DE102004022387A1 - Molding apparatus for ceramics has molding chamber, compressing component and laser which sinters powder in layers to produce molding, powder being transported by annular rake with shearing components which also compresses powder - Google Patents

Abstract

Molding apparatus for ceramics has a molding chamber (2) which is filled with powder (3), a compressing component and a laser (4) which sinters or melts the powder in layers to produce the molding (1). Powder is transported to the molding chamber by an annular rake (6) fitted with shearing components which also acts as the compressing component. Independent claims are included for: (A) a similar apparatus in which the rake is fitted with beads which compress the powder; and (B) use of a compressing component in ceramic molding apparatus as described.

Description

The The invention relates to devices for the rapid production of bodies with each at least one space with a support for body, a storage space for particles, a transport device for Particles from the storage space to the installation space and a laser, wherein laser beams over the cross-sectional area of the Installation space feasible are and upon impact of laser beams on a particle layer both particles together and at least one below arranged layer of sintered and / or fused particles sinter and / or merge.

method and devices for producing bodies from successively applied layers from particles and the irradiation of these layers with laser beams a laser, particles being with each other and with the underlying layer sinter and / or merge are known through publications.

A method and an apparatus for producing bodies of layered powder and a selective sintering of the respective applied layer are known from US 4863538 (Method and device for producing bodies by selective sintering) known. In this case, the powder of the respective layer is partially sintered by high-energy radiation. About the impact of radiation on the powder layer while the body is realized. To generate the respective body volume, the high-energy radiation is scanned. It mainly uses CO ₂ or Nd: YAG lasers with scanners, with a power of 50 W to 200 W and a focus of 100 μm to 300 μm. The result is a sintered body. However, this is characterized by the fact that a compound, without a melt is formed as in welding, arises. This results in bodies that are only partially used as a die-casting tools. By subsequent infiltration, the density of the sintered body can be increased. A major disadvantage continues to be the very long sintering time, especially for larger bodies, which is up to 100 hours, depending on the size of the component. Another disadvantage is the relatively large surface roughness of the sintered body. The device of this solution consists of a process controlled by a microcomputer. Other such publications are the US 5314003 and US 5393613 in which the bodies are made from a previously prepared mixed powder of various metals. One of the metals has a low melting point, so that sinter in a partial heating these powder parts. By the DE 43 09 524 C2 (Method for producing a three-dimensional object), a method is known, wherein the radiation effect in the core region of an object to a minimum deformation and in the envelope region to the smoothest possible and accurate surface. The determination of the envelope region is effected by subtraction in three-dimensional fashion of individual regions of the core region from the overall body. The irradiation takes place in different ways, depending on whether it is a single area in the core area or one in the shell area. In addition to the determination of the envelope areas different irradiation technologies for the realization of the object are necessary. In the DE 195 38 257 C2 (Method of manufacturing a three-dimensional object), the object to be manufactured is provided with a three-dimensional supporting structure of an inner core portion and an outer enveloping portion. The core region is preferably exposed twice, so that a strong solidification is achieved, while the envelope region is exposed only once. The envelope area is located wholly between the object and the supporting structure. The envelope region is soft, so that a separation of the object from the support structure should be carried out with the least expenditure of force and tools. At the same time, the thickness of the envelope region to ensure the function as a support structure is very low. However, difficulties arise in the separation of very small or microstructured objects from the support structure, which can be easily destroyed during separation. At the same time there must be attack surfaces for the tools. In the case of several objects on a support, such a separation is difficult to realize without destruction, so that such support structures are not suitable for producing a plurality of miniature bodies or microstructured bodies on a support. By the DE 199 52 998 C2 (Device for the direct production of bodies in the layer structure of powdery substances) devices are known with an evacuable processing chamber, in which at least two sub-chambers are integrated. One of the sub-chambers is the installation space and the other of the reservoir for the powder. As a result, no reactive atmosphere is present, by the joining of the powder particles arise both dense and non-porous layers and there is no heat conduction. Through the publication DE 199 53 000 C2 (Method and device for the rapid production of bodies) methods and devices are known, wherein advantageously body can be made dimensionally accurate sharp and fast with high density. Shape-correcting aftertreatments are avoided as far as possible, so that such bodies can be produced very economically. This is achieved by the use of two radiation sources during sintering or welding, the first of the generation of the contour and the second for rapid realization the interior of the body to be generated is used. The first radiation source is predominantly a laser of good beam quality, since a small focus is to be achieved. As the second radiation source, a high-power diode laser with line focus is advantageously used. A compaction of the powder applied is not provided, so that occur in aggregates of particles as particle agglomerates defects in the body.

