts of the build plane may be irradiated. For example, the available build plane may be subdivided into two portions, wherein a first location and a second location may be defined from which two portions of the build plane (build material applied in the two portions) may be irradiated. Thus, the beam guiding unit may be moved to a first position to irradiate build material arranged in a first portion of the available build plane, wherein, after irradiation of the build material, the beam guiding unit may be moved to a second position from which build material arranged in a second portion of the build plane may be irradiated.

In each of these positions, the beam guiding unit may be arranged eccentrically with respect to a center of a corresponding part of the build plane to be irradiated in the corresponding irradiation step, in particular outside the part of the build plane, i.e. arranged over an area outside the corresponding part of the build plane. Thus, the gas flow flowing over the build plane (and thus over the corresponding part of the build plane to be irradiated) may add to the calculation regarding the position of the arrangement of the beam guiding unit. Thus, the flow direction and/or flow velocity of the gas stream may be added to the calculation, arranging the beam guiding unit relative to the corresponding part of the build plane to be irradiated to ensure that the resulting residues are removed from the process chamber along a movement path (e.g. the flow path of the gas stream), wherein the energy beam does not interact with the residues.

The inventive arrangement may be further improved in that the irradiation device or the control unit may be adapted to select at least one beam guiding unit arranged behind the point of action (in particular all possible points of action) for the energy beam of the corresponding part of the build plane with respect to the flow direction of the gas flow flowing over the build plane, or the irradiation device or the control unit is adapted to move the at least one beam guiding unit into a position in which the at least one beam guiding unit is arranged behind the point of action (in particular all possible points of action) for the energy beam of the corresponding part of the build plane with respect to the flow direction of the gas flow flowing over the build plane.

According to a first alternative of this embodiment, the irradiation device or the control unit may be adapted to select one of the at least two beam guiding units to perform the irradiation process. In order to select between the available at least two beam guiding units, a portion of the build plane to be irradiated is added to the calculation, wherein a beam guiding unit arranged behind the point of action of the energy beam in the corresponding portion of the build plane to be irradiated is selected. In other words, the beam guide unit from the plurality of beam guide units may be selected so that a condition of guiding the energy beam to the action point without interfering with a residue generated in the irradiation process is satisfied during the irradiation process performed via the beam guide unit.

Then, a respective beam guiding unit is selected, which allows guiding the energy beam "behind" the residue (e.g. the cloud of residue) generated via the energy beam and guided out of the processing chamber via the gas flow. The arrangement of the beam guiding unit for performing the irradiation process with respect to a part of the build plane is chosen such that the beam guiding unit is arranged behind all possible points of action to which the energy beam has to be directed for performing the irradiation task (e.g. directing the energy beam along a beam path arranged in a part of the build plane), wherein all possible points of action on the beam path are arranged behind residues resulting from the irradiation process.

According to a second alternative of the embodiment, the irradiation device or the control unit may be adapted to move the at least one beam guiding unit into a position to perform the irradiation process for constructing a part of the plane. In this position, the beam directing unit is arranged behind all possible points of action and directs the energy beam behind residues produced in the irradiation process. In other words, the beam directing unit is arranged behind all possible points of action of the energy beam in a part of the build plane. Further, a plurality of portions of the build plane may be defined, or a plurality of illumination patterns may be defined that have to be generated in a plurality of positions of the build plane, wherein the illumination device or the control unit is adapted to move the beam guiding unit into the corresponding position to perform the illumination process. At each position, the beam directing unit is arranged behind the point of action to which the energy beam has to be directed to irradiate or generate the respective irradiation pattern. Of course, a combination of the two alternatives (i.e. selecting a suitable beam directing unit and/or moving more than one beam directing unit) may be performed arbitrarily.

Preferably, an illumination assembly movable relative to the build plane may be provided, the illumination assembly comprising at least one beam directing unit and at least one flow generating unit and/or at least one application unit arranged to form the assembly. The illumination assembly according to this embodiment allows to provide a compact assembly which is movable as one part on the component plane, wherein the illumination assembly may be positioned or arranged in a position from which an illumination process for a corresponding part of the build plane may be performed, wherein during the illumination process a gas flow may be generated via the flow generating unit of the illumination assembly. Preferably, the application unit is further provided with an illumination assembly allowing application of build material in a corresponding portion of the build plane.

