The invention relates to a laser metal deposition device. The invention further relates to a production cell comprising a laser deposition device. The invention further relates to a production system comprising a laser metal deposition device or a production cell. The invention further relates to a method for making a structure using a laser metal deposition device or a production cell or a production system.

A laser metal deposition device is known per se. In particular said laser metal deposition device may be a conventional laser metal deposition device and/or a so called ultra high speed laser metal deposition device. A laser metal deposition device may be used for making metal structures.

Said laser metal deposition device may comprise:

- a head, said head comprising:

- at least one supply means for supplying a feed material;

- at least one laser for melting said feed material;

- a support for supporting said melted feed material in layers deposited on top of the other, thereby forming a laser deposited structure,

wherein said head and said support are moveable with respect to each other.

Said laser metal deposition device may further comprise a controller arranged to control said laser metal deposition device. In particular said controller may be arranged to control the relative movement of the head and said support.

It is an object of the invention to improve said above described laser metal deposition device. In particular it may be an object of the invention to improve the relative movement of said head and said support. For example, improving the relative movement of said head and said support may allow for the layers to be deposited on top of the other to have any desired contour and/or may allow for an increased deposition speed.

At least one of the above described objects may be achieved by a laser metal deposition device according to the preamble of claim 1, wherein said support comprises a first support element that is moveable in at least an XY plane in a rotational direction and a second support element that is moveable in at least said XY plane in a rotational direction with respect to said first support element,

wherein the laser metal deposition device comprises a moving means to which said head is attached and that comprises a first moving element that is moveable in at least an XY plane in a rotational direction and a second moving element that is moveable in at least said XY plane in a rotational direction with respect to said first moving element and wherein the laser metal deposition device comprises a controller arranged to control the relative movement of the head and said support.

Practically said second support element supports said melted feed material in layers deposited on top of the other, thereby forming a laser deposited structure onto the second support element, and said first support element supports said second support element. Said second support element is rotatable with respect to the first support element and the first support element is also rotatable, for example with respect to a center of rotation. Typically, the rotational axes of the first and second support element do not coincide. By choosing a suitable rotational movement of both the first support element and the second support element, the layers can be deposited onto the second support in any desired contour. Said contour may for example have any desired regular or unregular shape. The movement of both the first support element and the second support element is freely programmable using said controller.

Said first support element and/or said second support element may be rotatable over any desired angle. For example, said first support element and/or said second support element may be rotatable over 360°, i.e. over a full circle. Alternatively said first support element and/or said second support element may be rotatable over any angle being smaller than 360°, such as for example 90°, 180°, or 270°. Typically, the second support element is rotatable of 360° and the first support element is, at least during a deposition process, rotatable over a smaller angle, such a window of between 15° and 45°, such as 30, 35 or 40°.

Said first support element and/or said second support element may be rotatable in a continuous direction or in a reciprocating direction.

The rotational movement of the first support element and/or said second support element may be controlled by said controller.

The XY plane may alternatively be referred to as the horizontal plane.

By providing said two support elements the structure to be formed thereon is movable along two axes simultaneously, i.e. along the X axis and the Y axis.

In an embodiment of said production system according to the invention said support, or, if applicable, said second support element thereof, comprises a zero point clamping system.

An advantage thereof is that said structure may be temporarily removed from said laser metal deposition device and afterwards repositioned in said laser metal deposition device in an accurate and/or repetitive way and/or at the same position and/or orientation. As such, the structure, or part thereof, may be temporarily removed from said laser metal deposition device and then repositioned to add further layers.

It is noted that, if desired, more than two support elements may be provided and that the invention is thus not limited to said two described support elements but may comprise further support elements. For example, in an embodiment said device may comprise a third support element, which may be rotationally attached to the above described shaft as the first support element and to which third support element the second support element may be rotationally attached. Said third support element may have a relatively short rotational arm as compared to the first support element. Such a third support element may reduce the impact of changing the direction of rotational movement of the first and/or second support element. In such an

embodiment the first, second and third support element may be controlled by the controller to move in such a manner that any contour of deposited layers can be made.

By using said first and second moving elements said head may be moved in the XY plane. Typically, the rotational axes of the first and second moving element do not coincide.

By moving both the head and the two support elements in the XY direction even more accurate and/or complex contours may be made and/or a speed of cladding may be increased, the latter being for example obtained by moving the head in an opposite direction to the first and/or second support element, thereby increasing a relative speed there between.

The movement of the moving means may be controlled by said controller. Said first moving element and/or said second moving element may be rotatable over any desired angle. For example, said first moving element and/or said second moving element may be rotatable over 360°, i.e. over a full circle. Alternatively said first moving element and/or said second moving element may be rotatable over any angle being smaller than 360°, such as for example 90°, 180°, or 270°. Typically, the second moving element is rotatable of 360° and the first moving element is, at least during a deposition process, rotatable over a smaller angle, such a window of between 15° and 45°, such as 30, 35 or 40°.