Of the in the claims 1, 19 and 24 indicated invention is the object of the body successively layered and interconnected To produce particles quickly.

These Task is with the features listed in the claims 1, 19 and 24 solved.

The Devices for producing bodies, each with at least a space with a carrier for body, one Storage room for Particles, a transport device for particles from the storage room to the installation space and with at least one laser, laser beams over the Cross sectional area the installation space feasible are and upon impact of laser beams on a particle layer both particles with each other and with at least one arranged underneath Sintering and / or sintering layer of sintered and / or fused particles merge, are characterized in particular by the fact that this body be made both with a high strength and fast can.

advantageously, is the transport device as a doctor blade simultaneously a shearing device for particle agglomerates and / or shearing particles are present on the carrier for particle agglomerates. As a result, in particular, forming agglomerates of particles simultaneously during of the contract and / or there is an increase in the surface tensions the particles through the energies occurring during shearing. Result are denser layers and thus denser bodies.

Especially Advantageously, shearing elements act in the immediate vicinity of the contour the body to be produced, the last sintered contour of the body is also shearing Element works. During the squeegee, this is superimposed on these contours or edges crushed or finely divided particles singulated Material directly on this contour or in the immediate vicinity of this Contour and is characterized by subsequent particles predominantly in the horizontal direction compacted. This results in denser and more dense areas concluding firmer areas of the body. These places are the contours of body cross sections whose quality determine the surface quality of the body.

As the edges of the shearing elements also affect their horizontal surfaces during doctoring and thus during transport of the particulate material over the Crushing shearing elements.

result is a particularly smooth and dense layer of powder over one already sintered area. Further important advantages of the space segmenting elements during the Doctor blades are the protection of body structures in front of rolling fragments and before the horizontal thrust of migrating powder clumps passing through the lower shearing elements partly in vertical compression reshaping, as well as the purge the doctor blade of approaches made of sintered and unsintered material.

roll effect in the transport device as a doctor blade by rolling a compression of the particle layer in the vertical direction, which is particularly smooth and dense powder layers are formed on the surface to be sintered.

advantageous Embodiments of the invention are in the claims 2 to 18 and 20 to 23 indicated.

A Connection of the doctor blade with an ultrasound generating device according to the embodiment of claim 2 advantageously leads to denser Layers, whereby existing particle agglomerates supported sheared become.

A segmented ring doctor as a transport device according to the development of claim 3 leads advantageously to the fact that the segmentation of the ring doctor several Blades are. This causes a larger shearing action and the powder more uniform in the Distributed space.

A segmented ring doctor with a grid construction or a squeegee with divided by elements in strips interior according to the development of the Patent claim 4 leads advantageously to a uniform and dense order of Particle.

The possibility a vertical movement of the squeegee next to a horizontal Movement according to the embodiment of claim 5 leads to a another possibility the compression of the particle layer. The segmentation works in the Connection with the already sintered layer as additional Scissors, wherein the ring doctor are also moved pulsating vertically can.

According to the embodiment of claim 6, there is at least one shear body on the carrier and adjoins the body to be produced without sanking on this. One or in particular a plurality of shear bodies on the construction platform are at the same time a holder for the body to be produced, so that positional changes of the body on the support, in particular during doctoring, are largely avoided. At the same time smooth and dense layers are generated during doctoring over the already sintered cross sections of the body, so that less roughness can be achieved.

The body to be produced at least partially enclosing, with each other ver affiliated shearing and to the body non-resonating shear bodies according to the embodiment of claim 7 provide a holder for the body to be produced or for several bodies to be produced. This will be position changes the body on the carrier especially when squeegee largely avoided. At the same time by means of these shear bodies a removal of the body or bodies easily done. So can with for example, a centrally located removal bar body easily from the carrier solved and be taken. By not ansintern the shear body to the or the body can These are also easily separated.

With the development of claim 8, wherein shear body with each other are connected and interconnected shear body a removal part for the produced body are, can the body be easily removed.

Predetermined breaking points the shearing sintered body according to the embodiment of claim 9 facilitate the removal of the body and increasing so the manageability of the body.

One Computer program product according to the embodiment of the claim 10 allows one fast automatic production of bodies, advantageously can be automatically removed and easily removed.

The Drives for a vertical movement of the carrier and / or the bottom of the storage space according to the development of the Guarantee patent claim 11 the realization of the body in a plane.