Furthermore, the invention relates to an irradiation apparatus for an apparatus for additive manufacturing of a three-dimensional object by means of successive layered selective irradiation and consolidation of layers of build material which can be consolidated by means of an energy beam generated via the irradiation apparatus, wherein the irradiation apparatus comprises at least one beam guiding unit adapted to guide the energy beam across a build plane of the apparatus at which the build material is applied to be irradiated, wherein the at least one beam guiding unit is arranged or arrangeable behind an action point (in particular all possible action points) of the energy beam in the build plane with respect to a flow direction of a gas stream flowing over the build plane.

Further, the invention relates to a method for operating at least one apparatus for additive manufacturing of a three-dimensional object by means of successive layered selective irradiation and consolidation of layers of build material which can be consolidated by means of an energy beam generated via an irradiation device, wherein the irradiation device comprises at least one beam guiding unit adapted to guide the energy beam across a build plane in which the build material is applied to be irradiated, wherein the at least one beam guiding unit is arranged behind an action point (in particular all possible action points) of the energy beam in the build plane with respect to a flow direction of a gas stream flowing over the build plane.

Of course, all features, details and advantages described with respect to the inventive arrangement can be transferred in full to the inventive illumination device and the inventive method.

Drawings

Exemplary embodiments of the present invention are described with reference to the accompanying drawings. The figures are schematic representations in which

Fig. 1 shows an inventive device according to a first embodiment in a side view;

FIG. 2 illustrates the apparatus of FIG. 1 in a top view;

fig. 3 shows an inventive device according to a second embodiment in a top view; and

fig. 4 shows an inventive device according to a third embodiment in a top view.

Detailed Description

Fig. 1 shows an apparatus 1 for additive manufacturing of a three-dimensional object 2 by means of successive layered selective irradiation and consolidation of layers of build material 3. For consolidating a layer of the build material 3, an irradiation device 4 comprising a beam source 5 (e.g. a laser source) is provided, which beam source 5 is adapted to generate an energy beam 6 (e.g. a laser beam). The illumination apparatus 4 further comprises a beam guiding unit 7 with a movable beam guiding element 8, e.g. a mirror element.

Thus, the irradiation device 4 is adapted to generate and direct the energy beam 6 across the available build plane 9, applying the build material 3 in layers in the build plane 9. As a result of the irradiation of the build material 3 in the build plane 9, a residue 10, such as soot, smoke or smoldering smoke, is generated. In order to remove residues 10 from a processing chamber 11 performing an additive manufacturing process, the apparatus 1 comprises a flow generating unit 12 adapted to generate a gas flow 13 flowing over the build plane 9. The flow generating unit 12 comprises a gas inlet 14 and a gas outlet 15, a gas flow 13 being generated between the gas inlet 14 and the gas outlet 15. Thus, a flow direction 16 along which the gas flow 13 flows through the process chamber 11 may be defined.

The gas stream 13 may be filled with the residue 10, wherein the residue 10 may be transported or removed from the process chamber 11 via the gas stream 13 flowing between the gas inlet 14 and the gas outlet 15. Thus, the build plane 9 comprises a first side 17 facing the gas inlet 14 (thus facing opposite to the flow direction 16) and a second side 18 facing the gas outlet 15 (thus facing in the flow direction 16).

The beam directing unit 7 of the embodiment of the device 1 according to the invention depicted in fig. 1 is arranged eccentrically with respect to the building plane 9. In particular, the beam directing unit 7 is arranged "outside" the building plane 9, on a side 17 of the building plane 9 facing opposite to the flow direction 16. The beam directing unit 7 is arranged behind an action point (20) (in particular all possible action points (20)) of the energy beam (6, 6') in the building plane (9) with respect to a flow direction (16) of a gas flow (13) flowing on the building plane (9). It may thus be that the irradiation device 4 (in particular, the beam guiding unit 7) is adapted to adjust an angle of incidence 19 of the energy beam 6 on the build plane 9 such that an action point 20 of the energy beam 6 in the build plane 9 is arranged behind ("upstream") the residue 10 resulting from the irradiation of the build material 3 via the energy beam 6 with respect to the flow direction 16.

Further, the beam directing unit 7 is arranged behind the action point 20 with respect to the flow direction 16 and the centre (not shown) of the building plane 9. Thus, the energy beam 6 directed along the beam guide path does not pass through the region of the process chamber 11 where the residue 10 (resulting from irradiating the build material 3) is present. Alternatively, the energy beam 6 is only directed through a first region of the process chamber 11 without residues 10, wherein the residues 10 are only generated or moved through a second region inside the process chamber 11. Of course, as the energy beam 6 is directed to different locations in the build plane 9 and the residue 10 moves through the process chamber 11 and out of the process chamber 11 via the gas stream 13, the positions of the first and second areas change during the additive manufacturing process (in particular, during irradiation of the build material 3), wherein the gas stream 13 flows along the flow direction 16 at a defined flow velocity.

