EP4436768A1 - Procédé de fabrication d'au moins un élément - Google Patents

Procédé de fabrication d'au moins un élément

Info

Publication number
EP4436768A1
EP4436768A1 EP22812495.4A EP22812495A EP4436768A1 EP 4436768 A1 EP4436768 A1 EP 4436768A1 EP 22812495 A EP22812495 A EP 22812495A EP 4436768 A1 EP4436768 A1 EP 4436768A1
Authority
EP
European Patent Office
Prior art keywords
building material
component
time
resulting
max
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
EP22812495.4A
Other languages
German (de)
English (en)
Inventor
Martin Neff
Uwe Hellstern
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.)
Arburg GmbH and Co KG
Original Assignee
Arburg GmbH and Co KG
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 Arburg GmbH and Co KG filed Critical Arburg GmbH and Co KG
Publication of EP4436768A1 publication Critical patent/EP4436768A1/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
    • B29C64/30—Auxiliary operations or equipment
    • B29C64/386—Data acquisition or data processing for additive manufacturing
    • B29C64/393—Data acquisition or data processing for additive manufacturing for controlling or regulating additive manufacturing processes
    • 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
    • B29C64/386—Data acquisition or data processing for additive manufacturing
    • 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
    • B29C64/118—Processes of additive manufacturing using only liquids or viscous materials, e.g. depositing a continuous bead of viscous material using filamentary material being melted, e.g. fused deposition modelling [FDM]
    • 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
    • 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
    • B33Y50/00—Data acquisition or data processing for 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
    • B33Y50/00—Data acquisition or data processing for additive manufacturing
    • B33Y50/02—Data acquisition or data processing for additive manufacturing for controlling or regulating additive manufacturing processes

Definitions

  • the invention relates to a method for producing at least one component according to the preamble of claim 1, a machine controller according to the preamble of claim 14, a machine according to the preamble of claim 15 and a computer program product according to the preamble of claim 16.
  • a “resulting dwell time” is understood to mean the length of time in which a building material, e.g. a plastic, a thermoplastic material or a support material, is melted in a machine and is under thermal stress.
  • a building material e.g. a plastic, a thermoplastic material or a support material
  • a production machine or a 3D printing machine a certain amount of building material is melted and remains in a heated nozzle at a certain temperature until the building material is discharged.
  • a “critical dwell time” is understood to mean the length of time in which there is just no degradation or thermal preloading of the building material as a result of the dwell time. If this critical dwell time is exceeded, degradation or thermal preloading of the building material occurs. Depending on the temperature and the dwell time, a degradation or thermal preloading of the building material and thus a physical and chemical structural change in the building material, e.g. a plastic, a thermoplastic material or a support material, can be caused, resulting in changes in the flow properties and/or negative effects on the mechanical properties of the manufactured components can be effected.
  • the Degradation or thermal preloading begins at lower temperatures the longer the building material is exposed to this temperature, i.e. with long residence times.
  • the critical residence time can also depend on the material itself, on the chemistry and/or on the pressure.
  • a wide variety of components for example for prototypes or small series, can be produced in a 3D printing process, for example in extruding or melting 3D printing processes such as FDM (e.g. EP 1 886 793 B1).
  • a certain amount of building material e.g. a plastic, a thermoplastic material or a support material
  • a machine e.g. a machine for processing plastics and other plasticizable masses, a production machine or a 3D printing machine.
  • the melted building material is initially under thermal stress in a heated nozzle.
  • the component is then produced layer by layer with a 3D printing machine, for example, by removing the building material from the nozzle.
  • the production of the component takes a corresponding amount of time, with the production time generally scaling with the size of the component. For example, if the building material stays at too high a temperature for too long, degradation or thermal preloading of the building material can occur, which can result in a physical and/or chemical structural change in the building material. This can, for example, lead to changes in the flow properties and/or negative effects on the mechanical properties of the manufactured components.
  • DE 10 2013 004 845 A1 discloses a condition monitoring device for a resin, the condition monitoring device comprising a temperature detection unit and a resin deterioration state calculation unit.
  • a warning is issued with a warning output unit if the deterioration state determined by the resin deterioration state calculation unit exceeds a predetermined limit value.
  • the melted building material provided is flushed out independently of the actual residence time, as a result of which the need for building material increases unnecessarily.
  • US 2020/0 005 224 A1 discloses oxidation induction times and residence times as well as different heating temperatures of the different materials from a database. If injection settings are made, the residence times and oxidation induction times from the database are compared and an automatic correction of the injection settings or conditions can be made.