The Development of claim 12, wherein the carrier over at least an easily detachable layered Clamping spring connection is connected to the drive, secures easy removal / loading of the carrier.

One Identification code of the shear body according to the embodiment of claim 13 guarantee a safe allocation of the manufactured body, especially in a Mass production. Especially on individually customized bodies on a carrier is that beneficial.

A Grid construction in the upper area of the installation space or more elongated and spaced in a plane arranged elements in upper area of the installation space as each segmentation of the installation space According to the embodiment of claim 14 advantageously lead to denser Layers without additional Sintered body. Wire-shaped elements After the development of claim 15 provide a simple Realization for this segmented space is.

A changeability the segmentation elements according to the embodiment of the claim 16 allows an adaptation of the shearing elements to those changing during the generation Cross sections of the body and thus increases their efficiency.

The Further development of claim 17 allows the fast and secure Arrangement of the bodies to be produced in the installation space.

The Further development of claim 18 ensures the automatic Adaptation of the shearing elements to those during generation itself changing Cross sections of the body.

advantageously, are the balls according to the embodiment of claim 20 in guided the grid of the squeegee, so that over the area a uniform distribution the balls guaranteed is.

A high density of the balls according to the embodiment of the claim 21 causes a high weight and thus effective compression of the Powder layer.

A Non-stick coating of the balls according to the embodiment of the claim 22 prevents particles of the powder from sticking to the balls and so that the applied layers deform.

Cheap dimensions for the Balls are according to the embodiment of claim 23 balls with a diameter greater than or equal 0.1 mm and less than or equal to 10 mm.

One embodiment The invention is illustrated in principle in the drawings and will be closer in the following described.

It demonstrate:

1 a device for the rapid production of bodies,

2 a sintered shear structure,

3 a body surrounded by shear bodies,

4 a sintered star with bodies,

5 a segmented ring doctor with strips,

6 a squeegee with a grid and balls and

7 a segmented space in a plan view.

A device for the rapid production of bodies 1 In particular, as a ceramic component with powder of low density consists essentially of both a device with a space 2 for the body 1 , a storage room for particles 3 in powder form and a transport device for particles 3 from the storage room to the installation space 2 as well as a laser 4 , wherein laser beams over the cross-sectional area of the installation space 2 are feasible.

The 1 shows a device for the rapid production of bodies 1 ,

In the installation space 2 there is a carrier 5 for the body 1 as a ceramic component. Upon impact of laser beams on a particle layer with low powder density both particles sinter and / or merge 3 with each other as well as with at least one underlying layer, so that the body 1 is produced as a ceramic component.

The carrier 5 and the bottom of the storage space are each arranged vertically movable via a drive. The carrier 5 can be connected to the drive via at least one easily releasable position-defined clamping spring connection. This is in particular at least one curved leaf spring, which is coupled to the moving part of the drive.

The transport device is a ring doctor 6 with a self-contained blade. With the squeegee 6 become particles 3 as a powder as a layer to and in the installation space 2 transported. The squeegee 6 is at the same time a first part of a shearing device for forming or existing particle agglomerates. The effect of shearing can be increased by the squeegee 6 is coupled to an ultrasound generating device. On the carrier 5 are shear bodies 7 as the second part of the shearing device (shown in the 2 ) attached to the body to be produced 1 adjoin (representation in the 3 ). The shear bodies 7 enclose the body 1 at least in some areas and do not sinter to the body to be produced 1 at. So store in the area of these shear body 7 the particularly fine-grained particles, so that when applied with the laser beams at these sites particularly dense and solid structures. These points are advantageously edges of the body to be produced 1 , The shear bodies 7 put in the further process of production and handling of the body 1 advantageously a protective device for the produced body 1 so that in particular damage when loosening the body 1 from the carrier 5 be avoided as far as possible. In one embodiment, these shear bodies 7 Predetermined breaking points made of non-sintered material. This can shear body 7 easily from the manufactured bodies 1 be separated. This is especially true of bodies 1 with a many-surface contour of the body 1 especially advantageous. In a further embodiment, these shear bodies 7 at the same time an identification code, so that produced body 1 are easily assignable. An identification code can for example consist of several depressions of the same and / or different geometries and / or distances from one another. Furthermore, shear bodies can also be used 7 be connected to each other, so that the interconnected shear body 7 a withdrawal part 8th for the body to be produced 1 are and the bodies 1 are easily removable. The 4 shows a sintered star as a sampling part 8th with bodies 1 ,

• – Übernahme der Daten der herzustellenden Körper 1,
• – Aufteilung der herzustellenden Körper 1 in einem verbundenen Scherkörper 7 (zum Beispiel sternenförmig),
• – automatische Berechnung des Scherkörpers 7 (Abstand zum herzustellenden Körper ca. 10 μm),
• – automatische Berechnung des Entnahmeteils 8,
• – automatische Berechnung der Sollbruchstellen und
• – Zuordnung der entsprechenden Sinterparameter für nicht festes Sintern auf dem Träger 5, herzustellenden Körper 1, Scherkörper 7 und Sollbruchstellen.