Fig. 2 illustrates the apparatus 1 of fig. 1 in a top view, wherein the dashed lines depict the beam guiding unit 7 arranged above a processing plane 21 containing the build plane 9, wherein the beam guiding unit 7 is arranged above the build plane 9/processing plane 21 as described before. The energy beam 6 may then be directed via the beam directing unit 7 (in particular, via the movable beam directing element 8) across the build plane 9 to selectively irradiate the build material 3 applied in the build plane 9. Thus, a corresponding cross section of the object 2 may be consolidated via the energy beam 6. In each point (e.g., each action point 20) of the build plane 9, a residue 10 is generated as a result of irradiating the build material 3 via the energy beam 6. As previously described, the residue 10 is moved via the gas flow 13, which may be loaded with the residue 10, to move the residue out of the process chamber 11 as the gas flow 13 flows from the gas inlet 14 to the gas outlet 15 via the flow generating unit 12.

As already described before, the building plane 9 extends between two sides 17, 18, i.e. a side 17 facing the gas inlet 14 and a side 18 facing the gas outlet 15. The beam guiding unit 7 is adapted to guide the energy beam 6 such that the energy beam 6 is incident on the build plane 9 and behind the "residue 10". The energy beam 6 can then be directed onto the build plane 9 such that the point of action 20 is arranged behind the residue 10 with respect to the flow direction 16. Thus, the energy beam 6 does not pass through the region in the process chamber 11 where the residue 10 is present. Thus, the irradiation device 4 is adapted to direct the energy beam 6 across the build plane 9 such that the point of action 20 is always "behind" the residue 10 moving along the flow direction 16 towards the gas outlet 15. Due to the arrangement of the beam guiding unit 7, the energy beam 6 can reach every point and area of the build plane 9 without interfering with residues 10 resulting from irradiating the same area or point.

For example, different parameters of the gas flow 13, such as the flow direction 16 and the flow velocity of the gas flow 13, may be added to the calculation in order to direct the energy beam 6 across the build plane 9.

Fig. 3 shows an inventive device 1 according to a second embodiment, wherein like numerals are used for like parts. The device 1 depicted in fig. 3 further comprises a flow generating unit 12 having a gas inlet 14 and a gas outlet 15, wherein the flow generating unit 12 generates a gas flow 13 flowing between the gas inlet 14 and the gas outlet 15. The gas flow 13 flows again over the build plane 9 contained in the process plane 21. The apparatus 1 depicted in fig. 3 comprises two beam guiding units 7, 7' (depicted via dashed lines) arranged above the processing plane 21.

The build plane 9 according to the second embodiment is subdivided into two parts 22, 23, wherein the first beam guiding unit 7 is assigned to illuminate a first part 22 of the build plane 9, wherein the second beam guiding unit 7' is assigned to illuminate a second part 23 of the build plane 9. As can further be taken from fig. 3, the first beam guiding unit 7 is arranged such that the angle of incidence 19 (fig. 1) can be adjusted such that the energy beam 6 is directed onto the first portion 22 of the build plane 9 and behind the residue 10 resulting from the irradiation of the build material 3. Similarly, the second beam guiding unit 7 'is arranged eccentrically to the second portion 23 of the build plane 9, wherein the second energy beam 6' can be guided onto the second portion 23 such that the point of action 20 (see fig. 1) is behind the residue 10 generated in the additive irradiation process.

Since the building plane 9 is subdivided into a first part 22 and a second part 23, the parts 22, 23 can be assigned to the beam guiding units 7, 7'. Thus, two objects 2, 2 '(or one large object) subdivided into irradiation processes performed using at least two beam guiding units 7, 7' can be constructed. While performing the irradiation process, it is beneficial to irradiate the build material via the first beam directing unit 7 in regions where the second beam directing unit 7 'is not irradiating the build material 3 to ensure that residues 10 produced by irradiation of the build material 3 via the energy beam 6 do not produce residues 10 that flow via the gas stream 13 into regions where the build material 3 is irradiated using the second energy beam 6'.

Of course, the arrangement depicted in fig. 3 is merely exemplary, wherein a plurality of beam guiding units 7, 7' may also be arranged in parallel and/or in series.

