CN113195132A - Method for additive manufacturing of at least one article, use of a print head and motor vehicle - Google Patents

Method for additive manufacturing of at least one article, use of a print head and motor vehicle Download PDF

Info

Publication number
CN113195132A
CN113195132A CN201980081846.3A CN201980081846A CN113195132A CN 113195132 A CN113195132 A CN 113195132A CN 201980081846 A CN201980081846 A CN 201980081846A CN 113195132 A CN113195132 A CN 113195132A
Authority
CN
China
Prior art keywords
article
powdery
additive manufacturing
additional
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
CN201980081846.3A
Other languages
Chinese (zh)
Inventor
A.沙德
S.克鲁尔
T·范德里希
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.)
Volkswagen AG
Original Assignee
Volkswagen 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 Volkswagen AG filed Critical Volkswagen AG
Publication of CN113195132A publication Critical patent/CN113195132A/en
Pending legal-status Critical Current

Links

Images

Classifications

    • BPERFORMING OPERATIONS; TRANSPORTING
    • B22CASTING; POWDER METALLURGY
    • B22FWORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
    • B22F10/00Additive manufacturing of workpieces or articles from metallic powder
    • B22F10/10Formation of a green body
    • B22F10/14Formation of a green body by jetting of binder onto a bed of metal powder
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B22CASTING; POWDER METALLURGY
    • B22FWORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
    • B22F10/00Additive manufacturing of workpieces or articles from metallic powder
    • B22F10/40Structures for supporting workpieces or articles during manufacture and removed afterwards
    • B22F10/43Structures for supporting workpieces or articles during manufacture and removed afterwards characterised by material
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B22CASTING; POWDER METALLURGY
    • B22FWORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
    • B22F10/00Additive manufacturing of workpieces or articles from metallic powder
    • B22F10/60Treatment of workpieces or articles after build-up
    • B22F10/66Treatment of workpieces or articles after build-up by mechanical means
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B22CASTING; POWDER METALLURGY
    • B22FWORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
    • B22F12/00Apparatus 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
    • B22F12/50Means for feeding of material, e.g. heads
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B29WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29CSHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C64/00Additive 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
    • B29C64/10Processes of additive manufacturing
    • B29C64/141Processes of additive manufacturing using only solid materials
    • B29C64/153Processes of additive manufacturing using only solid materials using layers of powder being selectively joined, e.g. by selective laser sintering or melting
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B29WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29CSHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C64/00Additive 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
    • B29C64/10Processes of additive manufacturing
    • B29C64/165Processes 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
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B29WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29CSHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C64/00Additive 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
    • B29C64/20Apparatus for additive manufacturing; Details thereof or accessories therefor
    • B29C64/205Means for applying layers
    • B29C64/209Heads; Nozzles
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B33ADDITIVE MANUFACTURING TECHNOLOGY
    • B33YADDITIVE MANUFACTURING, i.e. MANUFACTURING OF THREE-DIMENSIONAL [3-D] OBJECTS BY ADDITIVE DEPOSITION, ADDITIVE AGGLOMERATION OR ADDITIVE LAYERING, e.g. BY 3-D PRINTING, STEREOLITHOGRAPHY OR SELECTIVE LASER SINTERING
    • B33Y10/00Processes of additive manufacturing
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B33ADDITIVE MANUFACTURING TECHNOLOGY
    • B33YADDITIVE MANUFACTURING, i.e. MANUFACTURING OF THREE-DIMENSIONAL [3-D] OBJECTS BY ADDITIVE DEPOSITION, ADDITIVE AGGLOMERATION OR ADDITIVE LAYERING, e.g. BY 3-D PRINTING, STEREOLITHOGRAPHY OR SELECTIVE LASER SINTERING
    • B33Y30/00Apparatus for additive manufacturing; Details thereof or accessories therefor
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B33ADDITIVE MANUFACTURING TECHNOLOGY
    • B33YADDITIVE MANUFACTURING, i.e. MANUFACTURING OF THREE-DIMENSIONAL [3-D] OBJECTS BY ADDITIVE DEPOSITION, ADDITIVE AGGLOMERATION OR ADDITIVE LAYERING, e.g. BY 3-D PRINTING, STEREOLITHOGRAPHY OR SELECTIVE LASER SINTERING
    • B33Y40/00Auxiliary operations or equipment, e.g. for material handling
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B33ADDITIVE MANUFACTURING TECHNOLOGY
    • B33YADDITIVE MANUFACTURING, i.e. MANUFACTURING OF THREE-DIMENSIONAL [3-D] OBJECTS BY ADDITIVE DEPOSITION, ADDITIVE AGGLOMERATION OR ADDITIVE LAYERING, e.g. BY 3-D PRINTING, STEREOLITHOGRAPHY OR SELECTIVE LASER SINTERING
    • B33Y70/00Materials specially adapted for additive manufacturing
    • B33Y70/10Composites of different types of material, e.g. mixtures of ceramics and polymers or mixtures of metals and biomaterials
    • YGENERAL 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
    • Y02TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
    • Y02PCLIMATE CHANGE MITIGATION TECHNOLOGIES IN THE PRODUCTION OR PROCESSING OF GOODS
    • Y02P10/00Technologies related to metal processing
    • Y02P10/25Process efficiency

