EP4096856A1 - Imprimante 3d destinée à la fabrication additive d'un élément multicouche, procédé d'impression et élément - Google Patents

Imprimante 3d destinée à la fabrication additive d'un élément multicouche, procédé d'impression et élément

Info

Publication number
EP4096856A1
EP4096856A1 EP21702601.2A EP21702601A EP4096856A1 EP 4096856 A1 EP4096856 A1 EP 4096856A1 EP 21702601 A EP21702601 A EP 21702601A EP 4096856 A1 EP4096856 A1 EP 4096856A1
Authority
EP
European Patent Office
Prior art keywords
component
raw material
work surface
printer
layer
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Pending
Application number
EP21702601.2A
Other languages
German (de)
English (en)
Inventor
Christoph Recher
Thomas Lenzen
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
TDK Electronics AG
Original Assignee
TDK Electronics AG
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by TDK Electronics AG filed Critical TDK Electronics AG
Publication of EP4096856A1 publication Critical patent/EP4096856A1/fr
Pending legal-status Critical Current

Links

Classifications

    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C64/00—Additive manufacturing, i.e. manufacturing of three-dimensional [3D] objects by additive deposition, additive agglomeration or additive layering, e.g. by 3D printing, stereolithography or selective laser sintering
    • B29C64/10—Processes of additive manufacturing
    • B29C64/165—Processes of additive manufacturing using a combination of solid and fluid materials, e.g. a powder selectively bound by a liquid binder, catalyst, inhibitor or energy absorber
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C64/00—Additive manufacturing, i.e. manufacturing of three-dimensional [3D] objects by additive deposition, additive agglomeration or additive layering, e.g. by 3D printing, stereolithography or selective laser sintering
    • B29C64/20—Apparatus for additive manufacturing; Details thereof or accessories therefor
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B22—CASTING; POWDER METALLURGY
    • B22F—WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
    • B22F10/00—Additive manufacturing of workpieces or articles from metallic powder
    • B22F10/10—Formation of a green body
    • B22F10/12—Formation of a green body by photopolymerisation, e.g. stereolithography [SLA] or digital light processing [DLP]
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B22—CASTING; POWDER METALLURGY
    • B22F—WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
    • B22F10/00—Additive manufacturing of workpieces or articles from metallic powder
    • B22F10/10—Formation of a green body
    • B22F10/16—Formation of a green body by embedding the binder within the powder bed
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B22—CASTING; POWDER METALLURGY
    • B22F—WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
    • B22F10/00—Additive manufacturing of workpieces or articles from metallic powder
    • B22F10/20—Direct sintering or melting
    • B22F10/28—Powder bed fusion, e.g. selective laser melting [SLM] or electron beam melting [EBM]
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B22—CASTING; POWDER METALLURGY
    • B22F—WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
    • B22F10/00—Additive manufacturing of workpieces or articles from metallic powder
    • B22F10/70—Recycling
    • B22F10/73—Recycling of powder
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B22—CASTING; POWDER METALLURGY
    • B22F—WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
    • B22F12/00—Apparatus or devices specially adapted for additive manufacturing; Auxiliary means for additive manufacturing; Combinations of additive manufacturing apparatus or devices with other processing apparatus or devices
    • B22F12/50—Means for feeding of material, e.g. heads
    • B22F12/53—Nozzles
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B22—CASTING; POWDER METALLURGY
    • B22F—WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
    • B22F12/00—Apparatus or devices specially adapted for additive manufacturing; Auxiliary means for additive manufacturing; Combinations of additive manufacturing apparatus or devices with other processing apparatus or devices
    • B22F12/50—Means for feeding of material, e.g. heads
    • B22F12/55—Two or more means for feeding material
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B22—CASTING; POWDER METALLURGY
    • B22F—WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
    • B22F12/00—Apparatus or devices specially adapted for additive manufacturing; Auxiliary means for additive manufacturing; Combinations of additive manufacturing apparatus or devices with other processing apparatus or devices
    • B22F12/50—Means for feeding of material, e.g. heads
    • B22F12/58—Means for feeding of material, e.g. heads for changing the material composition, e.g. by mixing
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B22—CASTING; POWDER METALLURGY
    • B22F—WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
    • B22F12/00—Apparatus or devices specially adapted for additive manufacturing; Auxiliary means for additive manufacturing; Combinations of additive manufacturing apparatus or devices with other processing apparatus or devices
    • B22F12/60—Planarisation devices; Compression devices
