DE102005021641A1 - Mold, for rapid prototyping/manufacturing, is composed of assembled and bonded mold elements with milled contours to give the final contour - Google Patents

Abstract

To produce a molded body a number of mold elements (2.1-2.3) are made, where each has at least one flat joint surface (F2.3b) with an edge defining the working contour. The mold elements are assembled together as a mold (1) with their contours (L1,L2) in alignment and they are locked together. The mold material is removed by a miller (3) at the aligned contours to give a final mold contour, without removing material completely at a free joint surface for bonding with further molds.

Description

The This invention relates generally to the field of rapid production of shaped bodies, which also with the terms "Rapid Prototyping "or" Rapid Manufacturing "is called. The invention particularly relates to a method in which the shaped body by Connecting a plurality of sheet metal Form elements is produced with a predetermined contour.

• – Nakagawa T., Suzuki K.: "A Low Cost Blanking Tool With Bainite Steel Sheet Laminated", Proc. of 21^St Int. MTDR Conf., 1980;
• – Nakagawa T., Kunieda M.: "Manufacturing of Laminated Deep Drawing Dies by Laser Beam Cutting", Advanced Technology of Plasticity, 1984, Vol. 1;
• – Techel A., Himmer T., Beyer E., Heptner T.: "Automation Solutions for Metal Laminated Tooling", Laser Assisted Net Shape Engineering 4, Proc. of the Int. Conf. LANE 2004, Edited by Geiger M. et al., Meisenbach-Verlag Bamberg 2004, Vol. 1, pp. 561–566;
• – Prechtl M., Otto A., Geiger M., Graf D.: "Process Chain Towards Laminated Object Manufacturing with Metal Foil", Laser Assisted Net Shape Engineering 4, Proc. of the Int. Conf. LANE 2004, Edited by Geiger M. et al., Meisenbach-Verlag Bamberg 2004, Vol. 1, pp. 567–578;
• – Prechtl M., Pursche L., Otto A.: "System Technology and Data Preparation for Automated Laser Assisted Stacking of Metal Foil Contours", Laser Assisted Net Shape Engineering 4, Proc. of the Int. Conf. LANE 2004, Edited by Geiger M. et al., Meisenbach-Verlag Bamberg 2004, Vol. 1, pp. 601–610.

Such methods are known in the art. Reference is made, by way of example, to the following publications:

• - Nakagawa T., Suzuki K .: "A Low Cost Blanking Tool With Bainite Steel Sheet Laminated", Proc. of 21 ^St Int. MTDR Conf., 1980;
• - Nakagawa T., Kunieda M .: "Manufacturing of Laminated Deep Drawing This by Laser Beam Cutting", Advanced Technology of Plasticity, 1984, Vol. 1;
• - Techel A., Himmer T., Beyer E., Heptner T .: "Automation Solutions for Metal Laminated Tooling", Laser Assisted Net Shape Engineering 4, Proc. of the Int. Conf. LANE 2004, edited by Geiger M. et al., Meisenbach-Verlag Bamberg 2004 , Vol. 1, pp. 561-566;
• - Prechtl M., Otto A., Geiger M., Earl D .: "Process Chain Towards Laminated Object Manufacturing with Metal Foil", Laser Assisted Net Shape Engineering 4, Proc. of the Int. Conf. LANE 2004, Edited by Geiger M. et al., Meisenbach-Verlag Bamberg 2004, Vol. 1, pp. 567-578;
• - Prechtl M., Pursche L., Otto A .: "System Technology and Data Preparation for Automated Laser Assisted Stacking of Metal Foil Contours", Laser Assisted Net Shape Engineering 4, Proc. of the Int. Conf. LANE 2004, Edited by Geiger M. et al., Meisenbach-Verlag Bamberg 2004, Vol. 1, pp. 601-610.

at The known methods are the form elements to a package on top of each other stacked and then, for example, by means of diffusion welding together connected. Subsequently, will a surface of the molding removed to a predetermined final contour. In the known method It may disadvantageously happen that the shape elements in the diffusion welding not always consistent be connected to each other. Apart from that, it comes with the connection sometimes the molded elements to the fact that the molding warps and a assumes a different shape from the given contour. It can as a result not always the desired one Final contour are produced.