Fig. 4 shows an inventive device 1 according to a third embodiment. According to a third embodiment, the building plane 9 is subdivided into four sections 22-25. In the exemplary embodiment depicted in fig. 4, one large object 2 is to be illuminated, wherein it is also possible that a plurality of smaller objects 2 may be illuminated in sections 22-25 of the build plane 9. In order to perform the irradiation process, the apparatus 1 depicted in fig. 4 comprises a beam guiding unit 7 which is movable relative to the build plane 9, wherein four exemplary positions of the beam guiding unit 7 are depicted as dashed rectangles. Although the flow generating unit 12 is depicted as a separate unit, it is also possible to integrate the flow generating unit 12 into the beam guiding unit 7, wherein the beam guiding unit 7 and the flow generating unit 12 may form an irradiation assembly which is movable relative to the build plane 9. An application unit may further be included in the illumination assembly (not shown) to apply build material in portions 22-25 of the build plane 9.

The irradiation device 4 according to the third embodiment depicted in fig. 4 is adapted to control the movement of the beam guiding unit 7 with respect to the build plane 9 such that, as previously mentioned, the beam guiding unit 7 may be arranged such that the point of action 20 of the energy beam 6 is arranged behind the residue 10 generated in the irradiation process. Thus, the energy beam 7 may be arranged behind the point of action 20 with respect to the flow direction 16 of the gas flow 13. After the irradiation process in one of the sections 22-25 is finished, the irradiation device 4 may move the beam guiding unit 7 to the next position, as depicted via the dashed rectangle, to perform the irradiation process in the next section 22-25 of the build plane 9. Of course, a plurality of sections 22-25 of the build plane 9 may be arranged in parallel or in series, wherein the order in which the individual sections 22-25 of the build plane 9 are irradiated via the beam guiding unit 7 (in particular via the energy beam 6) may be chosen arbitrarily.

The inventive device 1 thus allows to direct an energy beam 6 across the build plane 9, wherein the point of action 20 of the energy beam 6 is located behind the residue 10 resulting from the irradiation of the build material 3 via the energy beam 6. This is achieved by arranging the beam directing unit 7 behind the point of action 20 with respect to the flow direction 16 of the gas flow 13 for removing the residues 10 from the process chamber 11. Thus, the irradiation device 4 is adapted to adjust the angle of incidence 19 such that the energy beam 6 is only directed through an area of the processing chamber 11 without residues 10, and residues 10 are only generated and directed in an area of the processing chamber 11 different from the area through which the energy beam 6 is directed. Thus, interaction of the energy beam 6 with the residue 10 can be avoided, and thus the negative effect of the residue 10 on the irradiation treatment can be reduced.

Of course, the inventive method may be performed on the inventive apparatus 1, preferably using the inventive irradiation device 4. It goes without saying that all features, details and advantages described with respect to the individual embodiments can be combined or interchanged at will.

Further aspects of the invention are provided by the subject matter of the following clauses:

1. an apparatus (1) for additive manufacturing of a three-dimensional object (2) by means of successive layered selective irradiation and consolidation of layers of build material (3), which layers of build material (3) can be consolidated by means of an energy beam (6, 6 ') generated via an irradiation device (4), wherein the irradiation device (4) comprises at least one beam guiding unit (7, 7 ') adapted to guide the energy beam (6, 6 ') across a build plane (9), in which build material (3) is applied to be irradiated, the at least one beam guiding unit (7, 7 ') being arranged behind an action point (20) of the energy beam (6, 6 ') in the build plane (9) with respect to a flow direction (16) of a gas stream (13) flowing on the build plane (9), in particular, behind all possible points of action (20).

2. According to the apparatus of any preceding item, the at least one beam directing unit (7, 7') is arranged on at least one portion (22-25) of the build plane (9) or a processing plane (21) containing the build plane (9) depending on the flow direction (16) of the gas flow (13).

3. The apparatus according to any of the preceding items, the at least one beam directing unit (7, 7') being arranged on a part (22-25) of the building plane (9) or a part (22-25) of the process plane (21) facing a side (17) of a process chamber (11), wherein the gas stream (13) is fed into the process chamber (11) or flows over the building plane (9) at the side (17) of the process chamber (11).

4. The apparatus according to any of the preceding items, said at least one beam guiding unit (7, 7 ') being arranged eccentrically with respect to the center of at least one portion (22-25) of said building plane (9) to which said at least one beam guiding unit (7, 7') is assigned.