  • Document JP 2016 159481 A discloses, for the field of injection molding machines not intended for additive manufacturing or 3-printing, an injection molding machine with a controller, the controller being configured to have a first dwell time for regulating the dwell time of the resin material in the heating cylinder and sets a second dwell time longer than the first dwell time. Further, the injection molding machine has a timer which counts a standby time from the time of execution of the previous injection to the time of execution of the next injection.
  • the controller is configured to drive an annunciator to notify the operator that the standby time is approaching the second dwell time and to drive the annunciator so that the resin material retained in the heating cylinder by the operator is operator is flushed, and to prohibit the operation of the injection molding machine until the flushing process is completed.
  • JP 2004001403 A discloses an injection molding machine for molding a molded product in which at least two kinds of resin materials having different compositions and color tones are integrated.
  • Document EP 3 970 945 A1 discloses 3D printing feedstocks containing filaments with separate layers or sections produced by co-extrusion, micro-layer co- extrusion or multi-component/fractal co-extrusion.
  • the filaments allow different materials to be deposited or combined simultaneously through one or more nozzles during the 3D printing process, enabling smaller layer sizes in the milli, micro and nano ranges.
  • Document WO 2021/049935 A1 discloses a dispensing head for additive manufacturing with continuous fiber reinforced fused filaments.
  • the dispensing head is configured to dispense a material onto a substrate support platform and includes one or more outlets for receiving a strand of fusible solid material and a reinforcing fiber and a material passage extending from the receiving inlets to a dispensing outlet.
  • the dispensing head further includes a material heating unit for fluidizing the material into a propulsion device for propelling the material through the material passage.
  • the object of the present invention is to provide a method for producing at least one component which is optimized with regard to the consumption of the required building material and the quality of the component.
  • This object is achieved by a method for producing at least one component having the features of claim 1, a machine control having the features of claim 14, a machine having the features of claim 15 and a computer program product having the features of claim 16.
  • the method for producing at least one component comprising at least two building materials, eg plastics, thermoplastic materials or support materials, each with a critical residence time T_x_max, comprises the steps below.
  • the component is manufactured using an additive manufacturing process or a 3D printing process, eg in a layered printing process (layer-by-layer method).
  • the support materials can be removed from the component after the manufacturing process, for example a 3D printing process, for example by breaking away (mechanical loosening) and/or by treatment with water and/or chemicals.
  • data for the production of the component such as CAD, geometry, machine, peripheral device, temperature, number of building materials, building material temperature and/or building material data are provided.
  • the data can also contain information about the machine used, e.g. a machine for processing plastics and other plasticizable masses, a production machine or a 3D printing machine, peripheral devices used or information about e.g. the size and setting of the discharge nozzles.
  • the data can be provided, for example, as a data record, in particular as a CAD data record, e.g. for data processing.
  • the data can, for example, also be provided in whole or in part separately for data processing.
  • the component is broken down into at least one construction phase, e.g. into one layer or several layers with corresponding construction phase information.
  • the construction stage information may include information similar to the data used to manufacture the component, for example information regarding the construction material, the volume of the construction material, the temperature of the construction material, the construction strategy, the manufacturing process and/or the machine used.
  • the decomposition can, for example, be carried out automatically by the data preparation based on the data provided or after a selection by the operator. For example, it is preferably possible for the operator to first select a construction strategy and then for the component to be broken down into at least one corresponding construction section with corresponding construction section information. It is also possible that the construction strategy is automatically selected depending on the component. It is also possible that when the component is broken down into construction sections, a requirement for construction material, e.g. support material, is also calculated.
  • At least one construction material volume and at least one average discharge rate per construction phase is derived from the construction phase information.
  • the at least one building material volume and the at least one average discharge rate per building section are derived for each building material.
  • the building material volume and the average discharge rate per building section are preferably dependent on the selected building strategy.
  • At least one construction time per construction section and at least one resulting residence time t_x per construction material are calculated from the building material volume and the discharge rate per construction section.
  • the building material volume per construction phase is required for the construction phase-related dosing.
  • at least one, preferably each, building material is melted shortly before the building material is deposited only in accordance with the volume of tree material required in the construction phase.
  • the building material can, for example, be processed discontinuously in a plasticizing unit, preferably according to a corresponding specification in terms of volume, for example from a data record, and be made available as a mass cushion. Provision can preferably be made for only a corresponding volume of building material to be melted for a specific construction phase. The mass cushion is then emptied during discharge. After that, "new" building material can be provided and/or melted down again. The melted building material can then be fed into the nozzle as soon as building material has been discharged from the nozzle. The nozzle is thus always filled with building material.
  • the resulting residence times are compared with the respective critical residence times of the corresponding building materials.