Around to counter these disadvantages, it has also been tried the moldings by means of high temperature soldering connect to. However, a molded body produced with this connection technology has no particularly good high-temperature strength. Apart from this requires the application of a solder on the mold elements to be joined a considerable effort or increased costs of the semifinished product.

task The invention is to the disadvantages of the prior art remove. In particular, a method is to be specified, with a molded body can be produced with an improved quality is. According to another object of the invention is in particular a a given final contour of the shaped body corresponding surface impeccable quality exhibit. After all should be produced with the method and monocrystalline moldings be.

These The object is solved by the features of claim 1. Advantageous embodiments of Invention emerge from the features of claims 2 to 21st

• a) Herstellen einer Mehrzahl von Formelementen, wobei jedes der Formelemente zumindest eine ebene Fügefläche und eine die Fügefläche randlich begrenzende, vorgegebene Arbeitskontur aufweist,
• b) Auflegen eines Formelements mit der Fügefläche auf eine Fügefläche eines darunterliegenden Formelements, wobei Konturen der übereinander liegenden Formelemente etwa in Ausrichtung sind,
• c) Verbinden der Formelemente und
• d) teilweises Abtragen einer durch die Konturen der verbundenen Formelemente gebildeten Arbeitsoberfläche auf eine vorgegebene Endkontur, wobei ein umlaufender Abschnitt der Arbeitskontur zumindest im Bereich des eine freie Fügefläche zum Verbinden mit einem weiteren Formelement aufweisenden Formelements nicht oder nicht vollständig abgetragen wird.

According to the invention, a method for producing a shaped body is provided with the following steps:

• a) producing a plurality of mold elements, wherein each of the mold elements has at least one planar joining surface and a predetermined working contour bordering the joining surface,
• b) placing a feature element with the joining surface on a joining surface of an underlying feature element, wherein contours of the superimposed form elements are approximately in alignment,
• c) connecting the mold elements and
• d) partial removal of a work surface formed by the contours of the connected mold elements to a predetermined final contour, wherein a peripheral portion of the working contour is not or not completely removed at least in the region of a free joining surface for connecting to a further mold element having element.

According to an essential aspect of the invention, a working surface formed by the contours of superimposed form elements is not completely removed to the predetermined final contour of the shaped body. The contours can include the working contour, the final contour or also intermediate contours. The removal takes place in such a way that at least in the region of a free joining surface for connecting to a further mold element a circumferential portion of the working contour at least partially is left standing. This can be achieved in a simple and effective way, a protection of a section already produced final contour. In particular, thus a particularly clean connection of the mold elements can be achieved at one of the later end contour corresponding circumferential edge. The moldings produced by the proposed method are characterized by an excellent surface quality. Finally, the inventive method allows the production of large-sized moldings and the realization of a high build-up rate.

To an advantageous embodiment of the invention, the form elements a working strength on. In this case, before placing another formula element the working strength to a given final strength be removed. This allows the realization of a particularly exact geometry of the molding. any when connecting the mold elements forming unevenness can by the removal of the working strength the given final strength be removed. This is at the same time the risk of a faulty Connection with the next minimizes the following shape element.

The Working contour, if necessary the working strength, is larger than the final contour and, if necessary the final strength. The working contour and the final contour and, if necessary, the working strength and the final strength can calculated by a given algorithm with a computer become. In particular, the computer can also use an order the superimposed Form elements are set. The working contour is dependent the final contour, if necessary the final strength of the formula element. The calculations can be made on the basis of a given CAD models respectively. In particular, it is possible the geometry of the form elements automatically by means of the computer to calculate. It is also possible using the calculated geometries, the features automatically with computer-controlled tools. Also the stacking up as well as the joining of the form elements can be computer controlled.

