DE102018107562A1 - Method for producing a component by means of powder-based 3D printing and such a component - Google Patents

Abstract

The invention relates to a method for producing a component by means of powder-based 3D printing and such a component. It is provided that a method for producing a component by means of powder-based 3D printing with at least one electrically conductive region (24, 38, 52) and at least an electrically insulating region (22, 36, 50) is provided. The method comprises the following steps: aligning a laser device (16) over a multi-material powder material, the laser device (16) being designed to have at least two different laser parameters, and processing the multi-material powder material by means of the laser device ( 16) for the production of the component, wherein a defined use of the two laser parameters is used. The multi-material powder material is produced from at least two materials, wherein the at least two materials have different melting and boiling points, such that at least one electrically conductive region (24, 24, 12) during processing due to the action of the different laser parameters on the multi-material powder material. 38, 52) and at least one electrically insulating region (22, 36, 50) is produced in the component.

Description

The invention relates to a method for producing a component by means of powder-based 3D printing and such a component itself.

For the production of components in 3D printing, there are various methods that are based on the local melting of a powdery starting material by a laser beam. The component produced thus consists of the same material as the starting powder. This limits the functionality of 3D-printed components to geometric functions (illustrative objects) and purely mechanical functions (plastic or metal components).

To extend the functionality of 3D printed components, it is necessary to realize different materials within a component. Thus, the integration of sensory or electrical functions requires electrically conductive or insulating materials in order to be able to produce conductor tracks in a base body. At the same time, at least two different materials and thus at least two different starting powders have always had to be used (multi-material component). In particular, in the powder bed-based process (SLS = selective laser sintering, SLM = selective laser melting), this requires a high overhead.

For the production of multi-material components in laser-based 3D printing, there are several approaches in powder bed-based processes which are based on the local deposition of a second material which is also in powder form. The local deposit is realized via ring coater, perforated discs, additional nozzles or a photoreceptor handling device (xerography).

Furthermore, there is an approach in which the printing process is interrupted again and again to suck powder from a previously printed shell-shaped cavity locally and fill the cavity with a paste-like secondary material, which is then cured via the laser.

The known solutions, which are based on the use of different powder starting materials, have the main drawback that mixing of the powders can not be completely avoided. Thus, the powder used in a printing process, which is not melted together directly to the component, can only be used to a limited extent for the production of another component. This results in high costs, since in conventional components, which are produced in 3D printing, only a small proportion of the powder required for the printing process forms the later component.

Another disadvantage is the wear on moving parts, such as the scraper or perforated disc, which occurs as a result of the abrasive action of the powder.

Another major disadvantage of the previously known methods is the web-like application of the filler and, if necessary, additional necessary steps, such as the multiple suction of powder for the paste application. As a result, the productivity compared to a mono-material printing process, in which powder material is distributed flat by a doctor, significantly reduced. Furthermore, the process control and the required equipment are much more complex than when processing a single output powder.

An example of a process with at least two different materials is in the DE 10 2014 007 562 A1 disclosed. An apparatus and a method for the production of three-dimensional molded parts with integrated pattern structure is shown. In this case, an additive manufacturing method is used, wherein the molded part itself is made of a non-electrically conductive material and the integrated circuit pattern is made of an electrically conductive material. The electrically conductive material consists of a TCO ink (TCO = transparent conducting oxides, transparent conductive oxides).

From the DE 10 2015 101 430 A1 For example, a method and apparatus for making three-dimensional objects composed of thick film and thin film structures will be described. In this case, at least two coating heads are moved relative to a workpiece, wherein the heads each produce different layers. For example, the thick structure may be made of plastic or ceramic, while the thin layers may be metal layers. In this respect, can be realized with two different materials, which are applied from each separate printheads, a hybrid material structure. For example, plastic bodies with embedded conductor tracks can thus be produced.

From the DE 20 2015 103 801 U1 is a 3D printer for the production of a space-shaped component as known to remove. The printer has two print heads, wherein one print head processes a plastic-containing base material and the other print head can produce an electrical functional element.

The invention is based on the object, a method for producing a component by means of powder-based 3D printing and such To provide component, which has an efficient and therefore cost-effective approach.