    • B22F12/67—Blades
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C64/00—Additive manufacturing, i.e. manufacturing of three-dimensional [3D] objects by additive deposition, additive agglomeration or additive layering, e.g. by 3D printing, stereolithography or selective laser sintering
    • B29C64/10—Processes of additive manufacturing
    • B29C64/106—Processes of additive manufacturing using only liquids or viscous materials, e.g. depositing a continuous bead of viscous material
    • B29C64/124—Processes of additive manufacturing using only liquids or viscous materials, e.g. depositing a continuous bead of viscous material using layers of liquid which are selectively solidified
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C64/00—Additive manufacturing, i.e. manufacturing of three-dimensional [3D] objects by additive deposition, additive agglomeration or additive layering, e.g. by 3D printing, stereolithography or selective laser sintering
    • B29C64/10—Processes of additive manufacturing
    • B29C64/106—Processes of additive manufacturing using only liquids or viscous materials, e.g. depositing a continuous bead of viscous material
    • B29C64/124—Processes of additive manufacturing using only liquids or viscous materials, e.g. depositing a continuous bead of viscous material using layers of liquid which are selectively solidified
    • B29C64/129—Processes of additive manufacturing using only liquids or viscous materials, e.g. depositing a continuous bead of viscous material using layers of liquid which are selectively solidified characterised by the energy source therefor, e.g. by global irradiation combined with a mask
    • B29C64/135—Processes of additive manufacturing using only liquids or viscous materials, e.g. depositing a continuous bead of viscous material using layers of liquid which are selectively solidified characterised by the energy source therefor, e.g. by global irradiation combined with a mask the energy source being concentrated, e.g. scanning lasers or focused light sources
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C64/00—Additive manufacturing, i.e. manufacturing of three-dimensional [3D] objects by additive deposition, additive agglomeration or additive layering, e.g. by 3D printing, stereolithography or selective laser sintering
    • B29C64/20—Apparatus for additive manufacturing; Details thereof or accessories therefor
    • B29C64/205—Means for applying layers
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C64/00—Additive manufacturing, i.e. manufacturing of three-dimensional [3D] objects by additive deposition, additive agglomeration or additive layering, e.g. by 3D printing, stereolithography or selective laser sintering
    • B29C64/20—Apparatus for additive manufacturing; Details thereof or accessories therefor
    • B29C64/227—Driving means
    • B29C64/232—Driving means for motion along the axis orthogonal to the plane of a layer
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C64/00—Additive manufacturing, i.e. manufacturing of three-dimensional [3D] objects by additive deposition, additive agglomeration or additive layering, e.g. by 3D printing, stereolithography or selective laser sintering
    • B29C64/20—Apparatus for additive manufacturing; Details thereof or accessories therefor
    • B29C64/227—Driving means
    • B29C64/236—Driving means for motion in a direction within the plane of a layer
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C64/00—Additive manufacturing, i.e. manufacturing of three-dimensional [3D] objects by additive deposition, additive agglomeration or additive layering, e.g. by 3D printing, stereolithography or selective laser sintering
    • B29C64/20—Apparatus for additive manufacturing; Details thereof or accessories therefor
    • B29C64/245—Platforms or substrates
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C64/00—Additive manufacturing, i.e. manufacturing of three-dimensional [3D] objects by additive deposition, additive agglomeration or additive layering, e.g. by 3D printing, stereolithography or selective laser sintering
    • B29C64/20—Apparatus for additive manufacturing; Details thereof or accessories therefor
    • B29C64/255—Enclosures for the building material, e.g. powder containers
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C64/00—Additive manufacturing, i.e. manufacturing of three-dimensional [3D] objects by additive deposition, additive agglomeration or additive layering, e.g. by 3D printing, stereolithography or selective laser sintering
    • B29C64/20—Apparatus for additive manufacturing; Details thereof or accessories therefor
    • B29C64/264—Arrangements for irradiation
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C64/00—Additive manufacturing, i.e. manufacturing of three-dimensional [3D] objects by additive deposition, additive agglomeration or additive layering, e.g. by 3D printing, stereolithography or selective laser sintering
    • B29C64/30—Auxiliary operations or equipment
    • B29C64/307—Handling of material to be used in additive manufacturing
    • B29C64/321—Feeding
    • B29C64/336—Feeding of two or more materials
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C64/00—Additive manufacturing, i.e. manufacturing of three-dimensional [3D] objects by additive deposition, additive agglomeration or additive layering, e.g. by 3D printing, stereolithography or selective laser sintering