Abstract

The invention relates to a method for additive manufacturing of at least one article, to the use of a print head and to a motor vehicle, in particular a passenger car. In a method for additive manufacturing of at least one article (20), a layer of powdered material (22) is arranged and, in order to firmly bond particles of the powdered material (22) to manufacture the article (20), a binder (27) is applied on at least one area of the powdered material (22). Additional material is applied to at least one region of the powdery material (22) in order to influence the properties of the object (20) to be produced at least in sections. The adhesive (27) and the additional material are applied by means of a common printing head (10) in at least partially segmented flow paths.

Description

Method for additive manufacturing of at least one article, use of a print head and motor vehicle
The invention relates to a method for additive manufacturing of at least one article, use of a print head and a motor vehicle, in particular a passenger car.
The additive manufacturing process (generations of Fertigunsverfahren) for manufacturing three-dimensional parts is a 3D-printing process, an adhesive jet forming technique. Here, the powdered material is applied layer by layer and optionally a binder is applied at the location where the powder is to be solidified to form the component. This process is repeated until the assembly is configured into the desired shape. The uncured powder is then removed.
In the production of metal parts by this method, such parts made of metal powder are sintered into finished parts after the above-described construction process. In this case, the material softens at high temperatures, but does not melt. Because the component has not yet had its full strength before the end of the sintering process and is subjected to gravity in the sintering furnace, deformation or warping may occur depending on the geometry and dimensions of the component. In particular, the projecting component regions can be deformed by gravity. The part also typically shrinks during sintering. The adhesion of the component bottom side to the base can lead to a deformation of the component region due to the respective frictional resistance.
It is known that the described deformations can also be counteracted by means of a support structure, which can be made of ceramic, for example, also called a sintering support. They locally support the component to be produced and thus prevent deformation mainly due to the effect of gravity. Since the melting point of the ceramic is higher than that of the metal, the use of the ceramic prevents the metal part to be manufactured from bonding to the support structure, and therefore it can be easily separated from the sintered part.
However, since such support structures cannot be manufactured in unlimited size and complexity, the size and complexity of the components to be manufactured are severely limited. Furthermore, during sintering, different material-dependent shrinkage of the support structure and the component takes place, so that the component may be deformed despite the use of the support structure.
A related method is known from EP 2529694B 1, which discloses a method for manufacturing ceramic molded articles by 3D inkjet printing. In this case, a ceramic slurry, i.e. a suspension of ceramic particles in a dispersion medium, is applied layer by layer to a support and is preferably solidified by a temperature change. The particles for making the body are output from the nozzle. The formed body is subjected to a chemical treatment or a thermal treatment to remove the binder. Several ceramic slurries are used, the proportions of which are controlled in a position-dependent manner, so that the composition of the body produced differs. A slurry with ceramic particles, a free-radically polymerizable binder and possibly a wax is used. The manufactured body is then sintered.
DE 102012101939 a1 describes a method and a device for the layer-by-layer construction of a molded body. The next layer is applied before the underlying layer hardens. The material for producing the molded body is applied from the nozzle, in particular while applying a support material around it, which is as heavy as the body material, and in this way prevents the flow or shearing of the body to be produced. Support material is also applied from the nozzle. The application takes place in substantially vertical layers, so that the support material is applied to the support material and not to the material used to form the molded body. As is clear from fig. 2c and paragraph [0088] of this document, the support material and the material used for producing the molded body are applied from spatially separated nozzles. The nozzles are not connected to each other. In particular, these materials are not output from a common printhead.
US 9,833,839B 2 discloses a method for manufacturing a body, a support material and an intermediate layer. The support structure is made of a first material. The intermediate layer is produced in such a way that it is in contact with the support structure. Adjacent to the intermediate layer, the surface of the body is made of a second material. The second material comprises a powder and a binder system with at least one binder, wherein the binder system is used to maintain the final shape of the body during processing of the body into the final part. The process includes debinding the final shape to remove the binder and sintering the final shape. The intermediate layer prevents the support structure from bonding with the body. The material of the intermediate layer is arranged with a deposition tool and the material for manufacturing the body is applied with a print head.
The object of the invention is to provide a method and a use which allow complex or large objects to be additively manufactured in a particularly simple and cost-effective manner.
This object is achieved by a method for additive manufacturing of at least one article according to claim 1 and by the use of a print head according to claim 10. The dependent claims 2 to 9 provide for the design of the method. Furthermore, a motor vehicle according to claim 11 is provided.
A first aspect of the invention is a method for additive manufacturing (or to be generative manufacturing) at least one article. A layer of powdered material is arranged and, in order to firmly bond the particles of powdered material to make the article, a binder is applied on at least one area of the powdered material. Furthermore, additional material is applied to at least one region of the powdery material in order to influence the properties of the object to be produced at least in sections. The adhesive and the additional material are applied by means of a common print head in at least partially segmented separate flow paths.
In particular, the method used is a method for 3D printing called binder jet forming technique. In this case, a large number of layers of powdery material are usually applied for the construction of the object and the material of each layer is cured locally by means of the application of an adhesive. The method features according to the invention can be implemented for each applied layer. The arrangement of the layers is usually done in such a way that a horizontal plane is obtained, wherein the article may consist of several planes or several layers. The article produced is then separated from the uncured powdered material surrounding it. Additional material may be applied in each layer.
The powder material is in particular a metallic material, i.e. the powder consists of at least one metal and/or at least one alloy. It may contain one or more components or substances, such as additional materials, alloying elements, or the like. It may be composed differently in different regions of a layer and/or in different layers. Generally, a homogeneous powder is used for all layers and/or for all regions of the respective layer. The powdered material is arranged on the receiving means or on a previously arranged layer.
A binder, also called a binder, is a material that holds powder particles together or binds them to each other to form a coherent article. This can be done mechanically, chemically, by adhesion and/or cohesion. The adhesive is usually applied in such a way that it is arranged in the cavities between the particles and establishes a firm bond between them, so that the particles are fixed or immovable relative to one another. The strong bonding of the particles is not contradictory to the fact that articles made in this way may only have a low strength.
When manufacturing articles made of metal, the articles made in this way are called green bodies or bodies and generally have only a low strength, so that the mechanical stresses on the bodies should be minimal. By means of a generally subsequent sintering process, articles having a higher strength than the green body are produced from the green body, wherein direct bonding or adhesion of the particles occurs between a large part of the respectively adjacent particles. This does not, of course, exclude the possibility of cavities or holes remaining in the article even after sintering.