In a preferred embodiment of the invention, it is provided that a method for producing a component by means of powder-based 3D printing with at least one electrically conductive region and at least one electrically insulating region is provided. The method comprises the following steps: aligning a laser device over a multi-material powder material, wherein the laser device is designed to have at least two different laser parameters, and processing the multi-material powder material by means of the laser device for producing the component, wherein a defined use of the two laser parameters is used. The multi-material powder material comprises at least two materials, wherein the at least two materials have different melting and boiling points, such that at least one electrically conductive region and at least one electrically insulating region during processing due to the action of the various laser parameters on the multi-material powder material Area is made in the component.

The invention thus consists in a method for producing a component with electrically conductive and insulating regions by powder-based 3D printing, wherein, in contrast to the known methods, only one powder material is used, which is produced from at least two materials. A defined use of the two laser parameters is to be understood such that a respective laser parameter is used in each case for a specific area of the component to be manufactured. This can be achieved by means of the laser device in the desired manner by the at least two laser parameters are controlled accordingly. In this way, an efficient method is possible, since directly and immediately only one starting powder material has to be processed by means of a laser device.

The advantage of the invention is that it can be used for producing a multi-material component in 3D printing with a conventional 3D printer for a monomaterial system with comparatively high productivity. In contrast to the previously known systems, no additional and complex material application systems, nozzles or suction systems are necessary, which can significantly slow down the component production process. Furthermore, eliminates the problem of unwanted mixing occurring when using multiple powders. As a result, the excess powder for the production of a component can be used to produce further components.

Further preferred embodiments of the invention will become apparent from the remaining, mentioned in the dependent claims characteristics.

In a further preferred embodiment of the invention, it is provided that the multi-material powder material is particulate and all powder particles of the multi-material powder material have substantially the same structure. The powder thus consists of several different materials or elements, which in conjunction with the laser parameters in 3D printing, the conductivity when connecting the particles can be set locally. The laser is thus not only a tool for melting the particles, but additionally causes a locally defined modification of the powder particles in terms of their structure and / or composition, whereby the resulting component can be influenced in various areas in terms of electrical conductivity. The essential difference to other methods is therefore the use of a multi-material powder whose conductivity can be adjusted locally via modification of the particles by the laser parameters. For this purpose, the materials present in a powder particle have different melting and boiling points, so that targeted individual materials are treated differently by adjusting the laser parameters. In this way, an efficient method is possible, as by means of a laser device directly and immediately only one starting powder material has to be processed.

Furthermore, in a preferred embodiment of the invention, it is provided that a core of at least one powder particle comprises an electrically conductive material and a shell of the powder particle comprises an electrically insulating material. By adjusting the laser parameters, a material can be selectively melted and / or removed. Thus, the adjustment of the conductivity can be accomplished, for example, by the removal of a single material component of the particulate powder. In this variant, the particles have a core of a conductive material. This core is covered with an electrically insulating material. By setting the laser parameters, it is now possible, for example, to produce a region in which only the sheathing in the edge region is melted. This results in a cohesion of several particles, in which the conductive powder cores are not connected to each other and thus acts electrically insulating. On the other hand, the laser parameters can be adjusted so that the sheath is vaporized / ablated and the materials are melted in the core, creating an electrically conductive area. In this way, an efficient method is possible, since directly and immediately only one starting powder material has to be processed by means of a laser device.

It is also provided in a preferred embodiment of the invention that a core of at least one powder particle comprises an electrically insulating material and a shell of the powder particle comprises an electrically conductive material. In this variant, therefore, the powder particles have a core of an electrically insulating material, which is coated with an electrically conductive sheath. By local adjustment of the laser parameters, either the cladding can be fused, resulting in a conductive bond, or the cladding is ablated and the cores are sintered together to form an insulating composite. In this way, an efficient method is possible, since directly and immediately only one starting powder material has to be processed by means of a laser device.

In addition, in a preferred embodiment of the invention, an envelope of at least one powder particle comprises an electrically conductive material and a core of the powder particle comprises an electrically insulating material, the shell being at least partially melted by the action of a first laser parameter from the laser device such that the materials of the sheath and the core form a composite material, whereby a first region is transformed, which differs in terms of its electrical conductivity of a second region, which is processed with a second laser parameter of the laser device. It is thus possible to choose the materials or chemical elements within a powder particle so that only the outer region of a particle is melted by setting the laser parameters to create a composite, creating a compound that differs in conductivity from the only on the edge region differs melted particles. In this way, an efficient method is possible, since directly and immediately only one starting powder material has to be processed by means of a laser device.