Said first moving element and/or said second moving element may be rotatable in a continuous direction or in a reciprocating direction.

Said second moving element may for example be embodied as or may comprise a substantially flat surface or as a second shaft. Said surface may have any desired shape such as round or square.

It is noted that, if desired, more than two moving elements may be provided and that the invention is thus not limited to said two described moving elements but may comprise further moving elements. For example, in an embodiment said device may comprise a third moving element, which may be rotationally attached to the above described shaft as the first moving element and to which third moving element the second moving element may be rotationally attached. Said third moving element may have a relatively short rotational arm as compared to the first moving element. Such a third moving element may reduce the impact of changing the direction of rotational movement of the first and/or second moving element.

By providing a laser metal deposition device which has the two rotatably movable support elements, wherein the second support element is tiltable, and wherein the head is moveable in at least an XY plane in a rotational direction and movable in the Z direction, a five axis simultaneous deposition device is provided.

Such a five axis simultaneous deposition device makes it possible produce structures no longer requiring temporary support structures to be formed to support complex structures, such as overhanging structures, thereby reducing production time and costs.

It should be noted that the rotational axis of the first moving element and the rotational axis of the first support element may coincide, however this is not always the case. For instance, the distance between the rotational axes of the first support element and the second support element may be larger or smaller than the distance between the rotational axes of the first moving element and the second moving element, as long as the moving element is able to move the head to the deposition location of the structure to be formed. In fact, the moving means may even be mounted at a location chosen independently of the location of the support, as long as the moving element is able to move the head to the deposition location of the structure to be formed, providing more freedom in the layout of the laser metal deposition device, in particular if it is part of a production cell as described hereafter.

In an embodiment of the laser metal deposition device according to the invention, the structure to be formed on the second support element is moveable along a trochoid path, such as a hypotrochoid path, by the movement in a rotational direction of said first support element and said second support element in the XY plane.

The ability of the structure to be formed to move along a trochoid path, which is a result of the configuration of the first support element, the second support element and the off-center position of the structure to be formed on the latter, i.e. spaced apart from the rotational axis of the the second support element, increases the flexibility in the movement of the structure. At each moment in time, starting from a first position, both the first support and second support element may be displaced in a positive and negative rotational direction in the XY plane, increasing the chance of selecting a suitable next position, in order to form the structure. Under most

circumstances, this does not require the deposition process to be interrupted, e.g. for reversing or changing the direction of movement of the first and/or second moving and/or support element.

In an embodiment of the laser metal deposition device according to the invention, the first support element is or comprises an elongated shaft, that is at one end thereof attached to a support drive means for rotating said shaft, and wherein the second support element is attached to the other end of the shaft.

The provision of an elongated shaft is preferred for practical reasons, since it increase the ease of movement of the support element along said trochoid path, leading to a large deflection with a relatively limited rotation of the first support element In an embodiment of the laser metal deposition device according to the invention, the shaft of the first support element extends in the XY plane.

In this way, the length of the shaft of the first support element is used to a large or even maximum extent to obtain a movement of the second support element by rotation of the first support element in the XY plane.

In an embodiment of the laser metal deposition device according to the invention, the head is moveable along a cycloid path by the movement in a rotational direction of said first moving element and said second moving element in the XY plane.

The ability of the head to move along a cycloid path, which is a result of the configuration of the first moving element, the second moving element and the position of the head on the latter, increases the flexibility in the movement of the head with respect to the structure to be formed. At each moment in time, starting from a first position, both the first moving and second moving element may be displaced in a positive and negative rotational direction in the XY plane, further increasing the chance of selecting a suitable next position, in order to form the structure. Under most circumstances, this does not require the deposition process to be interrupted, e.g. for reversing or changing the direction of movement of the first and/or second moving and/or support element.

In an embodiment of the laser metal deposition device according to the invention, the first moving element is or comprises an elongated shaft, that is at one end thereof attached to a drive means for rotating said shaft, and wherein the second moving element is attached to the other end of the shaft.

The provision of an elongated shaft is preferred for practical reasons, since it increase the ease of movement of the support element along said cycloid path.

In an embodiment of the laser metal deposition device according to the invention, said head is attached to the second moving element at an off-center location.

In this embodiment, if said second moving element is or comprises a round surface, said head is attached thereto at an off-center location. In other situations, said head is attached to an equivalent position spaced apart from the rotational axis of the second moving element.

The provision of said head at an off-center location further increases the flexibility in choosing a suitable next position for the head.

In an embodiment of the laser metal deposition device according to the invention, said controller is configured for depositing a substantially straight contour by rotationally moving said first support element and/or said second support element in the XY plane.