The production of the body 1 Also as a microbody can advantageously be done by means of a computer program product in the form of software in a controller. This will be the process

• - Taking over the data of the body to be produced 1 .
• - Division of the body to be produced 1 in a connected shear body 7 (for example, star shaped),
• - automatic calculation of the shear body 7 (Distance to the body to be produced approx. 10 μm),
• - automatic calculation of the sampling part 8th .
• - automatic calculation of the predetermined breaking points and
• - Assignment of the corresponding sintering parameters for non-solid sintering on the carrier 5 body to be manufactured 1 , Shear body 7 and predetermined breaking points.

In a further embodiment, the ring doctor has 6 as a segmented ring doctor a grid construction 10 or inside several elements arranged in a plane 9 , so this squeegee 6 is divided into strips (representation in the 5 ). The grid construction 10 or the elements 9 are other first parts of the shearing device for forming or existing particle agglomerates.

Grid bars of the grid construction 10 or these elements 9 can be guided, so that their position is changeable. About a software included in the controller as another computer program product, the data of the body to be produced 1 taken over, the division of the bodies to be produced 1 taking into account the arrangement of the grid construction 10 or the elements 9 guaranteed and the sintering parameters are assigned.

This can also be an automatic adaptation of the shearing elements to the during the generation of changing cross sections of the body 1 respectively.

In addition to the grid construction 10 in the squeegee 6 may in a further embodiment of the embodiment balls 11 between through the grid construction 10 existing bars are located (representation in the 6 ). The bars are simultaneously guides for these balls 11 , The balls each have a diameter of 0.1 to 10 mm inclusive.

A grating device 12 (Presentation in the 7 ) or a plurality of both elongated and spaced arranged in a plane elements may in a further embodiment in the upper region of the installation space 2 be arranged as a segmented space. The grating device is advantageously made of wire-shaped elements or the elements are wire-shaped. These elements shear the particle agglomerates.

Claims (24)