In particular, the adhesive is designed in such a way that it can be substantially removed or decomposed during the debinding process and/or under the action of heat. For example, the binder does not comprise additives or additional particles, which cause the properties of the article to be manufactured to change in the sintered state. Typically, the binder comprises a solution and/or a suspension.
The additional material may include a solution, suspension, particles, and/or solutes. In particular, the additional material does not include a binder or a polymer. For example, the additional material is composed in such a way: it withstands the debinding process and/or the heating action for substantially complete removal of the binder at its location in the cavity of the powdered material. Additional material is applied to at least one area of the powder that is affected or unaffected by the binder.
The property influence refers in particular to a property influence relative to the surrounding area, i.e. a local adjustment of a desired property of the article at a desired position. Of course, alternatively, additional material may be applied in all regions of one or more layers.
At least two different materials, namely the binder and the additional material, are therefore applied to the powdery material on at least partially sectionally different flow paths. In particular, these materials are applied by means of different application openings of the print head, so that separate flow paths exist at least between the print head and the powdery material or the object to be manufactured. Typically, the adhesive and the additional material are guided in completely different flow paths, which may for example extend substantially parallel. In particular, the adhesive and/or the additional material is applied in a corresponding continuous volume flow at least for part of the time period.
In particular, the adhesive is applied by means of at least one first application opening of the print head. In particular, the additional material is applied by means of at least one second application opening of the print head. Typically, the first and second application openings are identically configured.
A print head refers to a device having at least one application opening for applying a material, which device is arranged or arrangeable such that a relative movement between the print head and the article to be manufactured or a receiving device for receiving the article to be manufactured is enabled. In particular, the application openings of the print heads are movable by means of a common movement device, movement device or drive device. The application openings arranged in the print head are firmly or rigidly connected to one another. They may be arranged in separate rigidly interconnected housing parts of the print head or in a common housing. In particular, the printing head has at least two application openings of redundant design for each material to be applied, so that in the event of a malfunction of the application openings for the material to be applied, there is instead an additional application opening for this material. In particular, the print head or the corresponding application opening is provided for the discharge of a liquid material, for example a solution or a suspension. However, it is not excluded that the print head has at least one application opening for applying the powdery material. The application opening has in particular a larger cross section than the application opening for the output of the liquid material.
The additional material can penetrate the respective layer of the powdery material and in this way influence the material of this layer. For example, it may be suitable for influencing the material during or after the sintering process and may for this purpose comprise, for example, alloying elements for alloying with the metallic powdery material.
The additional material may comprise any individual element or any combination of alloying elements known in metallurgy, in particular C, Cu, Mn, Ni and/or Si. During the subsequent sintering process, the alloy can be formed at least in regions by a diffusion process of the powdery material which takes place under the action of heat and possibly increased pressure, which diffusion process can be enhanced by softening the material if necessary.
The additional material may comprise sintering additives and/or particles smaller than the powdered material, e.g. made of the same material as the powdered material. This may improve the sintering process, e.g. increase the sintering activity and thus the achievable density or strength of the sintered article. The additional material may comprise reinforcing particles, for example comprising tungsten carbide and/or elemental carbon, to locally increase the strength. The additional material can be provided to influence the chemical composition of the article to be produced or its material properties, for example the corrosion resistance to a defined medium or environment. It can be provided for the targeted influencing of physical properties, such as thermal and/or electrical conductivity. For this purpose it may comprise, for example, copper. Locally increased hardness can be achieved, for example, by using alloying elements, carbon and/or carbides. Improved wear resistance may also be achieved by using tungsten, in particular tungsten carbide and/or other wear resistant elements.
It is also possible to prevent the presence of a defined material in a defined region by the targeted absence of additional material in this region. For example, alloying elements that are problematic for the subsequent welding process, such as nickel, may be omitted at the areas of the article to be welded, or only be arranged where they are needed.
In one embodiment of the method, the object is sintered. It may be debonded beforehand. In particular, sintering is carried out at a temperature between 70% and 90% of the melting temperature of the powdered material or of the powdered material with possible alloying elements, for example at a temperature of about 80% of the melting temperature.
Since only one movement device is required for moving the print heads, a particularly simple and inexpensive manufacture is possible by means of the joint printing of the print heads. The accuracy that can be achieved is particularly high because the distance between the application openings is constant.
A further embodiment of the method for additive manufacturing of at least one object is characterized in that the material composition of the object to be manufactured at the location of the separating material is changed relative to at least one adjacent region as a result of the separating material arranged there. The articles can thus be separated in a targeted manner after the sintering process at this point and in particular have a predetermined breaking point.
Separability of the article after the sintering process means subdividing or separating the article into at least two parts. In particular, at least one first part of the manufactured article is a support structure for bearing against or supporting at least one region of the actual part to be manufactured, while the second part is the part to be manufactured. The two parts are separated from each other by means of a separating material, so that they are not connected to each other during sintering. In the following, the term "article" relates to an article to be additively manufactured, which article may comprise a "component" and in particular at least one support structure for at least partially supporting the component during a subsequent sintering process.
The support structure serves in particular to support a region of the component to be produced in a targeted manner during sintering. In this way, flow, shearing or deformation of at least a part of the body to be manufactured is prevented. Thus, only the green body having a low strength is protected from deformation or warping before the sintering process is finished. In particular the protruding component regions are protected against deformation caused by gravity.
The changed material composition means the property of deviating from the range in which the object is specifically deactivated. This can be achieved, for example, by locally reducing the strength, so that a predetermined breaking point is produced in the article, at which a targeted failure of the article can be achieved by the action of force. It is also possible, for example, to produce areas of increased brittleness by using carbon, so that the object can be broken in a targeted manner by direct force action. Another possibility is to arrange a material that is soluble in a solvent, for example water, and/or a material with a low melting point or low heat resistance as a separate material, which can be deactivated in a targeted manner when the temperature rises.