  • At least one adjustment of the data is made so that the respective resulting residence times t_x are below the respective critical residence times T_x_max of the corresponding building materials if at least one resulting residence time t_x exceeds the respective critical residence time T_x_max of the corresponding building material.
  • the adjustment can be designed, for example, in the form of an adjusted data set.
  • the adapted data record can be sent to the machine as a machine-readable code, e.g. as a G-code, in order to manufacture it specifically for the process.
  • the G code contains the respective NC data for moving the axes and the instructions for storing building materials.
  • the calculated data on the volume related to the construction phase and the calculated residence time can be given.
  • the adjusted data can, for example, be transferred to a machine control and/or the machine, whose control then continues to operate the corresponding construction progress with the adjusted data. The data is then used to manufacture the component.
  • At least one of the above-mentioned steps preferably takes place before the first production of the component, as a result of which the production process can advantageously be better planned and building material can be saved.
  • the adaptation preferably takes place in such a way that at least one construction section and/or the corresponding construction section information is changed.
  • the layers and/or building sections can be resized, decomposed, or divided up differently.
  • the adjustment can be carried out, for example, by data preparation. It is also possible for the data preparation to carry out the adjustment automatically or for the operator to select and/or adjust a construction section to be adjusted and the corresponding construction section information.
  • the adaptation is preferably carried out by changing at least one resulting residence time t_x.
  • the resulting dwell times t_x of all building materials are preferably changed. This can be realized, for example, by the building material being removed at a less relevant point in and/or on the component or at another point, so that the building material cannot remain for too long and there is thus advantageously no degradation or no thermal prestressing. Due to the discharge of the building material, "fresh" or thermally unstressed building material is made available earlier.
  • the resulting dwell time t_x is reduced, preferably set to zero.
  • the resulting residence time t_x is preferably changed, preferably reduced, by producing at least one additional element.
  • the additional element has at least one building material, but can also be made from several building materials.
  • the additional element is preferably at least one further component, which more preferably is at least partially inverse to the component to be produced. If, for example, for the sake of simplicity, a component built up in layers consists of a building material A and a building material B, where, for example, building material B can also be a support material and where only building material A is used at the beginning and towards the end, the corresponding component would For example, look like this: ABA.
  • the first layer consists of building material A
  • the second layer consists of building material B
  • the third layer again consists of building material A.
  • a corresponding further (inverse) component BAB is created, so that building material A is also between the beginning and the end of the manufacturing process is used, which advantageously prevents degradation or thermal prestressing of the building material A.
  • the building materials preferably have a resulting dwell time t_x of essentially zero, since they are used over the entire construction time either on the component itself or on the additional element or the further component. This advantageously results in essentially no degradation or no thermal prestressing of the building material.
  • the building material is preferably deposited in at least one construction section, preferably in each construction section first on the In the event of degradation or thermal preloading of the building material, the degraded or thermally preloaded building material is used first on the additional element, so that “fresh” or non-degraded or thermally preloaded building material is available again for the “right” component. Degraded or thermally preloaded building material can thus preferably be used or removed on the additional element in order to create space for “fresh” or thermally unloaded building material.
  • the additional element can preferably be designed as at least one part of the component. More preferably, the additional element can be implemented in the component. Advantageously, no further or additional component is produced in this way, which saves time. As a further advantage, less building material is discharged and the construction time and the dwell time of all building materials are correspondingly not increased. As a further advantage, the resultant dwell time of the other building materials is also not increased as a result.
  • the additional element can be added in the area of a support structure or a support geometry, or the additional element can be implemented in or form the support structure or the support geometry, the additional element comprising at least one building material.
  • the additional element is preferably removed after the component has been produced. For example, it is possible in this way to remove the support structure produced with a support material and the additional element embedded therein together after the production process.
  • the additional element can be removed, for example, by treating it with water and/or chemicals and/or by breaking it off (mechanical removal).
  • the adaptation is preferably carried out in such a way that at least one critical residence time T_x_max is changed, preferably increased.
  • T_x_max is changed, preferably increased.
  • the critical dwell time T_x_max of the building material depends, among other things, on the building material itself, the chemistry and the temperature. For example, a different building material could be used, chemical additives and/or stabilizers could be added to the building material, or the temperature of the building materials could be varied.
  • the respective temperature of the nozzle can be lowered to a non-critical temperature, so that a longer critical residence time T_x_max is realized without degradation or thermal preloading.
  • T_x_max a critical residence time
  • the temperature of a building material can be lowered after the first layers, if the building material is no longer required for the following layers.
  • the critical residence time T_x_max depends, among other things, on the temperature. If the temperature of the respective building material is preferably lowered, the critical residence time is advantageously greater overall or, for certain temperatures, approaches infinity. This means that at this specific temperature there is advantageously no degradation or thermal preloading of the building material.