    • B29C64/30—Auxiliary operations or equipment
    • B29C64/35—Cleaning
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C64/00—Additive manufacturing, i.e. manufacturing of three-dimensional [3D] objects by additive deposition, additive agglomeration or additive layering, e.g. by 3D printing, stereolithography or selective laser sintering
    • B29C64/30—Auxiliary operations or equipment
    • B29C64/357—Recycling
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B33—ADDITIVE MANUFACTURING TECHNOLOGY
    • B33Y—ADDITIVE MANUFACTURING, i.e. MANUFACTURING OF THREE-DIMENSIONAL [3D] OBJECTS BY ADDITIVE DEPOSITION, ADDITIVE AGGLOMERATION OR ADDITIVE LAYERING, e.g. BY 3D PRINTING, STEREOLITHOGRAPHY OR SELECTIVE LASER SINTERING
    • B33Y10/00—Processes of additive manufacturing
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B33—ADDITIVE MANUFACTURING TECHNOLOGY
    • B33Y—ADDITIVE MANUFACTURING, i.e. MANUFACTURING OF THREE-DIMENSIONAL [3D] OBJECTS BY ADDITIVE DEPOSITION, ADDITIVE AGGLOMERATION OR ADDITIVE LAYERING, e.g. BY 3D PRINTING, STEREOLITHOGRAPHY OR SELECTIVE LASER SINTERING
    • B33Y30/00—Apparatus for additive manufacturing; Details thereof or accessories therefor
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B33—ADDITIVE MANUFACTURING TECHNOLOGY
    • B33Y—ADDITIVE MANUFACTURING, i.e. MANUFACTURING OF THREE-DIMENSIONAL [3D] OBJECTS BY ADDITIVE DEPOSITION, ADDITIVE AGGLOMERATION OR ADDITIVE LAYERING, e.g. BY 3D PRINTING, STEREOLITHOGRAPHY OR SELECTIVE LASER SINTERING
    • B33Y40/00—Auxiliary operations or equipment, e.g. for material handling
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B33—ADDITIVE MANUFACTURING TECHNOLOGY
    • B33Y—ADDITIVE MANUFACTURING, i.e. MANUFACTURING OF THREE-DIMENSIONAL [3D] OBJECTS BY ADDITIVE DEPOSITION, ADDITIVE AGGLOMERATION OR ADDITIVE LAYERING, e.g. BY 3D PRINTING, STEREOLITHOGRAPHY OR SELECTIVE LASER SINTERING
    • B33Y80/00—Products made by additive manufacturing
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
    • Y02P—CLIMATE CHANGE MITIGATION TECHNOLOGIES IN THE PRODUCTION OR PROCESSING OF GOODS
    • Y02P10/00—Technologies related to metal processing
    • Y02P10/25—Process efficiency

Definitions

  • 3D printer for the additive manufacturing of a multi-layer component, printing process and component
  • the invention relates to a 3D printer for the additive manufacturing of a multilayer component, a method for the additive manufacturing of a three-dimensional, multilayer component and a 3D-printed, multilayer component.
  • multi-layer components can be structured and built up in layers.
  • Corresponding pressure equipment is characterized by the fact that a raw material is placed in a bath or applied to another work surface and is then structured and hardened in contact with a multilayer component. In some processes, only one layer of a raw material is applied to a work surface and then structured and hardened in contact with the component.
  • a multi-layer component is created by repeating the steps with possibly a different structure of the layer transferred to the component.
  • SLA stereolithography
  • DLP digital light processing
  • the raw material is irradiated by usually programmable digital radiation sources.
  • SLA processes generally use pivotable lasers for this purpose, while DLP processes use projectors, for example.
  • the irradiation follows a predetermined pattern.
  • the photosensitive raw material in this case hardens then by photopolymerization of a binder contained therein.
  • the international patent application WO 2015/107066 A1 discloses a DLP-3D printer in which the raw material is applied to a conveyor belt and transported by this to the work surface. Since, as a rule, only part of the available raw material is used to structure the new layer, more raw material has to be used than is necessary to manufacture the component. The excess of raw material used makes the printing process inefficient and expensive.
  • the entire printer including the recovery device In order to print with a second raw material, the entire printer including the recovery device must be cleaned in order to remove residues of the first raw material. This means that it is not possible to print a component that comprises several layers of different materials in one printing process.
  • the US application US 2017/0182708 A1 discloses a 3D printer with a laterally moving work surface. With the help of several raw material dispensers, different raw materials can be applied here. The work surface and the component must be cleaned before each material change. A recovery of excess raw material is not provided in the disclosed device. A large number of components contain multiple layers that comprise different materials. As a rule, this is only possible in 3D printing with complex manufacturing processes in which the individual components are, for example, printed separately and then joined together. Although the state of the art includes initial approaches to printing multi-layer components that comprise different materials, these are inefficient and expensive due to the excess raw material to be used and the outlay on equipment.