5. The apparatus according to any preceding item, the irradiation device (4) being adapted to direct the energy beam (6, 6 ') across the build plane (9), wherein the energy beam (6, 6') is incident on the build plane (9) from a side (17) of the process chamber (11), the gas stream (13) flowing on the build plane (9) at the side (17) of the process chamber (11) relative to a center of the portion (22-25) of the build plane (9) to be irradiated.

6. The apparatus according to any preceding item, the illumination device (4), in particular the at least one beam guiding unit (7, 7 '), is adapted to adjust an angle of incidence (19) of the energy beam (6, 6') on the build plane (9) in dependence on at least one parameter of the gas flow (13), preferably in dependence on a flow direction (16) and/or a flow velocity.

7. The apparatus according to any preceding item, the irradiation device (4), in particular the at least one beam guiding unit (7, 7 '), is adapted to adjust the angle of incidence (19) such that a beam guiding path along which the energy beam (6, 6') is guided extends only through a first region of the process chamber (11), in particular above the build plane (9), wherein residues (10) resulting from irradiating the build material (3) are only generated in a second region different from the first region.

8. The apparatus according to any of the preceding items, at least two beam guiding units (7, 7 '), wherein at least one first part (22-25) of the build plane (9) is assigned to a first beam guiding unit (7, 7 '), and at least one second part (22-25) of the build plane (9) is assigned to a second beam guiding unit (7, 7 ').

9. The apparatus according to any of the preceding items, the at least two beam directing units (7, 7') being arranged in series or in parallel with respect to the flow direction (16) of the gas stream (13).

10. The apparatus according to any of the preceding clauses, at least one beam guiding unit (7, 7 ') being movable relative to the build plane (9), wherein the apparatus (1), in particular the irradiation device (4), is adapted to move the at least one beam guiding unit (7, 7 ') to at least a portion (22-25) of the build plane (9) to be irradiated, wherein the apparatus (1) is adapted to position the beam guiding unit (7, 7 ') eccentrically relative to a center of the portion (22-25) of the build plane (9).

11. The apparatus according to any of the preceding items, the irradiation device (4) or the control unit being adapted to select at least one beam guiding unit (7, 7 '), the at least one beam guiding unit (7, 7') being arranged behind an action point (20) of the energy beam (6, 6 ') for a corresponding portion (22-25) of the build plane (9), in particular behind all possible action points (20), with respect to the flow direction (16) of the gas stream (13) flowing on the build plane (9), or the irradiation device (4) or the control unit being adapted to move at least one beam guiding unit (7, 7') to the at least one beam guiding unit (7), 7 ') is arranged at a position behind an action point (20) of the energy beam (6, 6 ') for the corresponding portion (22-25) of the building plane (9), in particular to a position where the at least one beam guiding unit (7, 7 ') is arranged behind all possible action points (20).

12. Apparatus according to any of the preceding claims, an irradiation assembly movable relative to the build plane (9), the irradiation assembly comprising at least one beam guiding unit (7, 7') and at least one flow generating unit (12) and/or at least one application unit arranged to form an assembly.

13. An irradiation apparatus (4) for an apparatus (1), the apparatus (1) being for additive manufacturing of a three-dimensional object (2) by means of successive layered selective irradiation and consolidation of layers of build material (3), the layers of build material (3) being consolidated by means of an energy beam (6, 6 ') generated via the irradiation apparatus (4), wherein the irradiation apparatus (4) comprises at least one beam guiding unit (7, 7') adapted to guide the energy beam (6, 6 ') across a build plane (9) of the apparatus (1), in which build material (3) is applied to be irradiated, the at least one beam guiding unit (7, 7') being arranged or arrangeable in the build plane (9) relative to a flow direction (16) of a gas flow (13) flowing over the build plane (9), 6'), in particular arranged or able to be arranged behind all possible points of action (20).

14. A method for operating at least one apparatus (1), the at least one apparatus (1) being for additive manufacturing of a three-dimensional object (2) by means of successive layered selective irradiation and consolidation of layers of build material (3), the layers of build material (3) being capable of consolidation by means of an energy beam (6, 6 ') generated via an irradiation device (4), wherein the irradiation device (4) comprises at least one beam guiding unit (7, 7 ') adapted to guide the energy beam (6, 6 ') across a build plane (9), in which build material (3) is applied to be irradiated, the at least one beam guiding unit (7, 7 ') being adapted to apply the energy beam (6, 6 ') in the build plane (9) in relation to a flow direction (16) of a gas flow (13) flowing over the build plane (9), the energy beam (6) being arranged in the build plane (9), 6'), in particular arranged behind all possible points of action (20).