To a further embodiment of the invention, the ablation means mill or laser performed. Of course can Other suitable techniques for removing the working contours and / or the working strengths be used on the final contour and possibly the final strength. Conveniently, is the ablation on the final contours and / or the final strength means of the computer in accordance performed with the calculation. With that you can particularly accurate results can be achieved.

To A further embodiment of the invention provides that the steps lit. b) to lit. d) are repeated until the molding the having predetermined shape. By gradually connecting the Form elements becomes a perfect, firm and consistent joining of the same guaranteed. Conveniently, After each step of joining, a section of the final contour is formed of the molding produced. After connecting with the last form element is the step lit. d) expediently omitted and it is made a predetermined final contour of the molding.

Conveniently, the connection takes place by means of welding or soldering. The selected connection technology depends on the size, the geometry and the mechanical requirements of the molding. In particular, also be considered combined welding processes, in which the mold element by means of a plurality produced simultaneously welds first is stapled to the underlying mold element. Subsequently, the Form elements in a second step over the entire surface connected become. As a welding process come beam welding, diffusion welding, laser beam welding, stud welding, electron beam welding, in particular under an atmosphere friction welding and the like. Into consideration.

To an advantageous embodiment of the invention, it is possible that Form elements only by spot welding to connect and the molded body produced subsequently to undergo a diffusion welding process as a whole. One such process is particularly suitable for the production of moldings, which made of soft metallic alloys with a relatively low Melting point, e.g. As copper and aluminum alloys become.

When Form elements can in particular sheet-shaped Form elements are used. Such sheet-like form elements have two parallel joining surfaces. The form elements can but also plate-shaped or cube-shaped. They are especially made of metal.

According to an advantageous embodiment of the invention, the mold elements are produced by joining a plurality of sub-elements. In this case, the sub-elements can be made of at least two different materials. To produce the mold elements, the sub-elements are arranged in a predetermined geometry in this case. This makes it possible to produce a shaped body from, for example, two different metals. A production of a shaped body from different metals can also be done by remelting and adding a filler material. The mold elements can be constructed in such a way in that a structure forming the shaped body is produced on the inside from a first metal and at the surface thereof from a second metal. This allows the targeted adjustment of certain mechanical or thermal properties of the molding.

The Form elements can also over thermal metal spraying method, e.g. By means of a spray compaction method, getting produced.

To A further embodiment of the invention provides that the joint surfaces of the Form and / or sub-elements with a joining agent, preferably a Lot, a flux or an adhesive coated. The proposed method is not on the joining of metallic mold elements limited. It can be applied in particular to form elements, which For example, made of plastic, wood, ceramic, partially sintered ceramic precursors and the like. Are made.

To a particularly advantageous embodiment of the invention is as a first mold element a single-crystalline substrate with at least a Substratfügefläche and one of the Substratfügefläche randlich limiting given working contour, being used for joining or after bonding, the molding element at least in a covering the Substratfügefläche Area and the substrate partially at least in a Substratfügefläche containing the substrate melted first portion, and wherein the melt is cooled, that a solidification front from the unmelted second section of the substrate in the direction of a free joining surface of the element element moves. It is not always necessary to produce a monocrystalline molding. the mold element with the substrate, for. B. by welding, connect to. The connection can also be made by to lay the mold element only on the substrate and then at least partially melted. - With the proposed further process steps, it is possible gradually a monocrystalline molding to produce polycrystalline molded elements. This made light possible in particular a cheap and rapid production of, for example, turbine blades and etc. ..

To an expedient embodiment of Invention is at any point of the solidification front an angle between a normal on the free joint surface and a normal to the melting or solidification front smaller 45 °, preferably less than 40 °. That is, a temperature field generating the melt is controlled that a relatively flat melting or solidification front is formed, which in the partially produced moldings at least until the monocrystalline Protruding area. Conveniently, However, the melt front protrudes so deeply into the partially produced moldings into it, that with it by a previous connection of the formula element manufactured welding structures Completely be melted.

