Device and method for producing a three-dimensional workpiece

An apparatus for producing a three-dimensional workpiece via an additive layer construction method, the apparatus comprising:

• a carrier adapted to receive material for producing the three-dimensional workpiece;
• a material supply unit adapted to supply material to the carrier and/or preceding material layers on top of the carrier,
• a layer depositing mechanism for forming the supplied material into a material layer on top of the carrier and/or the preceding material layers on top of the carrier,
• a solidification device adapted to solidify the material supplied to the carrier and/or the preceding material layers on top of the carrier for producing the three-dimensional workpiece, the solidification device comprising a laser and/or a particle source, and the solidification device comprising a beam steering optic comprising one or more deflectable mirrors,
• a gas supply unit adapted to supply a shielding gas to an area of the material layer that is to be solidified by the solidification device,
• a process chamber comprising the gas supply unit and the solidification device,
• a moving unit adapted to move the process chamber relative to the carrier, and
• a positioning system adapted to determine a position of the process chamber relative to the carrier,
• wherein the process chamber further comprises one or more of:
• a gas flow device adapted to form a flow of the shielding gas or a flow of a process gas, with the flow above a surface of the area of the material layer that is to be solidified by the solidification device,
• a heating unit adapted to heat up the material supplied on the carrier, and
• a safety device or part of a safety device adapted to prevent, during operation of the apparatus, release of process emissions to a surrounding of the process chamber,
• wherein at least one of the gas flow device, the heating unit and the safety device or part of the safety device of the process chamber is adapted to operate independently of a moving direction of the process chamber,
• the process chamber further comprising the material supply unit;
• the material supply unit comprising a ring-like shaped, end portion at a first side of the process chamber, wherein the material supply unit is adapted to supply, via the end portion, the material to the carrier on which the material is to be processed by the process chamber for producing the three-dimensional workpiece, and
• an opening at the first side of the process chamber for processing the material supplied on the carrier in order to produce the three-dimensional workpiece,
• wherein the end portion surrounds the opening, wherein the material supply unit comprises a bell-like shaped structure through which the material is suppliable to the carrier, and wherein the end portion forms an end part of the bell-like shaped structure,
• wherein the process chamber comprises a multi-wall structure, and wherein a first cavity formed between a first wall and a second wall of the multi-wall structure is comprised in or coupled to the material supply unit,
• wherein a third cavity is formed between a fifth wall and a sixth wall of the multi-wall structure, and wherein process gas is introducible into and/or extractable out of the process chamber via the third cavity, wherein the solidification device is offset from a center axis of the process chamber, wherein the center axis is defined as being perpendicular to a plane defined by an opening of the process chamber and running through a central point of the opening.

An apparatus for producing a three-dimensional workpiece via an additive layer construction method, the apparatus comprising:

• a carrier adapted to receive material for producing the three-dimensional workpiece;
• a material supply unit adapted to supply material to the carrier and/or preceding material layers on top of the carrier,
• a layer depositing mechanism for forming the supplied material into a material layer on top of the carrier and/or the preceding material layers on top of the carrier,
• a solidification device adapted to solidify the material supplied to the carrier and/or the preceding material layers on top of the carrier for producing the three-dimensional workpiece, the solidification device comprising a laser and/or a particle source, and the solidification device comprising a beam steering optic comprising one or more deflectable mirrors,
• a gas supply unit adapted to supply a shielding gas to an area of the material layer that is to be solidified by the solidification device,
• a process chamber comprising the gas supply unit and the solidification device,
• a moving unit adapted to move the process chamber relative to the carrier, and
• a positioning system adapted to determine a position of the process chamber relative to the carrier,
• wherein the process chamber further comprises one or more of:
• a gas flow device adapted to form a flow of the shielding gas or a flow of a process gas, with the flow above a surface of the area of the material layer that is to be solidified by the solidification device,
• a heating unit adapted to heat up the material supplied on the carrier, and
• a safety device or part of a safety device adapted to prevent, during operation of the apparatus, release of process emissions to a surrounding of the process chamber,
• wherein at least one of the gas flow device, the heating unit and the safety device or part of the safety device of the process chamber is adapted to operate independently of a moving direction of the process chamber,
• the process chamber further comprising the material supply unit;
• the material supply unit comprising a ring-like shaped, end portion at a first side of the process chamber, wherein the material supply unit is adapted to supply, via the end portion, the material to the carrier on which the material is to be processed by the process chamber for producing the three-dimensional workpiece, and
• an opening at the first side of the process chamber for processing the material supplied on the carrier in order to produce the three-dimensional workpiece,
• wherein the end portion surrounds the opening, wherein the material supply unit comprises a bell-like shaped structure through which the material is suppliable to the carrier, and wherein the end portion forms an end part of the bell-like shaped structure,
• further comprising a first seal arranged at the first side of the process chamber and between the end portion of the material supply unit and an opening for producing, in use of the process chamber, a first gas vortex.