  • the aim of the invention is therefore to specify a 3D printer and a printing method with which a multilayer component, which comprises different materials, can be manufactured in an efficient, resource-saving and cost-effective manner.
  • the invention according to claim 1 at least partially solves the problem described.
  • the present invention discloses a 3D printer for the additive manufacturing of a multilayer component.
  • the 3D printer includes a work surface on which the printing process takes place. Furthermore, the printer comprises at least two movable dispensers which are designed to coat the work surface with one of at least two different raw materials. In one embodiment, the work surface can be immobile.
  • the dispensers can comprise various technical embodiments.
  • the dispenser can be used as a nozzle coater, as a syringe pump, as a hose pump, as Inkjet head, be designed as a roller transfer apparatus or as a transfer film.
  • At least part of a layer of the respective raw material applied by the dispenser to the work surface is attached as a layer to the component during the printing process.
  • the manufacturing process is an additive photopolymerization process.
  • the first layer of the component can be joined directly to a construction panel provided for this purpose.
  • the other layers are each joined to the last printed layer of the component.
  • the printed component then grows layer by layer on the building board.
  • the 3D printer comprises at least two movable recovery devices for the selective recovery of the respective raw material, which is not used when adding a layer to the component, and for returning the recovered raw material to the respective dispenser.
  • the recovery devices can, in turn, have different technical designs. Possible embodiments are suction nozzles, wipers, blades or rollers.
  • Each individual raw material is assigned a dispenser, which applies only this one raw material, and a recovery device, which recovers only this one raw material and returns it to the associated dispenser.
  • the raw material can be returned to the respective dispenser in two ways.
  • the recovery device can be firmly connected to the movable dispenser with a hose.
  • the raw material can be transported back from the recovery device into a feed device, from which the dispenser can be filled before the start of a new printing step. In this case, the return device and the dispenser are not firmly connected to one another.
  • the movable dispenser makes it possible to decouple the place of material supply from the place of manufacture.
  • the movable recovery device makes it possible to decouple the place of manufacture from the place of material recovery. This enables the printer to be set up in a flexible manner.
  • the 3D printer can furthermore comprise a window in the work surface which is transparent to radiation.
  • the printer further comprises a radiation source which is arranged under the window, so that through the window it can expose the raw material on the window and thus harden it.
  • the radiation permeability of the work surface makes this possible Hardening of the raw material by exposure.
  • the radiation source is, for example, a laser (SLA method) or a projector (DLP method). Radiation is used here and below to include visible light, light in the infrared (IR) and ultraviolet (UV) range, X-rays and all other forms of electromagnetic radiation.
  • the raw materials used during the printing process include pastes, which can contain either a ceramic or a metallic or an organic powder and a photopolymerizable, that is to say polymerizing under radiation, organic binder.
  • a raw material can be structured and hardened by irradiating with light. For example, UV light stimulates a UV-sensitive organic binder for polymerization, whereby hardened structures are formed in the raw material.
  • a desired multilayer structure which comprises ceramic, metallic and polymer layers, can be set and maintained in the component.
  • the dispenser and the recovery device are designed as a single component. This means that the same component is used to coat the work surface with a new raw material and to remove any remaining, uncured raw material from the work surface.
  • This component comprises, for example, a container for storing the raw material, a coating device for coating the work surface, and a recovery device which recovers the raw material from the work surface and transports it into the container.
  • the coating device can be designed, for example, as a nozzle coater, as a syringe pump, as a hose pump or as an inkjet head.
  • the recovery device can for example be designed as a suction nozzle or a blade.
  • the component can, for example, be an element that can be moved laterally over the work surface. Ordering the Raw material on the work surface and the recovery can be carried out by this component simultaneously or in separate steps, so that the component either only applies the respective raw material or only returns it in one step.
  • Combining the dispenser and recovery device in one component reduces the outlay on equipment for constructing the 3D printer. Furthermore, it enables the application and recovery of the raw material to be carried out in one process step, as a result of which the printing process can be made more efficient.
  • At least two dispensers are implemented in one component.
  • the component can thus apply two different raw materials to the work surface. In one step, however, only one raw material is applied at a time.
  • the component is designed so that it can move laterally over the fixed work surface.
  • the component can furthermore comprise a container for storing the raw material.