In addition to the release material, additional material may be applied. This may be applied through at least one third application opening of the print head. In particular, the third application opening is of the same construction as the first and/or second application opening.
This configuration has the advantage that particularly large and complex components and components with arbitrarily protruding regions can be produced, since the support structure adapted to the respective component geometry can be produced in a targeted, reproducible and automated manner. These support structures can be made directly according to the dimensions of the component to be manufactured. They can be produced in the same process as the actual component and therefore can provide a fast and efficient process. Any complex support structure can be achieved by additive three-dimensional fabrication of the support structure. Since the support structure can be easily detached, the necessary post-processing is minimized.
In a further embodiment of the method, the separating material (trennematerial) is applied in such a way that it forms a phase on the powdery material that is at least substantially free of the powdery material. In other words, the separating material is applied in such a way that it is present at least in a partial region, but not in the form of a powder.
A phase of a separation material refers in particular to a layer of a separation material. The phase of the separator material may extend parallel to the layer of powdered material or at any other angle to the layer of powdered material. In other words, a layer of the separating material may be applied in or on the layer of the powdery material and/or the separating material may be arranged in an area within the layer of the powdery material, thereby forming a vertically or obliquely extending phase of the separating material. In particular, at least one further layer of the powdery material is arranged on the separating material. Of course, no further layer of powdered material is arranged on the last layer.
In this way, mechanical contact between the already applied powdery material and the layer of powdery material to be subsequently arranged is prevented. In other words, the separating material, which may be arranged, for example, as a layer and in this case also referred to as a separating layer, separates the powder regions located on both sides thereof or above and below it. This has the advantage that, during the subsequent sintering process, there is no bonding between the support structure and the component to be actually manufactured and therefore the support structure can be separated particularly easily and reproducibly. This allows a simple automation of the method.
In one embodiment, the articles are separated in a targeted manner at the location of the separating material. This is usually done after the sintering process. In particular, for this purpose, a force is applied to at least one region of the article such that it ruptures or separates in the region of the separating material to separate the support structure of the article. This can be done automatically. By separating the support structure from the manufactured article, the actual component to be manufactured is created.
In a further embodiment of the method, the separating material comprises and in particular consists of a material whose melting point differs from the melting point of the powdery material by at least 5%, in particular by at least 10%. Thus, during the sintering process for manufacturing the article, bonding (adhesion) between the separator material and the powdery material is reduced or prevented.
For example, the melting point of the material comprised by the separating material is at least 5%, in particular at least 10%, for example at least 20%, in one design at least 30%, in one embodiment at least 40% higher than the melting point of the powdered material, so that the material comprised by the separating material does not bond with the powdered material. All percentages related to temperature are based on the temperature scale in degrees celsius.
Alternatively, the melting point of the materials comprised by the separating material may be reduced by said percentage, such that there is a liquid phase separating the respective materials from each other during sintering.
In other words, the separating material is selected such that the component and the support structure are not sintered together. In particular, a ceramic separating material is used. The additional or separate material may comprise particles in suspension. Suspended ceramic particles are typically used.
The advantage of this embodiment is that the support structure can be separated in a targeted manner in a particularly simple manner by using the material according to the invention. In addition, materials that can be used as separation materials are available, have good processability and are inexpensive.
One embodiment of the method is characterized in that the separation material is liquid, pasty or powdery. For example, the release material may be applied as a viscous paste. It may for example comprise ceramic particles. In particular, in this case, the separated material forms a phase that is not affected by the powdery material, and therefore, only the separated material exists in a local area. The separation material can also be delivered to the powdery material as a powder or as a liquid, for example a solution or a suspension with suspended particles.
A further embodiment of the method for additive manufacturing of at least one article is characterized in that the powdery material and the additional material are arranged such that the additional material is located between regions of the powdery material that are not affected by the additional material. Thus, the material composition in the article to be manufactured changes at the location of the additional material relative to the surrounding area.
For example, a layer without some additional material can be arranged, a layer comprising or consisting of additional material can be arranged on this layer, and a layer without additional material can be arranged on this layer again. In particular, the additional material is applied to a powder layer, and then a powder layer is arranged on the additional material. In the case of the last layer to be manufactured, the additional material can be applied without a powder layer being applied thereon.
The additional material may be arranged in a first area arranged between second areas along the at least one spatial direction, wherein no additional material is arranged or arranged in the second areas. These regions can be located in one layer. Thus, the additional material may be arranged in a layer between areas of the powdered material that are not affected by the additional material.
In the case of a separating material, it can be arranged in or on the same layer as the component and/or the support structure to be actually manufactured and/or in or on a different layer. In particular, it is used to manufacture at least one region of reduced strength or reduced toughness of the article to be manufactured.
If the additional material influences the properties of the article after sintering, regions of varying properties can be produced in a targeted manner in this way.
In one embodiment, the region of the powdered material surrounding the additional material consists of the powdered material. In other words, the support structure and the part to be actually manufactured are made of the same powdery material. For example, a first part of the powder can be used for producing the component and a second part of the powder can be used for producing a support structure for bearing against or for supporting at least one region of the component, wherein a layer made of an additional material, for example a separating layer made of a separating material, is arranged between the first part and the second part of the powder.
This has the advantage that, on the one hand, the support structure and the component can be manufactured in a particularly simple and rapid manner. In addition, due to the same material during sintering, the shrinkage of these elements is the same, thereby preventing shrinkage-related warpage in the article, and the support structure can fulfill its function throughout the sintering process.
One embodiment of the method is characterized in that the amount of additional material applied per surface unit (or surface area) of the layer of powdery material is varied such that the object to be produced has different properties in different regions. This may be achieved in one or more layers to be applied.
In this way, different concentrations of the additional material in the article to be manufactured result in different properties. For example, the chemical composition, the magnetic properties, the electrical conductivity, the hardness, etc. of the article can be set in a targeted manner in this way.
The amount means especially volume or mass. This variation occurs in particular during the movement of the print head along the layer of powdered material. This means, for example, a change in the volumetric flow of the additional material.