  • the critical residence time T_x_max is preferably changed, preferably increased, by changing, preferably reducing, the temperature of at least one building material for at least a certain period of time. More preferably, the change in temperature takes place during, before and/or after the production of the component. In order to advantageously not provide too much building material unnecessarily and thus to reduce the resulting dwell time in the heated state, each building material is preferably only provided and melted according to the volume required in the building section shortly before the building material is deposited.
  • the temperature of the building materials of the component can be changed, which results in a longer critical residence time T_x_max, and at the same time at least one additional element, for example in the support structure of the component, can be added and/or implemented, resulting in a lower resulting residence time t_x results.
  • at least two adjustments can preferably take effect at the same time.
  • At least one monitoring of the resulting residence times t_x and/or the flow properties of the building materials is carried out during the manufacturing process.
  • the ACTUAL data of the machine is constantly compared with the TARGET data of the data processing by means of a controller and adjusted if necessary. It is also conceivable that several different monitorings are carried out.
  • the corresponding building material is preferably discharged and/or new building material is made available and/or processed.
  • the building materials A and C discharged and new or thermally unstressed building material A and C provided and/or processed.
  • the building material can be removed and new building material provided and/or processed by a machine control.
  • the thermally pre-loaded building material is preferably removed before the new building material is made available and/or processed.
  • the construction process can preferably be interrupted for this purpose. It is further preferred but also possible that during the Use of another building material, the thermally prestressed building material is discharged, which advantageously saves time.
  • At least one rinsing process is initiated when at least one resulting dwell time exceeds the corresponding critical dwell time of a building material and/or if there is a change in the flow properties.
  • the rinsing process can, for example, be carried out automatically by means of a rinsing station or manually by discharging into a corresponding collection container.
  • the task is also solved by a machine control for a machine for processing plastics and other plasticizable masses, in particular for a 3D printing machine.
  • the machine control is set up, implemented and/or designed to carry out the method described above.
  • the task is also solved by a machine for processing plastics and other plasticizable masses, in particular a 3D printing machine.
  • a machine for processing plastics and other plasticizable masses in particular a 3D printing machine.
  • the machine is set up, designed and/or constructed to carry out the method described above.
  • the task is also solved by a computer program product.
  • the computer program product is stored with a program code on a computer-readable medium for the purpose of optimizing the consumption of the required building material and the quality of the component in order to carry out the method described above.
  • Fig. 1 a flow chart
  • Fig. 2 - 4 alternatives of a component and another component (inverse component), 5 shows a component and a component with additional elements
  • FIGS. 8a, 8b flow charts.
  • Fig. 1 shows a flow chart 100, which shows the sequence of a method according to the invention for producing at least one component in an additive method or in a 3D printing process, having at least two building materials, e.g. plastics, thermoplastic materials or support materials, each with a critical residence time T_x_max , represents.
  • data 104 for the production of the component such as CAD, geometry, machine, peripheral device, temperature, number of building materials, building material temperature or building material data are provided.
  • the data can also contain information about the machine used, e.g. a machine for processing plastics and other plasticizable masses, a production machine or a 3D printing machine, peripheral devices or information about e.g.
  • the data 104 can be provided, for example, as a data set, e.g. as a CAD data set, for data processing 102, a machine controller and/or a machine. However, the data 104 can also be made available separately to the data preparation 102, for example.
  • the component is broken down by the data processing into at least one construction phase, eg into a layer or a plurality of layers n with corresponding construction phase information.
  • the decomposition can be performed automatically by the data preparation or according to an operator selection.
  • the construction strategy is automatically selected depending on the component.
  • a requirement S for construction material for example support material, is also calculated.
  • At least one construction material volume and at least one average discharge rate per construction section is derived from the construction section information.
  • the corresponding building material volume e.g. V_A_n, V_B_n, V_C_n, ... , V_S_n
  • the corresponding average discharge rate e.g. Q_A_n, Q_B_n, Q_C_n, ... , Q_S_n
  • the building material volume and the average discharge rate per construction phase are preferably dependent on the selected construction strategy.
  • the building material volume per construction phase is required, for example, for the construction phase-related dosing.
  • the building material is only melted according to the volume of tree material required in the construction section shortly before the building material is deposited.
  • a step 114 the resulting dwell times t_x (e.g. t_A, t_B, t_C, ... , t_S) are compared with the respective critical dwell times T_x_max of the corresponding building materials (e.g. T_A_max, T_B_max, T_C_max, ... , T_S_max). If the comparison shows that the resulting dwell times t_x of the respective building materials are below the respective critical dwell times T_x_max, the manufacturing process is not adjusted.