Device for the rapid production of bodies, each having at least one installation space with a support for the body, a storage space for particles, a transport device for particles from the storage space to the installation space, a compression device for particles and a laser, laser beams can be guided over the cross-sectional area of the installation space and the Impact of laser beams on a particle layer both sinter and / or sinter particles with one another and with at least one layer of sintered and / or fused particles, characterized in that the transpart device simultaneously has both a densification device and a first upper part of a shearing device as doctor blade forming or existing particle agglomerates and that a segmented space and / or shearing generated shear body ( 7 ) is present as a second lower part of the shearing device, which consists of at least one element or of a powder bed segmenting system of elements, so that during doctoring particle agglomerates either at least in the immediate vicinity of the contour or in the immediate vicinity of the contour and over the cross-sectional area to be sintered of the body ( 1 ), resulting in both a dense and smooth and thus a high geometric resolution and a high sintering density enabling packing of the particle layer at the contour and on the surface to be sintered. Device according to claim 1, characterized in that the squeegee is connected to an ultrasound generating device, so that an additional movement of the squeegee shearing particle agglomerates during the transport and the squeegeeing of particles ( 3 ) is available. Apparatus according to claim 1, characterized in that the transport device as a doctor blade coupled to a drive annular blade ( 6 ) having a segmented cross-section of the interior as a segmented annular blade, so that the annular blade ( 6 ) is movable in the horizontal direction either to the space or away from it. Device according to Patent Claim 3, characterized in that the segmented annular doctor blade has a grid construction ( 10 ) or that the cross-section of the interior of the segmented ring doctor with arranged in a plane elements ( 9 ) is divided into strips. Device according to claims 2 and 4, characterized that connected to an ultrasound generating device segmented ring doctor with at least one drive so coupled is that these squeegee independently from each other in both horizontal and vertical directions is movable. Device according to claim 1, characterized in that the shear body ( 7 ) on the body to be produced ( 1 ) abuts without being sintered on this. Device according to claim 1, characterized in that interconnected bodies ( 1 ) at least partially enclosing and thereby not on the body to be produced ( 1 ) sintered shear bodies ( 7 ) as a sintered body over a non-sintered layer of particles ( 3 ) with the carrier ( 5 ) are connected. Device according to claim 7, characterized in that shear bodies ( 7 ) and that interconnected shear body ( 7 ) an extraction part ( 8th ) for manufactured bodies ( 1 ) are. Device according to claim 1, characterized characterized in that the shear bodies ( 7 ) Have predetermined breaking points of non-sintered material. Device according to the claims 7 and 9 , characterized in that - the data of the bodies to be produced ( 1 ) receiving, - produced body ( 1 ) to at least one or in shear body ( 7 ) as a sintered body dividing, - shear body ( 7 ), at least one sampling part ( 8th ) and the predetermined breaking points calculating and - the parameters for unfixed sintering on the support ( 5 ), bodies to be produced ( 1 ), Shear body is implemented as a sintered body and predetermined breaking points assigning computer program product in a control, so that the contour of the body ( 1 ) and the shear body ( 7 ) according to the shape of the bodies to be produced ( 1 ) with predetermined breaking points and the removal part ( 8th ) is generated automatically. Device according to claim 1, characterized in that the carrier ( 5 ) via a drive or both the carrier ( 5 ) And the bottom of the storage space is arranged vertically movable in each case via a drive. Device according to claims 1 and 11, characterized in that the carrier ( 5 ) is connected to the drive via at least one easily releasable position-defined clamping spring connection. Device according to claim 6, characterized in that shear bodies ( 7 ) have an identification code. Device according to claim 1, characterized in that a grating device ( 12 ) in the upper area of the installation space ( 2 ) is arranged as a segmented space or that a plurality of elongated and spaced arranged in a plane elements in the upper region of the installation space ( 2 ) are located as a segmented space. Device according to claim 14, characterized in that that the grating device consists of wire-shaped elements or that the elements are wire-shaped are formed. Device according to claim 14, characterized in that the grating device as a variable segmentation of the installation space ( 1 ) is guided in the arrangement plane in grooves or that the elongated arranged in a plane elements as a variable segmentation of the installation space ( 1 ) are guided in grooves in the arrangement plane. Device according to claims 1 and 14, characterized in that - the data of the bodies to be produced ( 1 ), - the bodies to be produced ( 1 ) taking into account the arrangement of the grating device ( 12 ) or the elements in the installation space ( 2 ) is implemented in a controller, so that the fast and secure arrangement of the bodies to be produced ( 1 ) in the installation space ( 2 ) is guaranteed. Device according to claims 1 and 16, characterized in that the grating device which can be changed both in position by a drive and guided (FIG. 12 ) or which are both variable in their positions and guided elements via a controller connected to at least one drive and that in the control of a computer program product for segmentation of the installation space ( 2 ) is implemented for the respective layer according to the arrangement level. Device for the rapid production of bodies, each having at least one installation space with a support for the body, a storage space for particles, a transport device for particles from the storage space to the installation space, a compression device for particles and a laser, laser beams can be guided over the cross-sectional area of the installation space and the Impact of laser beams on a particle layer both sinter and / or fuse together particles with one another and with at least one layer of sintered and / or fused particles underneath, characterized in that the transport device acts as a ring doctor blade ( 6 ) and that balls ( 11 ) as compression device for particles ( 3 ) in the ring doctor blade ( 6 ) are located. Device according to claim 19, characterized in that above the balls ( 11 ) in the ring doctor blade ( 6 ) a grid construction ( 10 ) or that the balls ( 11 ) in a grid construction ( 10 ) within the squeegee ( 6 ) are at risk. Device according to claim 19, characterized in that the balls ( 11 ) consist of a high density material. Device according to claim 19, characterized in that the balls ( 11 ) have a non-stick coating. Device according to claim 19, characterized in that the balls ( 11 ) have a diameter greater than or equal to 0.1 mm and less than or equal to 10 mm. Use of compression means for the rapid production of bodies with devices each having at least a space with egg NEM carrier for body, a storage space for particles, a transport device for particles from the storage space to space, a densifier for particles and a laser, laser beams over the cross-sectional area of the installation space are feasible and when hitting laser beams on a particle layer both particles with each other and sintering and / or fusing at least one layer of sintered and / or fused particles arranged underneath, characterized in that a segmented installation space or a segmented ring doctor blade with or without balls is used in each case as a compaction device for applied particles.