The variation of the amount applied per surface unit may occur continuously, resulting in a graded material or a graded article, i.e. an article that varies continuously in terms of its composition in at least one spatial direction. The variation may also be discrete or stepwise, possibly in very small steps, to produce an article with graduated characteristics.
This design has the advantage that, in particular in connection with the geometrical variability of the additive manufacturing process, a particularly large degree of freedom can be achieved in the construction of the article. An article having a targeted area of defined mechanical properties can be made for a particular application. This has great potential for lightweight construction. Functionally integrated articles can be produced by targeted influencing of physical or thermophysical properties, i.e. in particular thermal conductivity.
A further embodiment of the method is characterized in that the additional material comprises particles and/or fibers. For example, locally increased stiffness or strength of the article to be manufactured may be produced by the fibers.
The particles or fibers have in particular a maximum diameter or length in the micrometer range, in particular in the nanometer range, so that they can be output by means of an application opening in the print head. Typically, they are in a suspended state. However, as mentioned above, it cannot be excluded that the particles or fibres are applied in solid form from a suitable application opening.
As described, the particles may consist of the same or similar material as the powdered material and have a smaller particle size than the particles of the powdered material, so that they are arranged in the interstices between them to increase the density of the green body and thus the sintering activity and density of the article to be manufactured.
This design advantageously allows greater variability in adjusting the desired characteristics.
A further embodiment of the method is characterized in that the additional material is applied to at least one region of the powdery material in which no adhesive is applied.
It is therefore also possible to apply additional material to powder areas that are not contained by the article to be manufactured. This makes it possible, for example, to improve the flowability of the powder using flow improvers known from the sintering art, such as fumed silica, and in this way facilitates the subsequent separation of the uncured powder, for example in cavities of complex geometry or having only a small cross section, for example in cooling channels located inside. This has the advantage that the freedom of construction for designing an article that can be produced by the method according to the invention is further increased.
The adhesive may be applied in one or more layers, with no additional material applied in the one or more layers. The additional material may be applied in one or more layers, with no adhesive applied in this layer or layers.
A second aspect of the invention is the use of a print head comprising a plurality of application openings for the separate application of materials, i.e. at least adhesive and additional material, for manufacturing an article by means of the method according to the invention.
In particular, at least one first application opening of the print head is used for applying the adhesive and at least one second application opening of the print head is used for applying the additional material. Furthermore, the print head can have at least one further application opening for applying at least one additional material, for example a further additional material.
In particular, a conventional print head may be used for manufacturing at least one article with the additive method according to the invention.
A third aspect of the invention is a motor vehicle, in particular a passenger car, comprising at least a part of an article manufactured by the method according to the invention.
In particular, the portion of the article is a component in which at least one support structure has been removed.
The invention is elucidated below on the basis of an embodiment shown in the drawing.
The figures show:
FIG. 1: is a schematic illustration of a process according to the invention, and
FIG. 2: a perspective view of a print head for carrying out the method according to the invention.
Fig. 1 schematically shows an apparatus 19 for carrying out an additive method according to the invention for manufacturing an article 20 by means of a binder injection molding technique. A three-part construction arrangement is shown with a central receptacle 18, the central receptacle 18 being used to arrange a powdery material 22, which in this embodiment is a metal powder, layer by layer. The powder supply sources 23 are arranged on both sides of the accommodating device 18. On the receiving device 18, a plurality of layers (not shown separately) of a powdery material 22 is already provided, which is locally solidified by applying the adhesive 20 in order to produce the object 20.
For this purpose, a print head 10 is shown, which is connected to an adhesive supply 28 by means of a line 29. The print head 10 has an application opening, not shown here, for applying the adhesive 20. It can move parallel to the layer of powdery material 22, wherein this movement is indicated by the arrow with reference numeral 30. The printing head 10 also has an application opening, not shown here, for applying additional material, by means of which the properties of the article 20 to be produced can be influenced at least in regions. For this purpose, the print head 10 is fluidically connected to a supply of additional material, which, like the adhesive supply 28, can be arranged movably separately from the print head 10 or on or in the print head 10 and jointly therewith.
The article 20 is manufactured layer by layer. To produce the layers of the article 20, the following method steps are carried out: the powder supply 23 is moved upwards by a defined height unit according to the arrows shown below each, and the central receiving device 18 is moved downwards by a defined height unit according to the arrows shown below it. This is done in particular in such a way that the volume of the powdered material 22 of the powder supply 23 provided in this way substantially corresponds to the volume released for arranging the layer of powdered material 22 above the receiving device 18.
A uniform layer of the powdery material 22 is applied or distributed by means of the placement device 25 onto a previously applied layer of the powdery material 22 which is cured locally by means of the adhesive 27. The arrangement device 25 is designed as a roller which is moved in the direction of the arrow parallel to the surface of the respective layer of powdery material 22 in order to distribute or possibly compact the powdery material 22. In other words, the powdery material 22 is arranged on the receiving device 18 or on a previously applied layer. The print head 10 is then moved parallel to the surface of the layer in the direction indicated by the arrow 30 over at least a part of the surface of the layer, and it applies the adhesive 27 by means of the print head 10 at least locally to cure the material. From the separate application opening additional material is applied by means of the print head 10.
In this way an article 20 is manufactured which comprises the component to be actually manufactured and at least one support structure for locally supporting the component during the subsequent sintering process. The support structure is made of the same powdery material 22 as the component, wherein the material of the support structure is spatially separated from the material of the component by means of a separating layer made of a ceramic separating material, so that the two elements do not sinter together and therefore the component can be separated from the support structure in a targeted manner in a simple and automatable manner after the sintering process.
Fig. 2 shows a perspective view and an enlarged detail of a print head 10 for use in the method according to the invention. The print head 10 has an enlarged illustration of a nozzle region 16 with six rows 14, wherein each row 14 has a plurality of application openings 12 for applying a respective material. Which are arranged one behind the other along the central longitudinal axis of the respective row 14, which is not shown here. The material to be applied is here a binder and at least one additional material, which may be a release material, for example. In particular, the respective two rows 14 are provided for applying the same material, so that there is a redundant design.
In addition, the printhead 10 has electrical contacts 40 for controlling the nozzle area.
List of reference numerals
Printhead 10
Application opening 12
Row 14
Nozzle area 16
Receiving device 18
Device 19
Article 20
Powdered material 22
Powder supply 23
Arranging device 25
Adhesive 27
Adhesive supply 28
Line 29
Movement 30
Contact 40