To an expedient embodiment of Invention, the mold element is melted along a predetermined path. Conveniently, is the way chosen, that the melting traces overlap. An overlap is such that the melt is a polycrystalline region completely melts on an adjacent melting trace. It can also repeatedly, in particular along predetermined paths, melted out become. With the proposed method can monocrystalline molded body with an excellent surface quality quickly and easily made.

following Be exemplary embodiments of Invention explained in more detail with reference to the drawings. Show it:

1a schematically the joining of a molding element with a partially finished molding,

1b schematically the partial removal of a working surface,

2a C shows schematically different form elements,

2d -F an operating force, an intermediate contour and a final contour of a feature element,

2g the arrangement of molded elements in a molded body,

3a -C the production of a formula element from subelements,

4 the production of a further formula element of subelements,

5a A first preparation of a monocrystalline molding and

6a -E a second production of a monocrystalline molding.

In the 1a and 1b there is a partially finished molded body 1 from three form elements 2.1 . 2.2 and 2.3 , The form elements 2.1 . 2.2 . 2.3 Here are made of a metal sheet. Each of the form elements 2.1 . 2.2 ., 2.3 has parallel joining surfaces F2.1a, F2.1b, F2.2a, F2.2b, F2.3a, F2.3b. The partially broken line L1 denotes a predetermined final contour of the shaped body 1 and the partially broken second line L2 has an intermediate contour. The vertical solid line L3 denotes the outer boundary of a working contour. The third form element 2.3 has a working strength S1. With S2 is a final strength of the third element element 2.3 designated.

For producing a shaped body 1 this is first constructed with the aid of a computer program. Subsequently, using predetermined parameters, such as an available sheet thickness and the like., The constructed shaped body 1 virtually in a variety of form elements 2.1 . 2.2 . 2.3 , ..., 2.n be disassembled. By means of the computer program, the number, the order and a working contour L3, an intermediate contour L2 and a final contour L1 can be determined. The form elements 2.1 . 2.2 . 2.3 , ..., 2.n For example, they can be cut from a sheet by means of a laser, water jet or cutting tools.

Subsequently, from the moldings 2.1 . 2.2 . 2.3 the molded body 1 built up. Like from the 1a and 1b can be seen, has to do with the first mold element 2.1 connected second mold element 2.2 in the region of its free joining surface F2.2b, a section projecting beyond the line L1 up to the line L2 projecting section. The second form element 2.2 may already be removed in the region of its first joining surface F2.2a on the designated by the line L1 final contour. Also the first form element 2.1 is already plotted on the designated by the line L1 final contour.

For further construction of the molding 1 becomes the third form element 2.3 on the free joining surface F2.2b of the second formula element 2.2 hung up. The third form element 2.3 has a working contour L3 extending beyond the intermediate contour L2 and an operating force S1.

The third form element 2.3 becomes with the second form element 2.2 for example, by welding, soldering, gluing or the like. Connected. If the form elements 2.1 . 2.2 . 2.3 are made of a metal sheet, the connection takes place in example, first by the simultaneous production of multiple welds. This is an undesirable deformation of the element to be joined 2.3 avoided. Subsequently, in a second step, the form element to be joined 2.3 for example, by beam welding over the entire surface with the underlying second mold element 2.2 get connected.

How out 1b it can be seen, a processing of the surface of the molding is now carried out in a further process step 1 , One is in the area of the second 2.2 and the third formula element 2.3 Partially removed from the intermediate contour L2 and the working contour L3 working surface. The ablation can with conventional techniques, for example by means of a milling machine 3 respectively. For ablation, however, other techniques, such. B. Laserabtragen and the like., Can be used. The removal of the work surface is such that a free joint surface F2.3b of the third element element 2.3 is removed to a predetermined final thickness S2. The marginal work surface is removed in sections on the final contour L1. In the area of the free joining surface F2.3b of the third formula element 2.3 However, an intermediate contour L2 is allowed to stand, which protrudes circumferentially peripherally over the final contour L1. The intermediate contour L2 serves to protect a sectionally already produced end contour L1 of the molding 1 ,