The combination of a support for moving the structure to be formed along a trochoid path, such as a hypotrochoid path, and a moving means for moving the head along a cycloid pathprovides the laser with two degrees of rotational freedom of the support and two degrees of rotational freedom of the moving means, totaling to at least four degrees of rotational freedom for the position of the laser with respect structure to be formed. This allows the laser metal deposition device to form a large variety of structures with limited or no necessity of interrupting the process for reversing the first and/or second moving and/or support element. For instance, it is possible to form a structure with a substantially straight contour by controlling a plurality of the first and second support element and first and second moving element to, summed up, result in the head following such a path with respect to the structure to be formed, during which deposition process the speed of the first and/or second support element and/or the first and/or second moving element may be different from each other.

In an embodiment of the laser metal deposition device according to the invention, said controller is configured for depositing a substantially curved or irregular contour by rotationally moving said first support element and/or said second support element in the XY plane.

In addition to, or as an alternative to the deposition of a substantially straight contour, the laser deposition device may also be used to form structures comprising other contours, such as a curved or irregular contour in a similar way. Again, the speed of the first and/or second support element and/or the first and/or second moving element may be different from each other during such a deposition process.

In an embodiment of the laser metal deposition device according to the invention, said second support element is or comprises a substantially flat surface.

A substantially flat surface is preferred, since it increases the flexibility in the design of the structure to be formed. Said surface may have any desired shape such as round or square.

In an embodiment of the laser metal deposition device according to the invention, said controller is arranged to move the first and second support element in a continuous rotational movement, while it controls the head to temporarily stop supplying feed material and to move to a next, restarting position for restarting supplying the feed material and thereby restarting depositing, wherein supplying the feed material will restart once the head and the first and second support elements are in desired positions.

Typically, stopping the supply of the feed material also comprises stopping the supply of gas which is supplied to the head for deposition.

An advantage of such an embodiment is that, should it be required to change the direction of the rotational movement of the first and/or second support element, no time is lost for changing the direction of the rotational movement of the first and/or second support element. Consequently, the load on the elements of the laser metal deposition device may be reduced. Furthermore, the amount of positioning errors may be reduced.

In an embodiment of the laser metal deposition device according to the invention, the controller is configured to deposit with a deposition speed of at least 5 meters per minute, preferably at least 10 meters per minute. Prior art laser metal deposition devices are typically able to achieve a deposition speed of 1-2 meters per minute. For typical structures, such conventional deposition processes will cost too much time. Simply increasing the deposition speed in such processes will impair the accuracy of the structure formed.

However, the combination of a support for moving the structure to be formed along a trochoid path, such as a hypotrochoid path, and a moving means for moving the head along a cycloid pathallows for a much higher deposition speed, without impairing the accuracy of the structure formed. Deposition speeds of at least 5 meters per minute or even at least 10 meters per minute may be attainable, significantly reducing the duration of a deposition process compared to deposition processes carried out with conventional laser metal deposition devices. Depending on the circumstances, higher deposition speeds, such as at least least 20 meters per minute, at least 30 meters per minute, at least 40 meters per minute, at least 50 meters per minute, at least 60 meters per minute, at least 70 meters per minute, at least 80 meters per minute or even at least 90 meters per minute may be attainable.

In an embodiment of the laser metal deposition device according to the invention, said controller is configured for deposition at a deposition speed which is constant or substantially constant.

By choosing a suitable rotational movement of both the first support element and the second support element, and possibly the moving means, the deposition speed may be kept constant. Depositing metal with the laser metal deposition device with a constant or at least substantially constant speed, which is typically higher then the deposition speeds achievable with conventional laser metal deposition devices, further reduces the duration of a deposition process.

In an embodiment of the laser metal deposition device according to the invention, said controller is configured for deposition at said constant deposition speed by varying the speed of the movement of the support and the moving means with respect to the environment.

In choosing a constant deposition speed, it is most important to keep the speed of the support and the moving means constant with respect to each other, and in particular the structure to be formed and the head. However, the speed of both the support and the moving means with respect to the environment may change. For instance, the head may move at a speed of 10 meters per minute, and the location of the support where structure is formed is moving at a speed of 5 meters per minute in the same direction, to obtain a net speed of 5 meters per minute. Shortly thereafter, the head may move at a speed of 7 meters per minute, and the location of the support where structure is formed is moving at a speed of 2 meters per minute, still resulting in a net speed of 5 meters per minute. In an embodiment of the laser metal deposition device according to the invention, said controller is arranged to control the first and second moving elements in a same, but opposite way as compared to the first and second support elements.

In order to obtain a certain speed, it may be preferred to move the first and second moving means in a same but opposite way as compared to the first and second support elements. As a consequence, the track width of the metal deposition is reduced, which may allow for more rapid cooling of the metal deposited, decreasing the amount of defects in the structure to be formed.