  • the data can then be given in a step 119, e.g. from the data preparation to a machine control or to a machine, e.g. a machine for processing plastics and other plasticizable masses, a production machine or a 3D printing machine. The data can then be used to manufacture the component.
  • step 116 the data 104 is adjusted such that the respective resulting dwell times t_x are below the respective critical residence times T_x_max of the corresponding building materials.
  • the data is then used in a step 118 to manufacture the component.
  • the data 104 is adjusted in such a way that at least one construction section and/or the corresponding construction section information is adjusted, e.g. by the data preparation 102.
  • the data set can then be adapted or machine commands can be added to change the construction section information.
  • a dwell time e.g. because a material is not discharged over several shifts - a temperature reduction can also be specified. This assumes that the residence time of the material is calculated not just for one shift, but over several shifts.
  • a rinsing process can be initiated.
  • the required amount of material that has to be provided per shift can preferably also be specified for the construction phase information.
  • the data 104 is adapted in such a way that at least one resulting dwell time t_x is changed. Due to the preferably shortened resulting dwell time t_x, the building material is under thermal stress for a shorter period of time, which prevents degradation.
  • the resulting dwell time t_x is changed, preferably reduced, by at least one additional element 210 being produced.
  • a component 200 is shown on the left, which is made up of two building materials 206 (S), 208 (A).
  • the resulting residence time t_x is changed in FIG. 2 in such a way that at least one additional element 210 is produced. in figure
  • the additional element 210 is a further component 202 (inverse component), which is at least partially inverse to the component 200.
  • the further component 202 (inverse component) is shown on the right-hand side in FIG. 2 .
  • the left-hand component in FIG. 2 could also represent the further component 202 (inverse component).
  • the component on the right would be the "correct” component.
  • Both building materials are preferably discharged in FIG.
  • none of the building materials "stands" any longer, which would increase the critical residence time.
  • the component 200 and the further component 202 are preferably produced in such a way that, for example, at least one construction section, for example a layer 204, preferably several layers, are removed in layers from bottom to top.
  • both building materials 208 (A) and 206 (S) were discharged for the same length or number of times, or for the building materials 208 (A) and 206 (S) that same volume was discharged.
  • the discharged volumes of the two building materials 208 (A) and 206 (S) in FIG. 2 are therefore preferably of the same size for the component 200 and for the further component 202 taken together. In principle, however, the discharged volumes can also be different. Essentially, the point is that both building materials are discharged and neither building material "stands" for longer, which increases the residence time. For example, the building materials can be discharged at different times with different critical residence times
  • the total volume of the component 200 is preferably consumed per building material.
  • the volume of the building material 206 (S) of the component 200 and the further component 202 corresponds to the volume of the building material 208 (A) of the component 200 and the further component 202, which, assuming an equal average discharge rate per layer in Fig. 2, respectively also an equal construction time of the building materials 206 (S) and 208 (A) results.
  • the resulting dwell time t_x of the building materials 206 (S) and 208 (A) is also the same or essentially zero in the case of parallel production of the components 200 and 202 in the exemplary embodiment in Fig. 2, since both building materials 206 (S) and 208 (A) are in constant use throughout the manufacturing process.
  • the building material is deposited preferably in at least one construction section, preferably in each construction section first on the additional element 210 or on the additional component 202.
  • the first layers with the construction material 206 (S) for the additional component 202 are removed , until the building material 208 (A) for the further component 202 has been discharged at least once in the manufacturing process for a specific time.
  • the building material 208 (A) for the further component 202 After a certain time or after a certain discharge of the building material 208 (A) for the further component 202, e.g. after a layer 204, the component 200 or in Fig. 2 the first layer 204 of the component 200 with the building material 208 (A) discharged.
  • the further component 202 is used in practice to remove thermally preloaded building material, so that the component 200 can be constructed from non-thermally preloaded building material. Therefore, the form of the further component 202 is in principle arbitrary.
  • the building materials 206 (S) and 208 (A) can also be discharged simultaneously or in parallel, since a separate discharge nozzle can be provided for each building material 206 (S), 208 (A), for example.
  • the component 200 and the further component 202 can be produced at the same time. In this case, the component 200 and the further component 202 are preferably produced at a distance from one another, since the discharge nozzles are at a distance from one another.
  • a component 300 is shown on the left-hand side, which is made up of three building materials 206 (S), 208 (A) and 310 (B).
  • the corresponding further component 302 (inverse component) is shown on the right-hand side, which in FIG. 3 is approximately twice the size of component 300.
  • further component 302 can also be broken down into a number of components.
  • the component 300 and/or the further component 302 can consist of at least one layer 204, preferably of several layers, e.g.