The 2a to c show different shape elements 2 , The working contour L3 denotes the outline of the feature 2 ,

The working contour L3, for example, in the 2a be rectangular contour of the sheet. In this case, such a rectangular working contour L3 facilitates the stacking of the form elements 2.1 . 2.2 . 2.3 , ..., 2.n , If the mold element has an inner contour, however, it is advantageous if it is cut out before placing the Forme element. This can be a cut mold core before placing on a partially produced moldings 1 be removed.

The Form elements can Also, positioning, such as holes or the like., Have.

How out 2 B it can be seen, the mold element 2 also from a variety, such as cube-shaped, sub-elements 5 be joined together. The subelements 5 can be welded together during the construction of the molding. Subsequently, the mold element 2 be cut out or milled along the working contour indicated by the broken line L3. How out 2c is apparent, it is possible with this technique in particular, made of different materials first partial elements 4.1 and second sub-elements 4.2 to connect with each other. The first sub-elements 4.1 can be made of a first metal and the second sub-elements 4.2 be made of a second metal. In this way, a predetermined mechanical and / or thermal property of the shaped body 1 be set.

The 2d shows the intermediate contour L2 of a feature element 2 with a working strength S1. 2e shows an intermediate contour L2 of a feature element 2 with a final strength S2. 2f finally shows the final contour L1 of a formula element 2 and the final strength S2. In 2g is a shaped body 1 shown, which consists of a variety of form elements 2.1 . 2.2 . 2.3 , ..., 2.n is made. It also exemplifies the location of the in 2f shown elements 2 in the molding 1 shown.

The 3a to 3c show a possibility for the production of a formula element 2 from a variety of sub-elements 4 ,

These can be the sub-elements 4 first on a free surface of a partially produced molding 1 by means of welds 5 be fixed. Subsequently, the surfaces between the sub-elements 4 by means of welds 6 be connected to each other over the entire area. As in 3c can be shown, while the welds 6 overlap. In this case, it is not necessary to provide further perpendicular thereto welding seams. Depending on the dimension of the subelements 4 But it is also possible to perform the welds crosswise and thus the surfaces between the sub-elements 4 to connect to each other over the entire area.

4 shows the production of a further formula element 2 from a variety of cube-shaped sub-elements 4 , In the process, the subelements become 4 first by means of stud or friction welding with a free joining surface of a partially prepared element element 1 connected. Subsequently, the between the form elements 4 located surfaces by means of welding seams produced by laser welding 6 connected with each other.

The 5a to 5e show a first production of a monocrystalline molding 1 , In this case, instead of a polycrystalline, for example, made of sheet metal, the first formula element is a monocrystalline substrate 7 used. The substrate 7 corresponds in geometry to a first form element. The substrate 7 For example, it may have a dendritic microstructure in which all dendrites have a given crystallographic orientation, e.g. B. the [100] orientation, perpendicular to the joint surface, have.

In 5a is a second form element 2.2 , which was originally formed polycrystalline, for the most part already been converted into a monocrystalline body.

The conversion is according to the out of the 5b to 5e apparent process steps takes place.

How out 5b can be seen, is placed on the free joining surface F2.2b third form element 2.3 initially, for example by welding with the second mold element 2.2 connected. In 5b are the welds produced by the reference numeral 6 designated.

Subsequently, the third shape element 2.3 completely melted at least in a section located between the final contour L1. A solidification front 8th in a melt S reaches into the monocrystalline formed second mold element 2.2 , An angle α between a normal on the solidification front 8th and a normal to the free joining surface F2.3b of the third formula element 2.3 is expediently less than 45 °. Subsequently, by a directed cooling the solidification front 8th slowly moves in the direction of the free joining surface F2.3b, so that at least one section of the third element element located between the final contour L1 2.3 forms a monocrystalline structure.