In another embodiment of the laser metal deposition device according to the invention said support or, if applicable, the first support element and/or the second support element thereof, is tiltable with respect to an or the XY plane.

An advantage of a tiltable support is that the structure that is supported thereby can be tilted with respect to the head, such that the head is allowed to supply said feed material substantially orthogonal and/or the laser is substantially orthogonal with respect to the structure supported by said support, even if said structure is oblique with respect to said support.

It is noted that tiltable with respect to the XY plane may alternatively be described as rotatable about the X axis.

Said support may be tiltable with respect to the XY plane over any suitable angle, such as for example between 0°, i.e. substantially horizontal, and 90° in either direction, i.e. -90° to +90°, i.e. substantially vertical. The support may be tiltable over any angle between this range, i.e. continuously, or in steps of certain degrees, i.e. indexed.

Practically, and if applicable, it is at least the second support element that is tiltable.

Practically, in the above described embodiment in which the first support element comprises said elongated shaft, said shaft may extend in the XY plane, i.e. substantially horizontally, and said shaft may be rotatable about its longitudinal axis, such that the second support element that is attached to the shaft is tiltable in the XY plane.

By providing said two support elements, wherein practically at least the second support element is tiltable, the structure to be formed thereon is movable along three axes simultaneously, i.e. along the X axis and the Y axis and about the X axis.

In another embodiment of the laser metal deposition device according to the invention said supply means is arranged to supply said feed material at a focal point of said laser, and wherein said laser is arranged such that said focal point thereof is arranged above a deposition location, such that said feed material is at least partly molten by said laser prior to being deposited at said deposition location.

A focal point of said laser being at the deposition location may result in a relatively large heat affected zone of the feed material and previous layers, which may cause problems. If said focal point is arranged above said deposition location the heat affected zone may be relative small. Such a laser metal deposition device may be a so called ultra high speed laser metal deposition device.

Such a ultra high speed laser metal deposition device results in a track width and/or height which is typically smaller than conventional laser metal deposition devices, increasing the cooling rate after deposition and consequently reducing the amount of defects.

In a conventional laser metal deposition device the focal point of the laser may be arranged at the deposition location.

Optionally, for example by exchanging the head and thereby the laser and supply means used, it can be allowed to switch between conventional and ultra high speed laser metal deposition. For example, conventional laser metal deposition may be used for large volumes to be deposited, and ultra high speed laser metal deposition may be used for, for example, transition layers and/or high demanding (parts of) structures.

As will be clear for the skilled person, at the start of a manufacturing process said deposition location may be directly on the support, or, if applicable, directly on the second support element. After applying a first layer, the deposition location is on top of the uppermost layer, and thereby the deposition location may continuously change after each layer.

In another embodiment of the laser metal deposition device according to the invention, said laser metal deposition device further comprises a moving means to which said head is attached for moving said head in at least a Z direction.

By moving said head in at least the Z direction, i.e. in a vertical direction, a distance between the support and the head may be adjusted. This is advantageous if the number of layers deposited on top of the other during making of the structure increases, as a result of which the deposition location changes. By moving the head in the Z direction the distance between the head and the deposition location may be kept substantially equal.

By providing said two support elements, wherein practically at least the second support element is tiltable, and said head that is movable in at least the Z direction, the second support element on which the structure is to be formed and the head are moveable with respect to each other along four axes simultaneously, i.e. along the X, Y and Z axis and about the X axis.

In accordance with an aspect of the invention said supply means may be arranged to supply different feed materials, or a plurality of supply means may be provided that each supply a different feed material, such that it is for example possible to exchange a said supply means from said plurality of supply means by a different supply means from said plurality of supply means. As a result thereof, structures made of multiple materials can be made. It is noted that any desired number of different feed materials may be provided, preferably more than two different types of feed material. Said feed material may be contained in a container. If different feed materials are provided, different containers each containing a different feed material may be provided.

Said feed material may be provided in any suitable way. For example, said feed material may be provided as a powder or as a flux cored wire, i.e. a hollow wire fdled with a powder.

Said supply means or each supply means may comprise a nozzle for supplying said feed material.

When using different feed materials, a first layer is preferably deposited with one or more feed materials in a fixed ratio during the deposition of this first layer, and a subsequent layer is then deposited with one or more feed materials in another fixed ratio which may be different from the ratio used for depositing the first layer.

In accordance with an aspect of the invention said head may comprise multiple, different lasers or said head or laser may be exchangeable, such that multiple heads, each having its own, different laser, or multiple lasers may be provided and may be exchangeably applied in the device. An advantage thereof is that each laser may have its own power and/or frequency and/or focal point.