  • the coating device can for example be designed as mentioned above.
  • the implementation of two dispensers in one component reduces the number of components required and thus simplifies the apparatus structure of the 3D printer.
  • the dispensers can always comprise a container for storing the raw material and a coating device for coating the work surface with raw material.
  • the container for storing the raw material can be used by the recovery device with unused raw material be refilled.
  • the recovery device can comprise a return device, such as a hose, with the aid of which the raw material is transported back in the dispenser. The transport can be promoted by a pump or a similar delivery unit. If the dispenser and recovery device are designed in one component, the return device is not necessary.
  • the container can also be filled with newly added raw material.
  • the container of the dispenser contains a mixing device with which the returned raw material and possibly added new raw material are mixed in order to guarantee a homogeneous composition of individual printed layers.
  • At least two recovery devices can be implemented in one component. Possible embodiments of the recovery device are mentioned above.
  • the component can furthermore comprise a container for storing the respective raw materials. The implementation of two recovery devices in one component reduces the equipment required for the construction of the 3D printer.
  • a component can comprise two dispensers and two recovery devices.
  • a combination of these components simplifies the structure of the printer and enables the recovery and application of different raw materials in one process step, which can considerably simplify the printing process. In one step, however, only one is used at a time Raw material applied and a raw material recovered.
  • the component can furthermore comprise two containers for storing the two different raw materials.
  • the component can move laterally over the entire area of the work surface with the width B and the length L used for the printing process.
  • a first unit of the component can be used to apply and recover a first raw material and a second unit of the same component can be used to apply and recover a second raw material. If the first raw material has been applied to the work surface and a printing process has been carried out with this raw material, the component is moved over the work surface with the first unit first in order to recover the first raw material. This can be done, for example, by sucking in the first raw material.
  • the raw material is stored in a first container in the component.
  • the second unit of the component which is moved over the work surface in the same step, applies a second raw material to the work surface, which is stored in a second container in the component.
  • the number of components, dispensers and recovery devices of the 3D printer is not limited. Instead of two, the 3D printer can also have three, four or more dispensers and recovery devices, each of which is assigned its own raw material. A single component can include all or more of these dispensers and / or recovery devices. Alternatively, the individual dispensers and / or recovery devices can also be designed in several individual components. One However, a higher number of components also increases the equipment required to construct the 3D printer.
  • the 3D printer comprises at least two channels which are attached to different edges of the work surface, wherein the movable recovery devices can push the unused raw material into the respective associated channel.
  • each raw material is assigned its own channel.
  • the recovery devices are designed, for example, as wipers or blades that push the unused raw material from the work surface into the associated channel by moving it laterally over the work surface.
  • the chute is connected to a return device which returns the raw material from the chute to an associated dispenser.
  • Several different gutters for different raw materials can be placed on different sides of the work surface.
  • the recovery devices move over the work surface in such a way that, when they move completely over the work surface, they can push the remaining raw materials completely into the respective associated channel.
  • the 3D printer comprises a cleaning device for cleaning the component from raw material.
  • the cleaning device can comprise a drive system with the aid of which the cleaning device can be moved laterally along the surface of the component.
  • the cleaning device can be, for example, a suction nozzle, a blade or a roller.
  • the cleaning device is preferably arranged such that it is positioned laterally next to the component in the passive state and can move laterally over the surface of the component in the active state.
  • a separate cleaning device can be provided for each raw material, so that the printer comprises at least two such cleaning devices.
  • Each cleaning device comprises a return device, each return device comprising a conveyor device which returns the recovered raw material to the respectively assigned dispenser.
  • the delivery device is, for example, a pump and the return device is a hose.
  • the separate return devices ensure that the raw material is not mixed and can therefore be reused.
  • the return device can be identical to the cleaning device.
  • a roller can be used which has an adhesive surface and removes any raw material remaining thereon by tracing the component surface. The roller can then be moved to the dispenser by a positioning system, where the raw material is removed from the roller and filled into the dispenser.
  • a roller transfer apparatus Such a device is called a roller transfer apparatus.
  • the cleaning device may comprise a transfer film having an adhesive surface.
  • the return device can be designed as a hose which contains, for example, a pump or a fan as a conveying device. If the cleaning device is designed as a blade that scrapes over the surface of the component, the return device can be a tub located under the component, which can be moved to the dispenser with the aid of a positioning system.
  • the invention further discloses a method for the additive manufacturing of a three-dimensional, multi-layer component and for the recovery of unconsumed raw material, which comprises the following steps:
  • the layer thickness of raw material at least corresponding to the desired layer thickness of a layer to be added to the component.