Claims (11)

1. A method for additive manufacturing of at least one article (20), in which method a layer of powdery material (22) is arranged, in order to firmly bond particles of the powdery material (22) for manufacturing the article (20), a bonding agent (27) is applied on at least one area of the powdery material (22), and an additional material is applied on at least one area of the powdery material (22) for influencing at least partially the properties of the article (20) to be manufactured, characterized in that the bonding agent (27) and the additional material are applied by means of a common print head (10) in at least partially segmented separate flow paths.
2. The method for additive manufacturing of at least one article (20) according to claim 1, characterized in that a separating material is applied as additional material or in addition to the additional material, such that the material composition in the article (20) to be manufactured at the location of the separating material changes with respect to at least one adjacent region due to the separating material arranged there, and the article (20) is specifically detachable at this location after the sintering process and has in particular a predetermined breaking point.
3. The method for additive manufacturing of at least one object (20) according to claim 2, characterized in that the separating material is applied such that it forms a phase on the powdery material (22) that is at least substantially free of the powdery material (22), wherein in particular at least one further layer of the powdery material (22) is arranged on the separating material.
4. Method for additive manufacturing of at least one object (20) according to one of claims 2 and 3, characterized in that the separating material comprises, in particular consists of, a material having a melting point which differs from the melting point of the powdery material (22) by at least 5%, in particular by at least 10%, so that bonding between the separating material and the powdery material (22) is reduced or prevented during sintering for manufacturing the object (20).
5. Method for additive manufacturing of at least one object (20) according to one of claims 2 to 4, characterized in that the separation material is liquid, pasty or powdery.
6. Method for additive manufacturing of at least one object (20) according to one of the preceding claims, characterized in that the powdery material (22) and the additional material are arranged such that the additional material is located between areas of the powdery material (22) that are not affected by the additional material, so that the material composition in the object (20) to be manufactured at the location of the additional material changes relative to the surrounding areas.
7. Method for additive manufacturing of at least one object (20) according to one of the preceding claims, characterized in that the amount of additional material applied per surface unit of the layer of powdery material (22) is varied, so that the object (20) to be manufactured has different properties in different areas.
8. Method for additive manufacturing of at least one article (20) according to one of the preceding claims, wherein the additional material comprises particles and/or fibres.
9. Method for additive manufacturing of at least one object (20) according to one of the preceding claims, characterized in that additional material is applied on at least one area of the powdery material (22) where no binder (27) is applied.
10. Use of a print head (10) comprising a plurality of application openings (12) for the separate application of material, i.e. at least adhesive (27) and additional material, for the manufacture of an article (20) by means of a method according to one of claims 1 to 9.
11. Motor vehicle, in particular passenger car, comprising at least a part of an article (20) manufactured by a method according to one of claims 1 to 9.
CN201980081846.3A 2018-12-19 2019-12-02 Method for additive manufacturing of at least one article, use of a print head and motor vehicle Pending CN113195132A (en)