It is also provided in a preferred embodiment of the invention that a shell of at least one powder particle comprises an electrically conductive material and a core of the powder particle comprises an electrically insulating material, wherein the material from the shell by means of a first laser parameter from the laser device react chemically with the material from the core to form a new material, thereby transforming a first region that differs in electrical conductivity from a second region being processed by the laser device with a second laser parameter. It is thus possible to choose the materials or chemical elements within a powder particle so that react by containing the laser parameters to create a composite, the materials containing each other in the common melting. The adjustment of the conductivity can thus be achieved not only by the removal of a single material component of the powder, but also by the chemical modification in the simultaneous melting of at least two materials. In this way, an efficient method is possible, since directly and immediately only one starting powder material has to be processed by means of a laser device.

In a further preferred embodiment of the invention it is provided that a shell of at least one powder particle comprises an electrically conductive material and a core of the powder particle comprises an electrically insulating material, wherein the material from the shell with by means of one of the laser parameters of the laser device alloying the material from the core thereby transforming a first region which differs in electrical conductivity from a second region being processed by the laser device with a second laser parameter. It is thus possible to select the materials or chemical elements within a powder particle such that by adjusting the laser parameters to create a composite, the containing materials form an alloy. The adjustment of the conductivity can thus be achieved not only by the removal of a single material component of the powder, but also by the chemical modification in the alloy formation in the simultaneous melting of at least two materials. In this way, an efficient method is possible, since directly and immediately only one starting powder material has to be processed by means of a laser device.

Furthermore, it is provided in a preferred embodiment of the invention that the electrically conductive material is a metal and the electrically insulating material is a polymer or sand or ceramic. These materials have been found to be particularly suitable for an efficient process. For example, the individual particles of the multi-material powder material may include a polymer sheath and a metal core. Also, a core of an electrically insulating material such as sand or other oxide ceramic is conceivable, which is coated with an electrically conductive sheath, for example made of metal. Also, ceramic cores are conceivable, which are sintered together, for example, to form an insulating composite.

It is also provided in a preferred embodiment of the invention that the electrically conductive material is aluminum and the electrically insulating material is silicon. These materials have also been found to be particularly suitable for an efficient process. A possible example for this would be silicon particles encased in aluminum, in which either the aluminum shell is melted or the aluminum melt is heated to such an extent that the silicon dissolves therein and a hypereutectic aluminum-silicon alloy is formed.

Finally, it is provided in a preferred embodiment of the invention that a component is provided, which with a method according to claims 1 to 9 will be produced. In principle, such a component is applicable in all vehicles in the form of electronics or sensors as well as in molds in the manufacture of plastic components. In the form of electronics and sensors such components are in principle everywhere applicable (rail vehicles, power engineering, etc.). Moreover, such a component is applicable in molds for the production of plastic components for all industries.

In general, it is also conceivable to transfer this approach of multi-material 3D printing to locally different heat conduction.

The various embodiments of the invention mentioned in this application are, unless otherwise stated in the individual case, advantageously combinable with each other.

• 1 ein Pulverpartikel eines Multi-Material-Pulverwerkstoffs;
• 2A einen Zustand von Pulverpartikeln gemäß 1 des Multi-Material-Pulverwerkstoffs vor der Behandlung mit einer Laservorrichtung;
• 2B einen Zustand von Pulverpartikeln gemäß 1 des Multi-Material-Pulverwerkstoffs nach der Behandlung mit einer Laservorrichtung;
• 3 ein anderes Pulverpartikel eines anderen Multi-Material-Pulverwerkstoffs;
• 4A einen Zustand der anderen Pulverpartikel gemäß 3 des anderen Multi-Material-Pulverwerkstoffs vor der Behandlung mit einer Laservorrichtung;
• 4B einen Zustand der anderen Pulverpartikel gemäß 3 des anderen Multi-Material-Pulverwerkstoffs nach der Behandlung mit einer Laservorrichtung;
• 5 ein weiteres Pulverpartikel eines weiteren Multi-Material-Pulverwerkstoffs;
• 6A einen Zustand der weiteren Pulverpartikel gemäß 5 des weiteren Multi-Material-Pulverwerkstoffs vor der Behandlung mit einer Laservorrichtung;
• 6B einen Zustand der weiteren Pulverpartikel gemäß 5 des weiteren Multi-Material-Pulverwerkstoffs nach der Behandlung mit einer Laservorrichtung.