  • the first layer of the component is manufactured in contact with the surface of a building board provided for this purpose. - Lifting the component comprising the new layer from the work surface.
  • Lifting off separates the component with the applied hardened layer from the uncured raw material. It is possible that some of the excess raw material will stick to the component.
  • the recovery device can for example be designed as a suction nozzle, blade or roller and furthermore comprise a device for returning a raw material to the dispenser.
  • a container for storing the raw material is usually present in the same component as the recovery device. From this, for example, a hose leads either directly to the associated dispenser or to a further container from which the first dispenser can be filled.
  • the dispenser and the recovery device can also be embodied in one and the same component, as described above.
  • the raw material is usually pushed to a channel attached to the side of the work surface, to which, for example, a hose for returning the raw material is attached.
  • the recovery device can be designed as a transfer roller machine. The transfer roller picks up raw material via its adhesive surface and can then be sent to the dispenser are moved, and there the raw material is returned to the appropriate dispenser.
  • the aforementioned method steps are repeated with a third or further raw material and a third or further dispenser and third or further recovery devices.
  • the third raw material is selectively returned to the appropriate dispenser.
  • the other raw materials are also selectively returned to the corresponding additional dispensers. There is no mixing of the raw materials, so that they can be used again in the printing process.
  • the work surface itself can remain motionless. Then, in the method described, when the raw material is applied and the raw material is recovered, the respective dispensers and / or recovery devices are each moved laterally over the work surface. This lateral movement allows the dispenser and recovery devices to reach the entire area of the work surface used for the printing process.
  • the work surface has a window that is transparent to radiation.
  • the window has at least the dimensions of the adding layer on.
  • a building board with the component is positioned over the window. The building board is lowered normal to the window until the distance between the surface of the component and the top of the work surface corresponds to the desired layer thickness of the new structured layer to be added to the component.
  • the building board is lowered so that the distance between the surface of the building board and the work surface corresponds to a desired thickness of the first layer.
  • the raw material is structured into a new layer and hardened by irradiating the multi-layer component through the window.
  • the raw material comprises a binder which has photosensitive properties. The irradiation causes the binder to polymerize.
  • the building board with the component and the new layer adhering to it is also lifted off the work surface.
  • the adhesion between the component and the building board is greater than the adhesion between the component and the work surface.
  • This greater adhesion of the component to the building board is ensured by selecting the material of the building board and by a high surface roughness of the building board compared to the work surface. A high roughness makes it easier for the component to adhere to the building board.
  • selecting the building board material it can be advantageous to choose a material with similar properties to the material of the component or a structured metal plate. In a procedure, the following subsequent steps are performed:
  • the cleaning device can be, for example, a suction nozzle, a blade or a roller.
  • the layers can be arranged next to one another both laterally and vertically.
  • the delimiting areas between different layers can run parallel to the outer surfaces of the component.
  • the materials of the component can include various metals and ceramics, or one of both. No additional connecting means, such as adhesives, are provided between the individual ceramic or metal layers.
  • the layer thicknesses can be variably adjusted in the printing process so that the component can be structured flexibly.
  • the component is in a first structure after printing and comprises a binder.
  • the binder is removed by a sintering step and the structure of the component is changed in the process. After sintering, the component is in a desired second structure.
  • Figure 2 Schematic plan view of the first embodiment of the 3D printer.
  • FIG. 3 Schematic representation in cross section of the first embodiment of the 3D printer in a cleaning step of the printing process.
  • Embodiment of the 3D printer with four dispensers Embodiment of the 3D printer with four dispensers
  • FIG. 6 Schematic representation of a printed, multilayer component in cross section.
  • FIG. 1 shows a first exemplary embodiment of the 3D printer 1.
  • the 3D printer 1 is designed for printing with two different raw materials.
  • the 3D printer 1 comprises a movable component 2, which has two dispensers 3a and 3b and comprises two recovery devices 4a and 4b.
  • the dispensers 3 are designed, for example, as nozzle coaters.
  • the recovery devices 4 are designed as wipers, for example.
  • the movable component 2 is movably attached over a work surface 5.
  • the component 2 is dimensioned, for example, in such a way that, in its longer extension, it can cover at least one section of the work surface 5 required for the printing process. This includes all areas of the work surface 5 on which raw material is to be applied in the course of the printing process. By one-dimensional lateral movement in the plane normal to its longer side, the component 2 can thus reach any required section of the work surface 5.
  • the component 2 is divided into a first unit (in the illustration on the right) and a second unit (in the illustration on the left).