Applications Claiming Priority (3)

Application Number Priority Date Filing Date Title
DE102018132938.5A DE102018132938A1 (en) 2018-12-19 2018-12-19 Process for the generative production of at least one object, use of a printhead and motor vehicle
DE102018132938.5 2018-12-19
PCT/EP2019/083254 WO2020126427A1 (en) 2018-12-19 2019-12-02 Method for the generative manufacture of at least one article, use of a printhead and motor vehicle

Publications (1)

Publication Number Publication Date
CN113195132A true CN113195132A (en) 2021-07-30

Family

ID=68766763

Family Applications (1)

Application Number Title Priority Date Filing Date
CN201980081846.3A Pending CN113195132A (en) 2018-12-19 2019-12-02 Method for additive manufacturing of at least one article, use of a print head and motor vehicle

Country Status (4)

Country Link
EP (1) EP3898032A1 (en)
CN (1) CN113195132A (en)
DE (1) DE102018132938A1 (en)
WO (1) WO2020126427A1 (en)

Families Citing this family (2)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
DE102020104296A1 (en) 2020-02-19 2021-08-19 Grob-Werke Gmbh & Co. Kg METHOD AND DEVICE FOR ADDITIVE MANUFACTURING OF A COMPONENT
CN115255382A (en) * 2022-07-25 2022-11-01 钟伟 3D printing conformal sintering supporting method and device thereof

Citations (8)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US20060071367A1 (en) * 2004-09-29 2006-04-06 Hunter Shawn D Fabricating a three-dimensional object
WO2015141782A1 (en) * 2014-03-19 2015-09-24 シーメット株式会社 Print head unit, three-dimensional additive layer manufacturing device, three-dimensional additive layer manufacturing method, and manufacturing product
CN106573434A (en) * 2014-08-08 2017-04-19 伊士曼化工公司 Additive manufacturing using miscible materials
US20170157831A1 (en) * 2015-12-08 2017-06-08 Xerox Corporation System and method for operation of multi-nozzle extrusion printheads in three-dimensional object printers
US20170297097A1 (en) * 2016-04-14 2017-10-19 Desktop Metal, Inc. Fabricating an interface layer for removable support
CN108103541A (en) * 2017-11-09 2018-06-01 河南理工大学 A kind of metal three-dimensional increasing material manufacturing apparatus and method
US20180154439A1 (en) * 2016-12-02 2018-06-07 Markforged, Inc. Additively manufactured parts with debinding acceleration
WO2018200512A1 (en) * 2017-04-24 2018-11-01 Markforged, Inc. Sintering additively manufactured parts in microwave oven