As described above, the supply means and/or laser may be exchangeable, either on its own or together with the head.

It is noted that said structure made by said laser metal deposition device may be any type of structure.

Said controller may in particular be arranged to control the movement of the various elements, such as the first and second support element and the moving means, such that the production speed is relatively high, preferably as high as possible, while preferably obtaining a substantially constant depositing speed for a certain layer.

Typically, said laser metal deposition device comprises at least one measuring means, such as an incremental measuring means but preferably an absolute measuring means, for determining the positions of the first and/or second support and/or moving element, in terms of rotation and/or tilting, where applicable.

It is further noted that said laser metal deposition device may further comprise any other standard features well known to the skilled person, such as cooling means, protection gas, or the like. These features are not part of the invention and therefor not described in further detail.

The invention further relates to a production cell, comprising a laser deposition device as described above and in particular in any one or more of the above described embodiments and/or having any one or more of the above described features, alone or in combination, and further comprising at least one of: at least one processing device for processing said laser deposited structure or part thereof, said processing device being for example chosen from a group comprising an annealing device and a surface treating device;

at least one inspection means for inspecting said laser deposited structure or part thereof;

at least one correction device for correcting said laser deposited structure or part thereof, said correction device being for example chosen from a group comprising a high speed milling device and high speed grinding device;

wherein said support, or, if applicable, the first support element and/or the second support element thereof, is moveable between an area where said laser metal deposition device is arranged and at least one other area where said at least one processing device and/or said at least one inspection means and/or said at least one correction device is arranged.

An advantage of providing such a production cell is that during the process of making a structure using said laser metal deposition device, said structure or part thereof can be processed by said processing device and/or can be inspected by said inspection device and/or can be corrected by said correction device. Said processing device may alternatively be denoted as an intermediate processing device. Said inspection device preferably is or comprises a quality inspection device.

Said support, or, if applicable, the first support element and/or the second support element thereof, may be arranged to move between said areas after each or a chosen number of deposited layers.

An advantage thereof is that each or a chosen number of deposited layers of the structure to be made can be processed and/or inspected and/or corrected. If, for example, a failure is discovered in one or several layers of the structure by said inspection means, said correction device can be applied for correcting said structure, for example by removing said one or several layer(s). This may save time in comparison to inspecting a completed structure and/or may save material because corrections can be made prior to completing a whole structure. Alternatively or additionally, the quality of the structure can be improved if said structure is processed by said processing device after each or several layers. Alternatively or additionally, the accuracy of making the structure may be increased because the structure does not have to be removed from the production cell between the different steps of depositing and/of processing and/or inspecting and/or correcting. More in particular, the structure may remain on the support, or, if applicable, on the second support element thereof.

Said production cell can be programmed in any desired way, thereby moving the support between said areas in any desired way, for example after any desired number of layers and/or between any desired areas. Practically said annealing device may comprise an ultrasonic hammer or may make use of Eddy current.

Practically said inspection means may comprise a hardness or strength sensor for measuring a hardness or strength of each or a chosen number of deposited layers or may make use of Eddy current. It found by the applicant that, although it is alternatively possible to use visual inspection means such as a camera, a said hardness or strength sensor or using Eddy current may be faster than a visual inspection means and thereby be preferred if timing is crucial. Indirect inspection is preferred, since it reduces the number of situations in which it becomes necessary to remove the structure from the support for inspection.

The invention further relates to a production system, comprising a laser metal deposition device as described above and in particular in any one or more of the above described

embodiments and/or having any one or more of the above described features, alone or in combination or a production cell as described above and in particular in any one or more of the above described embodiments and/or having any one or more of the above described features, alone or in combination, and further comprising at least one of:

at least one processing device, said processing device being chosen from a group comprising a machining device, milling device, turning device, multitasking device, and a grinding device;

at least one post processing device, said post processing device being chosen from a group comprising an annealing oven, a polishing device; and a coating device;

at least one inspection means for inspecting a structure or part thereof made by said laser metal deposition device or said production cell and/or said processing device; and comprising a transporting means for transporting said structure or part thereof between an area where said laser deposition device or said production cell is arranged and/or an area where said at least one processing device is arranged and/or an area where said at least one post processing device is arranged and/or an area where said at least one inspection means is arranged.

An advantage of said production system is that a structure can be made using different techniques and/or devices. This may allow for complex structures to be made and/or to save material. For example, a structure can be made that is partly made by said laser metal deposition device, either as a stand alone device or being part of said production cell, and partly made by any one or more of said processing and/or post processing device(s). Said inspection means can be used for inspecting said structure made.

Said inspection means may be any suitable type of inspection means, such as a scanner, e.g. an optical scanner or CT scanner, or a measuring sensor. As described above, said support, or, if applicable, said second support element thereof, may comprise said zero point clamping system. An advantage thereof is that said structure or part thereof may be repositioned in said production cell or laser metal deposition device in an accurate and/or repetitive way and/or at a same position and/or orientation.