  • the first unit is used for the application and recovery of the first raw material.
  • the second unit is used for the application and recovery of the second raw material.
  • Each unit also comprises a container 6 for storing raw material.
  • These containers 6 can be filled with the aid of feed devices 7.
  • a first feed device 7a for filling a first container 6a
  • a feed device 7b for filling a second container 6b.
  • the feed devices 7 can be filled from the outside with newly added raw material.
  • the feed devices 7 can be recovered Record raw material that has not been used in the printing process.
  • the component 2 is shifted to the first or second side of the work surface 5. If the component 2 is located, for example, on the edge of the first side of the work surface 5, the first container 6a can be filled by the first feed device 7a. The same applies to the second page.
  • the first recovery device 4a which is designed as a wiper, wipes the remaining raw material into the first channel 8a as it moves over the work surface 5.
  • This channel 8a is connected to the feed device 7a via a first hose 9a.
  • the hose 9a comprises a pump which also conveys the raw material from the channel 8a to the feed device 7a. The same applies to the second page.
  • the work surface 5 also contains a radiation-permeable window which takes up most of the area.
  • a projector 10 is arranged below the window, which irradiates the raw material between the window and existing components 11, which is to be added to the components 11 as a new layer, in a predetermined pattern and thereby structures and hardens it. Exemplary light beams 10b are shown in the figure.
  • the pattern can be defined, for example, in the form of a mask placed on the projector 7. Alternatively, the pattern can be digitally preprogrammed, for example.
  • the pattern can be designed in such a way that the new layer only covers an area of the underside of the previous component 11 after it has been printed onto the component 11. In a later printing process, a further layer can thus also be printed laterally next to an existing layer.
  • the number of possible attached components 11 depends on the geometry of the components 11 and the building board 12. In the present example, four components 11 are attached to the building board 12.
  • the building board 12 comprises an underside with a high surface roughness to which the components 11 adhere well.
  • the building board 12 is arranged parallel to the work surface 5 above the latter.
  • the building board 12 with the components 11 can be raised and lowered normal to the work surface 5.
  • the positioning system 13 is positioned centrally above the work surface 5 and vertically to it.
  • the 3D printer 1 comprises a cleaning device 14, which can be moved along the undersides of the components 11 with the aid of a drive system.
  • Said drive system is therefore positioned parallel to the building board 12 at a sufficiently large distance above the work surface 5 and in front of or behind the positioning system 13.
  • the cleaning device 14 is designed as a blade that can scrape off unused raw material from the components 11.
  • Figure 2 shows the first embodiment of the 3D printer 1 in plan view. Between the two channels 8a and 8b is the work surface 5, which is radiolucent. The first channel 8a is connected to the first feeding device 7a through the first hose 9a. The same applies to the second page.
  • Each channel with hose and feed device is assigned to a specific raw material. The raw materials are not mixed during the printing process. In this way, the purity of the raw materials is preserved so that they can be used again in the process.
  • the movable component 2 extends over a width B of the work surface 5 required for the printing process. It comprises two dispensers 3a and 3b, two recovery devices 4a and 4b and two containers 6a and 6b for applying, recovering and storing the two raw materials.
  • a first step A the first dispenser 3 a applies a first raw material to the work surface 5 as described above. As a result of the lateral movement of the dispenser 3 a over the work surface 5, this can be completely coated with raw material.
  • the first dispenser 3a is moved to the edge of the associated side of the work surface 5 so that it does further printing processes are not blocked. Instead, a second or, alternatively, a third dispenser is used from a second or third side of the work surface 5 and the entire process is repeated with a further raw material. Since at least one layer of the component 11 is then already adhering to the building board 12, in a step F corresponding to step B, the component 11 is lowered so that the distance between the component 11 and the work surface 5 corresponds to the thickness of a desired new layer. Superfluous raw material is now displaced to the edges of the existing layers of the components 11.
  • the first raw material is, for example, a ceramic raw material containing an organic binder.
  • the second raw material is, for example, a metallic paste which also contains the organic binder.
  • Further layers can again contain the same or further different raw materials. Each layer can be applied with a different structure or as a different pattern, so that a component can be produced with any external spatial shape and any internal structure.
  • FIG. 4 shows a second exemplary embodiment of the 3D printer 1.
  • the second exemplary embodiment is essentially the same as the first exemplary embodiment.
  • the 3D printer 1 now comprises two separate and separately movable components 2a and 2b.
  • Each component 2 comprises a dispenser 3, a recovery device 4 and a container 6.
  • Each component 2 is assigned to a raw material.