  • the respective discharged volumes of the three building materials 206 (S), 208 (A) and 310 (B), i.e. the component 300 and the further component 302 taken together, are the same overall and correspond to the volume of the component 300 in Fig. 3, so that the same construction time for the three construction materials 206 (S), 208 (A) and 310 (B) results, provided that the average discharge rate per layer is the same. Also, in the case of a parallel production of the components 300 and 302 in the exemplary embodiment according to FIG 206 (S), 208 (A) and 310 (B) are in constant use throughout the 3D printing process.
  • a component 400 is shown on the left-hand side in FIG. 206 (S), 310 (B) and 412 (C).
  • the additional element 210 or a further component 402 which is about three times as large as the component 400 is shown on the right-hand side.
  • the component 400 and/or the further component 402 can be constructed in layers from at least one layer 204, preferably from a plurality of layers. As in the exemplary embodiments in FIG. 2 and FIG the same in each case, provided that the mean discharge rate is the same for each shift Build time for the four building materials 208 (A), 206 (S), 310 (B) and 412 (C).
  • the resulting dwell time t_x of the building materials 208 (A), 206 (S), 310 (B) and 412 (C) is the same or essentially the same zero because the build materials 208 (A), 206 (S), 310 (B) and 412 (C) are in constant use throughout the 3D printing process.
  • the component can have any number of building materials. If more building materials are used in further exemplary embodiments, the size of the further component increases accordingly.
  • a component 500 is shown on the left-hand side, which is made up of two building materials 206 (S) and 208 (A) and corresponds to component 200 from FIG.
  • the build material 206 (S) can be, for example, a support material that can be removed after the manufacturing process.
  • the component 500 is made up of at least one layer 204, preferably a plurality of layers, in an additive manufacturing process or a 3D printing process, e.g. in a layer-by-layer printing process (layer-by-layer method).
  • At least one additional element 210 is implemented in Fig. 5 in the component 500, e.g., in a support structure consisting of the building material 206 (S).
  • FIG. 5 The result is shown on the right-hand side in FIG. 5 as component 502 with two additional elements 210.
  • two additional elements 210 consisting of the building material 208 (A) were implemented on the component 500 on the left-hand side, which can be removed together with the building material 206 (S) after the manufacturing process.
  • the construction material 208 (A) is thus used or removed more frequently as a result of the implementation of the additional elements 210 , so that the overall residence time of the construction material 208 (A) is advantageously shorter.
  • the additional elements 210 in FIG. 5 also advantageously have the additional task of being a support structure during the manufacturing process, since this stabilizes the entire component 502 .
  • the form of the additional elements 210 is arbitrary. It is important that the appropriate building material is used or removed, so that the resulting residence time t_x is reduced.
  • only the building material 208 (A) is used in the lower layers of the component 500 .
  • less build material 208 (A) and more build material 206 (S) is used. It can therefore happen that the building material 208 (A) “stands” for a long time and the resulting dwell time of the building material 208 (A) increases accordingly and becomes greater than the critical dwell time.
  • the reason for this is that little material is discharged and thus remains longer in the thermally stressed state, as a result of which the resulting residence time of the building material 208 (A) increases. Therefore, in the exemplary embodiment in FIG. 5 , two additional elements 210 are implemented in the building material 206 (S) of the component 502 on the right-hand side. This reduces the residence time of the build material 208(A) since the build material 208(A) is in use at shorter intervals. Furthermore, the building material 208 (A) is also advantageously used in a meaningful way, for example as a support structure.
  • the additional element 210 is removed.
  • the build material 206 (S) surrounding the additional elements 210 is a support material that can be removed after the manufacturing process, for example by treatment with water and/or chemicals and/or by breaking away (mechanical removal). By removing the build material 206(S), the additional elements 210 embedded therein are also removed.
  • the adaptation takes place in such a way that at least one critical dwell time T_x_max is changed.
  • the critical residence time T_x_max of the building material depends, among other things, on the building material itself, on the chemistry and on the temperature. For example, a different building material could be used, chemical additives and/or stabilizers could be added to the building material, or the temperature could be varied. For example, if the temperature of the respective building material is lowered, the critical dwell time T_x_max increases. This preferably approaches infinity for a corresponding temperature, so that no degradation or thermal preloading can occur.
  • the critical dwell time T_x_max is changed by changing, preferably lowering, the temperature of at least one building material for at least a certain period of time.
  • FIG. 6 shows a component 600 which is made up of four building materials 310 (B), 412 (C), 206 (S) and 208 (A) and corresponds to component 400 from FIG. 4 .
  • the component 600 in FIG. 6 is made up of several layers, layered from bottom to top.