Family Cites Families (5)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
SE520565C2 (en) * 2000-06-16 2003-07-29 Ivf Industriforskning Och Utve Method and apparatus for making objects by FFF
DE102008045984A1 (en) * 2008-09-05 2010-03-11 Mtu Aero Engines Gmbh Method for producing a component and device therefor
EP2529694B1 (en) 2011-05-31 2017-11-15 Ivoclar Vivadent AG Method for generative production of ceramic forms by means of 3D jet printing
DE102012101939A1 (en) 2012-03-08 2013-09-12 Klaus Schwärzler Method and device for the layered construction of a shaped body
US20180099334A1 (en) * 2016-10-12 2018-04-12 Baker Hughes Incorporated Method and apparatus for additively manufacturing multi-material parts

Patent Citations (8)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US20060071367A1 (en) * 2004-09-29 2006-04-06 Hunter Shawn D Fabricating a three-dimensional object
WO2015141782A1 (en) * 2014-03-19 2015-09-24 シーメット株式会社 Print head unit, three-dimensional additive layer manufacturing device, three-dimensional additive layer manufacturing method, and manufacturing product
CN106573434A (en) * 2014-08-08 2017-04-19 伊士曼化工公司 Additive manufacturing using miscible materials
US20170157831A1 (en) * 2015-12-08 2017-06-08 Xerox Corporation System and method for operation of multi-nozzle extrusion printheads in three-dimensional object printers
US20170297097A1 (en) * 2016-04-14 2017-10-19 Desktop Metal, Inc. Fabricating an interface layer for removable support
US20180154439A1 (en) * 2016-12-02 2018-06-07 Markforged, Inc. Additively manufactured parts with debinding acceleration
WO2018200512A1 (en) * 2017-04-24 2018-11-01 Markforged, Inc. Sintering additively manufactured parts in microwave oven
CN108103541A (en) * 2017-11-09 2018-06-01 河南理工大学 A kind of metal three-dimensional increasing material manufacturing apparatus and method

Also Published As

Publication number Publication date
DE102018132938A1 (en) 2020-06-25
WO2020126427A1 (en) 2020-06-25
EP3898032A1 (en) 2021-10-27

Similar Documents

Publication Publication Date Title
JP6519100B2 (en) Sinter-forming method, liquid binder, and sinter-formed product
CN110494238B (en) Additive manufacturing using recoater with in-situ replaceable recoater blades
Ramazani et al. Metal FDM, a new extrusion-based additive manufacturing technology for manufacturing of metallic parts: a review
JP4421477B2 (en) Casting method
JP3472779B2 (en) Variable welding laminated rapid molding method and rapid molding apparatus
US5989476A (en) Process of making a molded refractory article
US11420254B2 (en) Method of forming an object using 3D printing
US20150125334A1 (en) Materials and Process Using a Three Dimensional Printer to Fabricate Sintered Powder Metal Components
JP2019518865A (en) Sputtering target assembly with graded interlayer and method of making
Scheithauer et al. Droplet-based additive manufacturing of hard metal components by thermoplastic 3D printing (T3DP)
CN113195132A (en) Method for additive manufacturing of at least one article, use of a print head and motor vehicle
US10343217B2 (en) Nanoparticle enhancement for additive manufacturing
US7063815B2 (en) Production of composite materials by powder injection molding and infiltration
WO2019246321A1 (en) Methods and compositions for the preparation of powders for binder-based three-dimensional additive metal manufacturing
WO2018170422A1 (en) Base plate in additive manufacturing
CN111836711A (en) Additive manufacturing method and apparatus
US20170021526A1 (en) Exothermic powders for additive manufacturing
US20220274172A1 (en) Coprinted supports with printed parts
CN114012106A (en) Laser additive manufacturing and forming method of static mixer
JP6724974B2 (en) Sinter modeling method, liquid binder, and sinter model
JP7216363B2 (en) Manufacturing method of three-dimensional object and three-dimensional modeling system
Greulich Rapid prototyping and fabrication of tools and metal parts by laser sintering of metal powders
Kruth et al. Selectice laser sintering: state-of-the-art
Dolinšek Investigation of direct metal laser sintering process
US11911822B2 (en) Multi-layer composites with varied layer thicknesses and related methods

Legal Events

Date Code Title Description
PB01 Publication
PB01 Publication
SE01 Entry into force of request for substantive examination
SE01 Entry into force of request for substantive examination
RJ01 Rejection of invention patent application after publication
RJ01 Rejection of invention patent application after publication

Application publication date: 20210730