  • the two components 2a and 2b can be moved laterally over the work surface 5 separately and independently of one another.
  • the first raw material (hatched) can first be applied from the dispenser 3b to the work surface 5 by moving the component 2b over the work surface 5 from the channel 8b to the channel 8a.
  • the container 6b of the component 2b was previously filled with the corresponding raw material through the feed device 7b.
  • the component 2a is immovable on the edge of the work surface 5 to which the channel 8a is attached, so that it does not obstruct the component 2b.
  • the actual printing process is carried out analogously to steps B, C and E of the first exemplary embodiment.
  • the component 2b is located on the side of the channel 8a during the printing process. After printing, the component 2b moves back in the direction of the channel 8b in order to completely remove the remaining, uncured raw material from the work surface 5 with the aid of the recovery device 4b.
  • a second raw material (dotted) can be applied to the work surface 5 by the dispenser 3a of the component 2a analogously to the first raw material.
  • the component 2b moves from the channel 8a to the channel 8b.
  • FIG. 5 shows a third exemplary embodiment of the 3D printer 1, which is essentially the same as the two previous exemplary embodiments.
  • the 3D printer 1 here comprises four separate and separately movable components 2, each of which comprises a dispenser 3, recovery device 4 and container 6.
  • the work surface 5 has a square shape, so that the channels 8a, 8b and components 2a, 2b are arranged parallel to one another on the first and second sides, while the two additional channels 8c, 8d and components 2c, 2d are arranged vertically thereto. The two additional channels and components are again arranged parallel to one another.
  • the movable components 2b, c and d are arranged on the edge of the work surface 5 next to their respective channel 9b, c and d. These components are not in active use.
  • the component 2a which has been filled on the first side by the feed device 7a, moves over the work surface 5 in order to coat the work surface 5 with a first raw material (dotted).
  • FIG. 6 shows a printed, multilayer component 11 by way of example and schematically.
  • the component 11 here comprises four vertically stacked planes 15a to 15d, which comprise six layers 16a to 16f.
  • the top layer 16f corresponds to the layer produced first in the printing process.
  • the lowest layers 16a and 16b in the figure were produced last in the printing process.
  • the component 11 comprises layers of three different materials, which are represented by different hatching.
  • One of the three materials is a metal, the other two different polymers or ceramics.
  • the layer thicknesses of the component 11 can vary.
  • the top layer 16f in the component 11 shown is thinner, the lowermost two layers 16a and 16b are thicker than the other layers of the component 11.

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Abstract

L'invention concerne une imprimante 3D (1) destinée à la fabrication additive d'un élément (11) multicouche. L'imprimante 3D (1) comporte une surface de travail (5). En outre, l'imprimante 3D (1) comprend au moins deux distributeurs (3) mobiles qui sont conçus pour revêtir la surface de travail (5) avec respectivement une parmi au moins deux matières premières différentes. Au moins une partie de la matière première respective est ajoutée à l'élément (11) sous la forme d'une couche, au cours d'une étape de fabrication. L'imprimante 3D (1) comprend également au moins deux dispositifs de récupération (4) mobiles destinés à récupérer de manière sélective la matière première respective qui n'est pas consommée lors de l'ajout d'une couche sur l'élément (11) et servant en outre à réinjecter la matière première récupérée dans le distributeur (3) associé respectif.
EP21702601.2A 2020-01-29 2021-01-21 Imprimante 3d destinée à la fabrication additive d'un élément multicouche, procédé d'impression et élément Pending EP4096856A1 (fr)

Applications Claiming Priority (2)

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ATGM50015/2020U AT16822U3 (de) 2020-01-29 2020-01-29 3D-Drucker zur additiven Fertigung eines mehrschichtigen Bauteils, Druckverfahren und Bauteil
PCT/EP2021/051346 WO2021151778A1 (fr) 2020-01-29 2021-01-21 Imprimante 3d destinée à la fabrication additive d'un élément multicouche, procédé d'impression et élément

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EP (1) EP4096856A1 (fr)
JP (1) JP7476304B2 (fr)
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JP2023504969A (ja) 2023-02-08
KR102927134B1 (ko) 2026-02-13
JP7476304B2 (ja) 2024-04-30
WO2021151778A1 (fr) 2021-08-05
US20220339861A1 (en) 2022-10-27
AT16822U2 (de) 2020-10-15
AT16822U3 (de) 2020-12-15
KR20220050981A (ko) 2022-04-25
US12076920B2 (en) 2024-09-03
US20240391165A1 (en) 2024-11-28

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