  • the temperature of the build material 208 (A) is lowered since the build material 208 (A) is no longer needed for the remainder of the 3D printing process.
  • the temperatures of the building materials 412(C) and 206(S) are raised to an appropriate temperature beforehand because these building materials were not needed before.
  • the respective temperature of the building material or the corresponding nozzle can be lowered to a non-critical temperature, so that a longer resulting residence time without material degradation is realized or the critical residence time is longer, preferably approaching infinity.
  • the temperatures of the building materials 412 (C) and 206 (S) are lowered since these are also no longer required.
  • the temperatures are correspondingly low, so that the critical dwell time T_x_max is correspondingly large, preferably tending to infinity.
  • the temperature of the building material 310 (B) is preferably increased, since the building material 310 (B) was only needed in the further course of the production of the component 600, but was not needed beforehand. Since the building material 310 (B) is subsequently used for the complete remaining time, the resulting dwell time of the building material 310 (B) is preferably less than the critical dwell time T_x_max of the building material 310 (B) despite the temperature increase of the building material 310 (B), so that no degradation or thermal prestressing of the building material 310 (B) occurs.
  • a component 700 is shown on the left-hand side in FIG. 7, which is made up of three building materials 208 (A), 206 (S) and 310 (B) and corresponds to component 300 from FIG.
  • the component 700 in FIG. 7 is also constructed from a plurality of layers or in layers from bottom to top.
  • the component 700 is adapted in such a way that at least one additional element 210 is added to the component 700, as already explained above with reference to FIG.
  • the result is shown as part 702 on the right-hand side of FIG.
  • the component 702 has two additional elements 210 consisting of the building material 208 (A).
  • the building material 206 (S) surrounding the additional elements 210 is preferably a support material which can be removed after the manufacturing process with the additional elements 210 embedded therein. A further adjustment corresponding to the right-hand side in FIG are not previously required (see also the embodiment of FIG. 6). At a point in time 714, the temperatures of the building materials 208 (A) and 206 (S) that are no longer required are lowered, so that their critical residence time T_x_max is increased, preferably approaching infinity.
  • ACTUAL Machine data is constantly compared with the TARGET data of the data processing using a controller and adjusted if necessary.
  • at least one monitoring of the resulting dwell times and/or the flow properties of the building materials is preferably carried out during the production of the component.
  • the real construction time of the building materials of each construction phase is compared with the construction time per construction phase calculated from the data preparation. If there is degradation or thermal stress on the material, the flow properties change and there are deviations or fluctuations, for example in the process pressure, which can be detected by the machine or its measuring sensors.
  • the corresponding resulting dwell time t_x is reduced in a further preferred embodiment by new building material being provided and /or is processed.
  • the corresponding building material is discharged, e.g. in an additional element 210 and/or new building material is provided and/or processed.
  • the processing and/or provision of the new building material preferably takes place after the discharge.
  • At least one rinsing process is initiated when at least one resulting dwell time exceeds the corresponding critical dwell time of a building material and/or if there is a change in the flow properties.
  • deviations are determined during the construction process, e.g. in the construction time per construction section, in the process pressure or in the viscosity of the construction material, different methods are used depending on the machine equipment. If, for example, there is a rinsing station, a rinsing process is initiated so that degraded or thermally prestressed building material can be rinsed out. If there is no rinsing station, the building process is interrupted, for example, and the operator is asked to manually collect the thermally pre-damaged building material in an appropriate container. In principle, it is also possible that the construction process is not interrupted and that the thermally preloaded construction material is flushed out while other construction materials are in use.
  • a machine 806 e.g. a machine for processing plastics and other plasticizable masses, a production machine or a 3D printing machine, receives data from a data preparation 804 in a step 808, e.g. with regard to the building material volume, the building material temperature and/or the construction time provided for each construction phase.
  • data for example CAD, geometry, machine, peripheral device, temperature, number of building materials, building material temperature or building material data can also be provided.
  • the data is transmitted to engine 806 as engine instructions 820.
  • a flow chart 802 according to a further exemplary embodiment is shown in FIG. 8 b .
  • the machine 806 starts the production of the component, for example with the data 808 and/or machine instructions 820 provided in Fig. 8a.
  • the building material is metered using the data regarding the building material volume per construction section.
  • the building material is laid down accordingly in order to manufacture the component.
  • the actual construction times T_x, n, real per construction phase of the individual construction materials are preferably monitored with the calculated construction times per construction phase and/or the process pressure p. This can, for example, compare and/or monitor the actual construction time per construction section with the calculated construction time per construction section. If there is degradation or thermal stress on the material, the flow properties change and there are deviations or fluctuations, e.g. in the process pressure.