An apparatus for producing a three-dimensional workpiece via an additive layer construction method, the apparatus comprising:

• a carrier adapted to receive material for producing the three-dimensional workpiece;
• a material supply unit adapted to supply material to the carrier and/or preceding material layers on top of the carrier,
• a layer depositing mechanism for forming the supplied material into a material layer on top of the carrier and/or the preceding material layers on top of the carrier,
• a solidification device adapted to solidify the material supplied to the carrier and/or the preceding material layers on top of the carrier for producing the three-dimensional workpiece, the solidification device comprising a laser and/or a particle source, and the solidification device comprising a beam steering optic comprising one or more deflectable mirrors,
• a gas supply unit adapted to supply a shielding gas to an area of the material layer that is to be solidified by the solidification device,
• a process chamber comprising the gas supply unit and the solidification device,
• a moving unit adapted to move the process chamber relative to the carrier, and
• a positioning system adapted to determine a position of the process chamber relative to the carrier,
• wherein the process chamber further comprises one or more of:
• a gas flow device adapted to form a flow of the shielding gas or a flow of a process gas, with the flow above a surface of the area of the material layer that is to be solidified by the solidification device,
• a heating unit adapted to heat up the material supplied on the carrier, and
• a safety device or part of a safety device adapted to prevent, during operation of the apparatus, release of process emissions to a surrounding of the process chamber,
• wherein at least one of the gas flow device, the heating unit and the safety device or part of the safety device of the process chamber is adapted to operate independently of a moving direction of the process chamber,
• the process chamber further comprising the material supply unit;
• the material supply unit comprising a ring-like shaped, end portion at a first side of the process chamber, wherein the material supply unit is adapted to supply, via the end portion, the material to the carrier on which the material is to be processed by the process chamber for producing the three-dimensional workpiece, and
• an opening at the first side of the process chamber for processing the material supplied on the carrier in order to produce the three-dimensional workpiece,
• wherein the end portion surrounds the opening, wherein the material supply unit comprises a bell-like shaped structure through which the material is suppliable to the carrier, and wherein the end portion forms an end part of the bell-like shaped structure,
• further comprising a third seal arranged at the first side of the process chamber and radially outwards from the end portion of the material supply unit for producing, in use of the process chamber, a second gas vortex.

An apparatus for producing a three-dimensional workpiece via an additive layer construction method, the apparatus comprising:

• a carrier adapted to receive material for producing the three-dimensional workpiece;
• a material supply unit adapted to supply material to the carrier and/or preceding material layers on top of the carrier,
• a layer depositing mechanism for forming the supplied material into a material layer on top of the carrier and/or the preceding material layers on top of the carrier,
• a solidification device adapted to solidify the material supplied to the carrier and/or the preceding material layers on top of the carrier for producing the three-dimensional workpiece, the solidification device comprising a laser and/or a particle source, and the solidification device comprising a beam steering optic comprising one or more deflectable mirrors,
• a gas supply unit adapted to supply a shielding gas to an area of the material layer that is to be solidified by the solidification device,
• a process chamber comprising the gas supply unit and the solidification device,
• a moving unit adapted to move the process chamber relative to the carrier, and
• a positioning system adapted to determine a position of the process chamber relative to the carrier,
• wherein the process chamber further comprises one or more of:
• a gas flow device adapted to form a flow of the shielding gas or a flow of a process gas, with the flow above a surface of the area of the material layer that is to be solidified by the solidification device,
• a heating unit adapted to heat up the material supplied on the carrier, and
• a safety device or part of a safety device adapted to prevent, during operation of the apparatus, release of process emissions to a surrounding of the process chamber,
• wherein at least one of the gas flow device, the heating unit and the safety device or part of the safety device of the process chamber is adapted to operate independently of a moving direction of the process chamber,
• the process chamber further comprising the material supply unit;
• the material supply unit comprising a ring-like shaped, end portion at a first side of the process chamber, wherein the material supply unit is adapted to supply, via the end portion, the material to the carrier on which the material is to be processed by the process chamber for producing the three-dimensional workpiece, and
• an opening at the first side of the process chamber for processing the material supplied on the carrier in order to produce the three-dimensional workpiece,
• wherein the end portion surrounds the opening, wherein the material supply unit comprises a bell-like shaped structure through which the material is suppliable to the carrier, and wherein the end portion forms an end part of the bell-like shaped structure,
• further comprising a safety control device for use with the process chamber, wherein the safety control device comprises:
• a sensor adapted to sense a state of the process chamber and/or of an enclosure in which the process chamber is arranged, and
• a control unit adapted to control the solidification device,
• wherein the control unit is coupled to the sensor, and
• wherein the control unit is adapted to prevent releasing radiation and/or particles stemming from the solidification device and/or to switch off the solidification device upon the sensor sensing that the state satisfies a predefined condition.