5d shows the shaped body 1 before removing the work surface. The removal of the work surface takes place as in the 1a and 1b has already been explained.

5e shows the situation after the partial removal of the working surface. The manufactured molding 1 has similar to in 1b in the area of the free joining surface F2.3b a protrusion bordering on an intermediate contour L2 forms an already produced end contour L1 against mechanical and thermal influences when applying further form elements 2.n protects.

6a to 6e shows a second production of a monocrystalline molding 1 , Unlike in the 5a to 5e The first method described here becomes one on the monocrystalline substrate 7 resting first form element 2.1 not completely, but in sections, melted. The melt S can do this along a predetermined path in the first mold element 2.1 be generated. Also in this case, the cooling of the melt S is such that the solidification front 8th in the direction of the free joining surface F2.1b moves, wherein the angle α is always less than 45 ° and thus the first mold element 2.1 forms a eininkinkristalline structure.

Like from the 6a to 6e can be seen further, the first mold element 2.1 at its the joining surface F2.lb opposite joining surface F2.1a a recess, with which the first mold element 2.1 positive fit on the substrate 7 can be hung up. That allows with the inventive method, for example, a repair of a damaged molding 1 , In this case, the substrate forms 7 a section of a damaged molding 1 , which subsequently by stepping on of form elements 2.1 . 2.2 . 2.3 , ..., 2.n can be rebuilt in its monocrystalline structure and with a predetermined contour.

With the proposed method can be in a simple and cost-effective manner Produce components that have a complicated geometry, which are composed of different materials or have a monocrystalline or directionally solidified microstructure. The proposed method is particularly suitable for the production of turbine blades, tools and the like. It can essentially automated and computer-controlled.

1

moldings

2, 2.1, 2.2, 2.3, 2.n

forming element

3

milling machine

4, 4.1, 4.2

subelement

5

WeldingSpot

6

Weld

7

substratum

8th

solidification front

F2.1a to F2.3b

joining surface

L1

final contour

L2

between contour

L3

work contour

S

melt

S1

working strength

S2

final thickness

α

angle

Claims (21)