  • the production is completed in a step 818.
  • a step 822 if at least one resulting dwell time t_x is exceeded by the corresponding critical dwell time T_x_max of a building material and/or if the flow properties of a building material change, the resulting dwell time t_x is reduced by providing and/or processing new building material.
  • the corresponding building material is removed before the new building material is made available and/or processed. If, for example, there is a rinsing station, in a further preferred exemplary embodiment at least one rinsing process can be initiated, so that degraded or thermally preloaded building material can be rinsed out.
  • the rinsing process can be carried out manually or, for example, the machine instructions 820 can be processed and the construction material provided can be discharged, e.g. in an additional element 210, e.g. implemented as a support geometry.
  • a machine control for a machine for processing plastics and other plasticizable masses, in particular for a 3D printing machine is disclosed, which is set up, implemented and/or constructed in order to implement at least one of the previously described methods while achieving the stated execute benefits.
  • a machine for processing plastics and other plasticizable masses in particular a 3D printing machine, is disclosed in a further exemplary embodiment, which is set up, designed and/or constructed to carry out at least one of the methods described above while achieving the advantages mentioned.
  • a further exemplary embodiment is a computer program product with a program code, which is stored on a computer-readable medium, for carrying out at least one of the methods described above while achieving the advantages mentioned.

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Abstract

Dans un procédé de production, au moyen d'un procédé de fabrication additive ou d'un processus d'impression 3D, d'au moins un composant comprenant au moins deux matériaux de construction ayant chacun un temps de séjour critique T_x_max, des données pour produire le composant sont fournies et le composant est divisé en au moins une partie de construction ayant des informations de partie de construction correspondantes. Après dérivation d'au moins un volume de matériau de construction et d'au moins un taux d'élimination moyen par partie de construction à partir des informations de partie de construction, au moins un temps de construction par partie de construction et au moins un temps de séjour résultant t_x pour chaque matériau de construction sont calculés à partir du volume de matériau de construction et du taux d'élimination. Les temps de séjour résultants t_x sont comparés aux temps de séjour critiques respectifs T_x_max des matériaux de construction correspondants. Grâce au fait qu'au moins une adaptation des données est réalisée, de telle sorte que les temps de séjour résultants respectifs t_x sont inférieurs aux temps de séjour critiques respectifs T_x_max des matériaux de construction correspondants, si au moins un temps de séjour résultant t_x dépasse le temps de séjour critique respectif T_x_max du matériau de construction correspondant, le résultat est une optimisation en ce qui concerne la consommation du matériau de construction requis et la qualité du composant.
EP22812495.4A 2021-11-03 2022-10-26 Procédé de fabrication d'au moins un élément Pending EP4436768A1 (fr)

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DE102021128639.5A DE102021128639A1 (de) 2021-11-03 2021-11-03 Verfahren zur Herstellung wenigstens eines Bauteils
PCT/EP2022/079889 WO2023078750A1 (fr) 2021-11-03 2022-10-26 Procédé de production d'au moins un composant

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DE102006037927A1 (de) 2006-08-11 2008-02-14 Karl Hehl Verfahren und Vorrichtung zur Herstellung eines dreidimensionalen Gegenstandes sowie Verwendung einer kunststofftechnischen Einheit zu dessen Herstellung
DE102012004988A1 (de) * 2012-03-14 2013-09-19 Arburg Gmbh + Co. Kg Verfahren zur Ausbringung eines Volumenstroms
JP5302436B1 (ja) 2012-03-27 2013-10-02 ファナック株式会社 射出成形機の樹脂の状態監視装置
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WO2015077262A1 (fr) 2013-11-19 2015-05-28 Guill Tool & Engineering Entrées d'impression 3d coextrudées, multicouche et multicomposant
JP6552838B2 (ja) 2015-02-27 2019-07-31 東洋機械金属株式会社 射出成形機
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WO2018142967A1 (fr) 2017-01-31 2018-08-09 日精樹脂工業株式会社 Procédé et dispositif d'aide au réglage d'une condition de moulage
CA3092735A1 (fr) * 2018-04-03 2019-10-10 Westfall Acquisition Iii, Inc. Procede de micromoulages d'articles
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EP3792039A1 (fr) 2019-09-10 2021-03-17 Nederlandse Organisatie voor toegepast- natuurwetenschappelijk Onderzoek TNO Tête de distribution pour fabrication d'additif de type à filament fusionné et renforcé par des fibres continues
WO2021092419A1 (fr) * 2019-11-08 2021-05-14 The University Of North Carolina At Chapel Hill Oligomères de poly(amide-imide) réactifs, procédés et articles

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WO2023078750A1 (fr) 2023-05-11

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