Concept Laser GmbH

Apparatus ( 1 ) for additively manufacturing three-dimensional objects ( 2 ) by means of successive layerwise selective irradiation and consolidation of layers of a build material ( 3 ) which 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 ′) that is adapted to guide the energy beam ( 6, 6 ′) across a build plane ( 9 ) in which build material ( 3 ) is applied to be irradiated, wherein the at least one beam guiding unit ( 7, 7 ′) is arranged behind a point of impact ( 20 ) of the energy beam ( 6, 6 ′) in the build plane ( 9 ), in particular all possible points of impact ( 20 ), with respect to a streaming direction ( 16 ) of the gas stream ( 13 ) streaming over the build plane ( 9 ).

The invention relates to an apparatus ( 1 ) for the additive manufacturing of at least one three-dimensional object ( 2 ) by selectively compacting layer by layer at least one compactible building material ( 3 ) by means of at least one energy beam ( 5 ) generated by at least one radiation generating device ( 4 ), comprising at least one radiation generating device ( 4 ) for generating at least one energy beam ( 5 ) for compacting at least one compactible building material ( 3 ), at least one coating device ( 8 ) for carrying out at least one coating operation to apply a defined building material layer ( 9 ) of at least one compactible building material ( 3 ) to a building plane ( 10 ) or to a building material layer ( 9 ) of at least one compactible building material ( 3 ) that has previously been applied in the course of carrying out a previous coating operation, and also at least one recording device ( 11 ) for recording layer information describing, at least for certain portions, the quality, in particular of the surface, of a building material layer ( 9 ) applied by means of the coating device ( 8 ) in the course of carrying out a coating operation, wherein the at least one recording device ( 11 ) is designed to record corresponding layer information during a coating operation carried out by means of the coating device ( 8 ).

Build material handling unit for a powder module for an apparatus for additively manufacturing three-dimensional objects, which apparatus is adapted to successively layerwise selectively irradiate and consolidate layers of a build material which can be consolidated by means of an energy source, wherein the build material handling unit is coupled or can be coupled with a powder module, wherein the build material handling unit is adapted to level and/or compact a volume of build material arranged inside a powder chamber of the powder module by controlling the gas pressure inside the powder chamber.

A fluid flow apparatus configured to provide a flow of fluid with particular flow profiles to a process chamber of an additive manufacturing apparatus is provided. The fluid flow apparatus includes a plurality of openings forming a first flow region, a second flow region, a third flow region, and a fourth flow region in adjacent arrangement along an axis in the process chamber between the build platform and the laser window. A controller is configured to execute instructions that perform operations that include flowing, via the second flow region, the flow of fluid along a second distance along the axis at a second velocity range between approximately 1.0 meters per second (m/s) and 6.0 m/s, and flowing, via the fourth flow region, another flow of fluid along a fourth distance along the axis at a fourth velocity range between approximately 0.1 m/s and 4.5 m/s.

A method of additively manufacturing three-dimensional objects, and/or a method of controlling one or more irradiation parameters of the energy beam system, may include determining an irradiation setting using an irradiation control model and outputting an irradiation control command to an energy beam system based at least in part on the irradiation setting. The irradiation control model may be configured to determine the irradiation setting based at least in part on a power density factor and/or an irradiation vector factor. The irradiation control command may be configured to change one or more irradiation parameters for additively manufacturing a three-dimensional object. An additive manufacturing system may include an energy beam system and a control system that includes an irradiation controller. The irradiation controller may include a control module configured to perform such a method.

A method of additively manufacturing a three-dimensional object may include allocating irradiation of respective ones of a plurality of sequential layers of construction material between a first region and a second region based at least in part on a first irradiation time and/or a second irradiation time. Irradiation of the first region is allocated to a first scanner and the first irradiation time is indicative of a time required for the first scanner to irradiate the first region with respect to at least one of the plurality of sequential layers of construction material. Irradiation of the second region is allocated to a second scanner and the second irradiation time is indicative of a time required for the second scanner to irradiate the second region with respect to at least one of the plurality of sequential layers of construction material. The first irradiation time and the second irradiation time may be at least approximately the same.

An optical system may include a first optical assembly and a first scan field expansion assembly. The first optical assembly may include or may be configured as a first flat-field lens. The first flat-field lens may have a first nominal scan field with a first flat focal plane. The first scan field expansion assembly may include one or more first field-expanding optical elements configured to provide a first expanded scan field coinciding with the first flat focal plane. The first expanded scan field may have a cross-sectional width and/or area that exceeds a corresponding cross-sectional width and/or area of the first nominal scan field. A method of additively manufacturing a three-dimensional object may include directing a first energy beam through the first optical assembly, and directing the first energy beam through the first scan field expansion assembly.

A build unit for additively manufacturing three-dimensional objects may include an energy beam system having one or more irradiation devices respectively configured to direct one or more energy beams onto a region of a powder bed, and an inertization system including an irradiation chamber defining an irradiation plenum, one or more supply manifolds, and a return manifold. The one or more supply manifolds may include a downflow manifold configured to provide a downward flow of a process gas through at least a portion of the irradiation plenum defined by the irradiation chamber, and/or a crossflow manifold configured to provide a lateral flow of the process gas through at least a portion of the irradiation plenum defined by the irradiation chamber. The return manifold may evacuate or otherwise remove process gas from the irradiation plenum defined by the irradiation chamber.

Determination device ( 2 ) for determining at least one parameter of an energy beam ( 4 ), in particular an energy beam ( 4 ) generated via an irradiation device of an apparatus ( 1 ) for additively manufacturing three-dimensional objects, which determination device ( 2 ) comprises two determination units ( 5, 6 ) arrangeable or arranged in succession in a beam path ( 3 ) of the energy beam ( 4 ), characterized in that each determination unit ( 5, 6 ) builds or comprises at least one complementary pattern element ( 15, 18, 21, 23, 24, 27, 30 ), wherein at least two pattern elements ( 15, 18, 21, 23, 24, 27, 30 ) of the two determination units ( 5, 6 ) complement each other to a superordinate pattern ( 32, 35 ).

A system ( 1 ) for additive manufacturing of three-dimensional objects, comprising one or more working stations ( 21 ), which are provided for performing at least one working process in the additive manufacturing of three-dimensional objects, at least one freely positionable mobile storage unit ( 2 ) comprising a rack-like storage device ( 4 ) comprising at least one storage room ( 5 ) provided for storing at least one powder module ( 6 ), especially for the purpose of conveying the powder module ( 6 ) between different working stations ( 21 ) of the system ( 1 ), and at least one driverless, freely movable mobile conveying unit ( 3 ) comprising a receiving device ( 12 ) provided for receiving at least one mobile storage unit ( 2 ) for the purpose of conveying the storage unit ( 2 ) between different working stations ( 21 ) of the system ( 1 ).