Process for producing a shaped article ( 1 ) comprising the following steps: a) producing a plurality of shaped elements ( 2.1 . 2.2 . 2.3 , ..., 2.n ), each of the form elements ( 2.1 . 2.2 . 2.3 , ..., 2.n ) at least one planar joining surface (F2.1a, F2.2b, F2.2a, F2.2b, F2.3a, F2.3b) and one joining surface (F2.1a, F2.2b, F2.2a, F2.2b , F2.3a, F2.3b) has a marginally limiting, predetermined working contour (L3), b) applying a feature element ( 2.1 . 2.2 . 2.3 , ..., 2.n ) with the joint surface (F2.1a, F2.2b, F2.2a, F2.2b, F2.3a, F2.3b) on a joining surface (F2.1a, F2.2b, F2.2a, F2.2b, F2 .3a, F2.3b) of an underlying formula element ( 2.1 . 2.2 . 2.3 , ..., 2.n ), wherein contours (L1, L2, L3) of the superposed form elements ( 2.1 . 2.2 . 2.3 , ..., 2.n ) are in alignment, c) connecting the form elements ( 2.1 . 2.2 . 2.3 , ..., 2.n ) and d) partially removing one of the contours (L1, L2, L3) of the connected form elements ( 2.1 . 2.2 . 2.3 , ..., 2.n ), wherein a circumferential portion of the working contour (L1) at least in the region of a free joint surface (F2.1a, F2.2b, F2.2a, F2.2b, F2.3a, F2. 3b) for connection to another form element ( 2.1 . 2.2 . 2.3 , ..., 2.n ) ( 2.1 . 2.2 . 2.3 , ..., 2.n ) is not or not completely removed. Method according to claim 1, wherein the shaped elements ( 2.1 . 2.2 . 2.3 , ..., 2.n ) have a working strength (S1). Method according to one of the preceding claims, wherein prior to applying a further formula element ( 2.1 . 2.2 . 2.3 , ..., 2.n ) the working strength (S1) is removed to a predetermined final thickness (S2). Method according to one of the preceding claims, wherein the working contour (L3), if necessary the working strength (S1), greater than the final contour (L1) and possibly the final thickness (S2). Method according to one of the preceding claims, wherein the working contour (L3) and the final contour (L1) and, if necessary, the working strength (S1) and the final strength (S2) calculated by means of a predetermined algorithm with a computer become. Method according to one of the preceding claims, wherein the removal by means of milling ( 3 ) or laser is performed. Method according to one of the preceding claims, wherein the removal to the final contour (L1) and / or the final thickness (S2) by means of the computer in accordance performed with the calculation becomes. Method according to one of the preceding claims, wherein the steps lit. b) to lit. d) until the shaped body ( 1 ) has a predetermined shape. Method according to one of the preceding claims, wherein after joining with a last molding element ( 2.1 . 2.2 . 2.3 , ..., 2.n ) the step lit. d) omitted and a predetermined final contour (L1) of the shaped body ( 1 ) will be produced. Method according to one of the preceding claims, wherein joining by welding or Soldering is performed. Method according to one of the preceding claims, wherein as molding elements ( 2.1 . 2.2 . 2.3 , ..., 2.n ) sheet-shaped elements used who the. Method according to one of the preceding claims, wherein the shaped elements ( 2.1 . 2.2 . 2.3 , ..., 2.n ) by joining a plurality of sub-elements ( 4 . 4.1 . 4.2 ) getting produced. Method according to one of the preceding claims, wherein the sub-elements ( 4 . 4.1 . 4.2 ) are made of at least two different materials. Method according to one of the preceding claims, wherein for the production of the molded elements ( 2.1 . 2.2 . 2.3 , ..., 2.n ) the subelements ( 4 . 4.1 . 4.2 ) are arranged in a predetermined geometry. Method according to one of the preceding claims, wherein the joining surfaces (F2.1a, F2.2b, F2.2a, F2.2b, F2.3a, F2.3b) of the mold ( 2.1 . 2.2 . 2.3 , ..., 2.n ) and / or subelements ( 4 . 4.1 . 4.2 ) are coated with a joining agent, preferably a solder, a flux or an adhesive. Method according to one of the preceding claims, wherein as a first shaped element ( 2.1 . 2.2 . 2.3 , ..., 2.n ) a monocrystalline substrate ( 7 ) with at least one substrate joining surface and a predetermined working contour (L3) bordering the substrate joining surface is used. Method according to one of the preceding claims, wherein for bonding or after bonding a substrate ( 7 ) superimposed form element ( 2.1 . 2.2 . 2.3 , ..., 2.n ) at least in a region covering the substrate surface and the substrate ( 7 ) is partially melted at least in a substrate section surface containing the first portion, and wherein the melt (S) is cooled so that a solidification front ( 8th ) from the unmelted second portion of the substrate ( 7 ) in the direction of a free joining surface (F2.1a, F2.2b, F2.2a, F2.2b, F2.3a, F2.3b) of the formula element ( 2.1 . 2.2 . 2.3 , ..., 2.n ) moves. Method according to one of the preceding claims, wherein an angle α between a normal to the free joining surface (F2.1a, F2.2b, F2.2a, F2.2b, F2.3a, F2.3b) and a normal to the solidification front ( 8th ) <45 °, preferably <40 °. Method according to one of the preceding claims, wherein the shaped element ( 2.1 . 2.2 . 2.3 , ..., 2.n ) is melted along a given before way. Method according to one of the preceding claims, wherein the shaped element ( 2.1 . 2.2 . 2.3 , ..., 2.n ) is repeatedly melted overlapping, in particular along predetermined paths. The method of claim 20, wherein when overlapping Melt a polycrystalline region of an adjacent melting trace is melted.