When the laser metal deposition device which has the two support elements, wherein the second support element is tiltable, and wherein the head is moveable in at least an XY plane in a rotational direction and movable in the Z direction, a five axis simultaneous deposition device is provided. This makes it possible post-process and/or inspect structures without the necessity of removing temporary support structures to be formed to support complex structures, such as overhanging structures, thereby reducing process time and costs.

In an embodiment of said production system according to the invention said production system is arranged for making a first structure or part thereof using said laser metal deposition device or production cell, and for simultaneously processing at least one other structure or part thereof using said processing device and/or for simultaneously post processing at least one other structure or part thereof using said post processing device and/or for simultaneously inspecting at least one other structure or part thereof using said inspecting means during making of said first structure or part thereof.

Said laser metal deposition device, either as a stand alone device or being part of said production cell, can be used for making any structure, in particular for making a complex structure. However, said laser metal deposition device can be relatively slow, or simultaneous use of the other parts of the production system may be preferred for other reasons. Therefor it is

advantageous that the processing device(s) and/or post processing device(s) and/or inspection means of the production system can simultaneously be used for making or inspecting other structures or parts thereof, increasing the efficiency of operation.

Said transporting means can be embodied in any suitable way. For example, said transporting means may comprise a robot or manipulator that is preferably arranged centrally between said areas or moveable along a central axis between said areas. Such a robot or manipulator may advantageously be used for transporting structures between the different areas where said different devices or means are located.

The invention also relates to a method for making a structure thereof using a laser deposition device as described above and in particular in any one or more of the above described embodiments and/or having any one or more of the above described features, alone or in combination or a production cell as described above and in particular in any one or more of the above described embodiments and/or having any one or more of the above described features, alone or in combination or a production system as described above and in particular in any one or more of the above described embodiments and/or having any one or more of the above described features, alone or in combination.

In an embodiment of the method according to the invention, the laser metal deposition device is at least according to claim 8, wherein the method comprises the step of depositing a substantially straight contour by rotationally moving the first support element and/or the second support element of said laser metal deposition device or said production cell in the XY plane.

In an embodiment of the method according to the invention, the laser metal deposition device is at least according to claim 9, wherein the method comprises the step of depositing a substantially curved or irregular contour by rotationally moving the first support element and/or the second support element of said laser metal deposition device or said production cell in the XY plane. In an embodiment of the method according to the invention, the method comprises the step of depositing at a deposition speed which is constant or substantially constant.

In an embodiment of the method according to the invention, the step of depositing at said constant deposition speed is executed by varying the speed of the movement of the support and the moving means with respect to the environment.

However, in this case, the net speed of the support, and especially the location at which the structure is formed thereon, with respect to the head stays constant. This may for instance be beneficial when the direction of deposition is changed, e.g. reversed.

In an embodiment of the method according to the invention said method comprises the simultaneous steps of:

a) making a first structure or part thereof using said laser metal deposition device or production cell, and at least one of:

b) processing at least one other structure or part thereof using said processing device; c) post processing at least one other structure or part thereof using said post processing device; and

d) inspecting at least one other structure or part thereof using said inspecting means.

Said laser metal deposition device, either as a stand alone device or being part of said production cell, can be used for making any structure, in particular for making a complex structure. However, said laser metal deposition device can be relatively slow. Therefor it is advantageous that the processing device(s) and/or post processing device(s) and/or inspection means of the production system can simultaneously be used for making or inspecting other structures or parts thereof.

In another embodiment of the method according to the invention a structure is made using at least said laser metal deposition device according to any of claims 1 - 18 or said production cell according to any of claims 19 - 22, wherein said supply means is arranged for supplying different types of feed material, such that layers of different materials are deposited on top of the other, and wherein optionally a transition feed material is supplied between supplying different types of feed material, thereby obtaining a transition layer between layers of different materials

An advantage of this embodiment is that multimaterial structures, i.e. structures made of multiple, different materials, can be made.

An advantage of providing a transition layer is that the change on failure such as cracks between neighboring layers made of different materials is reduced, since tensions in structure are distributed over a larger area or volume.

Said transition feed material can for example be a mix of materials, said mix being composed of the two different types of feed material between which said transition feed material layer is applied. Said mix may comprise the two different materials in any suitable amount or percentage. Said amount or percentage may optionally vary and/or change, for example per transition layer. For example, if at least one layer of a first material is provided, and it is intended to change to at least one layer of a second material, a first transition layer may be provided on top of the uppermost layer of the first material, said first transition layer comprising a percentage of the first material that is larger than a percentage of the second material, and then a second transition layer may be provided on top of the first transition layer, said second transition layer having a lower percentage of the first material and a higher percentage of the second material compared to the first transition layer. Optionally a third, or even more, transition layers may be provided, wherein the percentage of the first material is gradually reduced and the percentage of the second material is gradually increased, until the layer of second material is deposited on top of the uppermost transition layer. For example, three transition layers may be provided wherein the first transition layer has 75% of the first material and 25% of the second material, the second transition layer has 50% of both the first and the second material, and the third transition layer has 25% of the first material and 75% of the second material. More in particular, the decrease of the first material and increase of the second material may be defined by the number of transition layers, and may be linearly decreased or increased, or in any suitable, non-linear way. Said percentage may either be a percentage of weight or volume.

Said laser metal deposition device according to the invention may for example comprise a mixing unit or mixing chamber for mixing said different feed materials. Said mixing unit may connect to two or more feed material storages, each feed material storage being at least partly filled by one type of feed of material. In particular, said mixing unit may be a powder switch. Said powder switch may be programmable in order to obtain a desired mixing ratio.

The invention will be further elucidated with reference to figures, wherein:

Figure 1A is a schematic perspective view of a laser metal deposition device according to a first embodiment of the invention;

Figure IB is a detail of the laser metal deposition device of figure 1A; Figure 1C is a schematic top view of the laser metal deposition device of figure 1A;

Figure 2 is a schematic perspective view of a variant of a laser metal deposition device according to figure 1 ;

Figure 3 is a schematic top view of a production cell comprising the laser metal deposition device of figure 1 ;

Figure 4 is a schematic top view of a production cell comprising the laser metal deposition device of figure 2, and

Figure 5 is a schematic top view of a production system according to the invention.

In the figures same reference numerals will be used for the same elements, or increased by 100 for similar elements.

Figures 1A, IB and 1C show a laser metal deposition (LMD) device 1 according to an embodiment of the invention. Centrally arranged in said production cell is a rotator 2, to which rotator 2 an elongated shaft or arm 3 is attached. Said elongated shaft 3 is rotatable in a horizontal XY plane by means of said rotator 2 in the direction indicated by arrow 61. Said rotator 2 hereby defines a centre of rotation for the shaft 3. Two ring shaped elements 4 for supporting said shaft 3 are provided at a mutual radial distance from each other and at a radial distance from said rotator 2. A support table 5 for supporting a structure to be formed thereon at an off-center position, spaced apart from the rotational axis of support table 5 is attached to said shaft 3 at an end zone of the shaft 3 that is opposite to the rotator 2. As indicated by arrow 60, the support table 5 is rotatable with respect to the shaft 3, in particular about a centre of rotation of the support table 5. Because the rotatable support table 5 is attached to the rotatable shaft 3, the support table 5 and thereby the structure to be formed thereon is able to make a trochoid movement, such as a hypotrochoid movement. Said shaft 3 is further rotatable about its longitudinal axis, such that the support table 5 is indexingly or continuously tiltable with respect to the horizontal XY plane, as indicated by arrow 64. By means of said rotatable shaft 3 and said rotatable and tiltable support table 5, which respectively define a first support element 3 and a second support element 5, said support table 5 and thereby the structure to be formed thereon is moveable in 4 degrees of freedom. The movement of the shaft 3 and support table 5 may be controlled by a controller (not shown). The shaft 3 and/or the inner or outer ring shaped element 4 may comprise a means for measuring the absolute rotational position of that shaft 3 or ring shaped element 4.

Said laser deposition device 1 further comprises a LMD head 7. Said head 7 comprises a nozzle 8 for supplying a feed material, for example in the form of a metal powder, and at least one laser (not visible) for melting said feed material. By supplying and melting said feed material, layers of feed material can be formed on top of the other on the support table 5, thereby forming a laser deposited metal structure 10 on the support table 5. Said nozzle 8 can in particular be arranged to supply different types of feed material, such that structures of different materials and optionally of multiple, different materials can be formed. Said nozzle 8 is arranged to supply said feed material at a focal point of said laser, wherein said laser is arranged such that said focal point thereof is arranged above a deposition location, such that said feed material is at least partly molten by said laser prior to being deposited at said deposition location. Said deposition location may be located directly at the support table 5 at the start of a manufacturing process or at an uppermost layer of the structure 10 during a manufacturing process. In this first embodiment the head 7 is attached to a rotatable carrier element 11, which carrier element 11 is rotatable with respect to a carrier shaft 12, in a direction indicated by arrow 62, which carrier shaft 12 is rotatable in the horizontal XY plane by means of a rotator 13, in a direction indicated by arrow 63. Because the rotatable carrier element 11 is attached to the rotatable carrier shaft 12, the carrier element 11 and thereby the head 7 mounted off-center thereon, spaced apart from the rotational axis of carrier element 11, is able to make a cycloid movement. Said carrier shaft 12 and carrier element 11 define a first moving element and second moving element, respectively. By means of said rotatable carrier shaft 12 and said rotatable carrier element 11 said head 7 is movable in the horizontal XY plane. The carrier shaft 12 is support by two ring shaped elements 14, which are provided at a mutual radial distance from each other and at a radial distance from said rotator 13. Said head 7 is movable in a Z direction 9 by moving the rotator 13, and thereby the carrier shaft 12 in the Z direction, such that a distance between the support table 5 and the head 7 can be adjusted and in particular a distance between the deposition location that changes during the manufacturing process and the head 7 can be maintained substantially equal during the manufacturing process.

The movement of the head 7, shaft 12 and carrier element 11 may be controlled by said controller (not shown). By means of said movable head 7, the head 7 and the support table 5 are movable with respect to each other in 6 degrees of freedom. The shaft 12 and/or the inner or outer ring shaped element 14 may comprise a means for measuring the absolute rotational position of that shaft 12 or ring shaped element 14.

A storage 15 comprising additional heads 7 is provided, such that it is possible to exchange the head 7 by another head 7, said another head 7 for example having a different laser.

Alternatively or additionally said storage 15 may comprise lasers and/or nozzles stored therein for exchanging a laser or nozzle by another laser or nozzle. Said support table 5 comprises a zero point clamping system 16, such that said structure 10 can be removed from the support table 5 and be brought back into the same position and orientation.

It is noted that said controller may be arranged to control the movement of the shaft 3 and support table 5 in a same, but opposite way as the shaft 12 and carrier element 11.

Figure 1C in particular shows the arrangement of the head 7 at an off-center position with respect to the rotational axis of the carrier element 11. Furthermore, it discloses that location at which the structure 10 is formed is off-center with respect to the rotational axis of support table 5. Figure 2 shows an alternative laser metal deposition device 101. Only the differences between the laser metal deposition device 1 of figure 1 and the laser metal deposition device 101 of figure 2 will be described here. For a further description of the laser metal deposition device 101 of figure 2, the reader is referred to the description of figure 1.

The laser metal deposition device 101 of the second embodiment differs in that the LMD head 7 is movable in the horizontal XY plane by means of a linear delta robot 18. Said linear delta robot 18 is able to move the head 7 in both the horizontal XY plane as in the vertical Z direction.

Figures 3 and 4 show a production cell having the laser metal deposition device 1 of figure 1 and the laser metal deposition device 101 of figure 2, respectively. The production cell of the embodiments of figures 3 and 4 further comprises a processing device 20 and an inspection unit 30. Said processing device 20 may be any suitable processing device, such as an annealing device anda surface treating device. If said processing device 20 is an annealing device, it may in particular comprise an ultrasonic hammer or may make use of Eddy current. Said inspection unit 30 may be any suitable inspection unit. For example, said inspection unit may comprise a hardness or strength sensor for measuring a hardness or strength of each or a chosen number of deposited layers. In this first embodiment the production cell further comprises a correction device 40 for correcting said laser deposited structure 10 or part thereof, said correction device being for example chosen from a group comprising a high speed milling device and high speed grinding device. By means of said rotatable shaft 3 said support table 5 on which said structure 10 is formed is movable between an area of the laser deposition device 1, an area of the processing device 20, an area of the inspection unit 30, and an area of the correcting device 40, and optionally any other area of any other processing device, inspection means, or correction device optionally provided. Said rotatable shaft 3 may be controlled by said controller to move between said areas in any suitable way. For example, said support table 5 may be arranged to move between the areas after each or several deposited layers.

Figure 5 shows an exemplary arrangement of a production system according to an embodiment of the invention. In this embodiment the production system comprises a production cell 100, for example a production cell according to the one shown in figure 3 or in figure 4. The production system in this embodiment further comprises an annealing oven 200, a surface treatment device 300, a CNC-tuming device 400, a CNC-milling device 500, a CNC-grinding device 600, and a CNC-machining device 700. A robot or manipulator 801 is movable along a central axis 800, which is centrally arranged between the devices 100 - 700, such that structures or parts thereof can be transported between the several devices provided in the production system. Using said production system structures can be made by using one or more of the different devices provided in the production system. Because the laser metal deposition process may be a relatively slow process, it is possible to make or process other structures simultaneously to making a structure in the production cell 100.

It is noted that the invention is not limited to the shown embodiments but also extends to variants within the scope of the appended claims.

For example, it will be clear for the skilled person that the many practical arrangements that together define the laser metal deposition device or production cell, can be arranged in any suitable way. Further, it will be clear for the skilled person that the production cell and/or production system may comprise any suitable combination of devices, which devices may be arranged at any suitable location with respect to each other.