The invention will be explained below in embodiments with reference to the accompanying drawings. Show it:

• 1 a powder particle of a multi-material powder material;
• 2A a state of powder particles according to 1 the multi-material powder material before treatment with a laser device;
• 2 B a state of powder particles according to 1 the multi-material powder material after treatment with a laser device;
• 3 another powder particle of another multi-material powder material;
• 4A a state of the other powder particles according to 3 the other multi-material powder material before treatment with a laser device;
• 4B a state of the other powder particles according to 3 the other multi-material powder material after treatment with a laser device;
• 5 another powder particle of another multi-material powder material;
• 6A a state of the other powder particles according to 5 the further multi-material powder material before treatment with a laser device;
• 6B a state of the other powder particles according to 5 further multi-material powder material after treatment with a laser device.

1 shows a powder particle 10 a multi-material powder material. A case 12 is constructed of an insulating material, such as a polymer, and a core 14 is constructed of a conductive material, such as metal.

2A shows a state of powder particles 10 of the multi-material powder material prior to treatment with a laser device 16 , The laser device 16 is directed to the multi-material powder material so that unillustrated laser beams can strike the material for the purpose of processing. A block arrow points with respect to the image plane from left to right and indicates the direction of movement of the laser device 16 at. The multi-material powder material consists of the individual powder particles 10 from 1 , In first areas 18 become the powder particles 10 of the multi-material powder material with a first laser parameter and in a second range 20 edited with a second laser parameter. As the laser device 16 is not aligned above the corresponding areas, are the individual powder particles 10 still in their original condition.

2 B shows a state of powder particles 10 of the multi-material powder material after treatment with a laser device 16 , where now the laser device 16 relative to the image plane from left to right was guided over the material. This is again indicated by a block arrow. The individual powder particles 10 were exposed to the effect of the two laser parameters, leaving an electrically insulating area 22 and an electrically conductive area 24 were manufactured. Here, the material of the shell 12 in the electrically insulating region connected to each other and in the electrically conductive region 24 volatilizes, so that now there is the material of the core 14 (or the individual cores) remains.

3 shows another powder particle 26 a multi-material powder material. A case 28 is made of a conductive material, for example metal, built and a core 30 is constructed of an insulating material, such as a polymer.

4A shows a state of powder particles 26 of the multi-material powder material prior to treatment with a laser device 16 , The laser device 16 is directed to the multi-material powder material so that unillustrated laser beams can strike the material for the purpose of processing. A block arrow points with respect to the image plane from left to right and indicates the direction of movement of the laser device 16 at. The multi-material powder material consists of the individual powder particles 26 from 3 , In first areas 32 become the powder particles 26 of the multi-material powder material with a first laser parameter and in a second range 34 edited with a second laser parameter. As the laser device 16 is not aligned above the corresponding areas, are the individual powder particles 26 still in their original condition.

4B shows a state of powder particles 26 of the multi-material powder material after treatment with a laser device 16 , where now the laser device 16 relative to the image plane from left to right was guided over the material. This is again indicated by a block arrow. The individual powder particles 26 were exposed to the effect of the two laser parameters, leaving an electrically insulating area 36 and an electrically conductive area 38 were manufactured. Here, the material of the shell 28 in the electrically conductive region 38 connected together so that it is now electrically conductive. In the electrically insulating region 36 has the material of the shell 28 volatilizes, leaving the material of the core 30 (or the cores) remains and this is now electrically insulating.

5 shows another powder particle 40 a multi-material powder material. A case 42 is constructed of a conductive material, such as aluminum, and a core 44 is constructed of an insulating material, such as silicon.

6A shows a state of powder particles 40 of the multi-material powder material prior to treatment with a laser device 16 , The laser device 16 is directed to the multi-material powder material so that unillustrated laser beams can strike the material for the purpose of processing. A block arrow points with respect to the image plane from left to right and indicates the direction of movement of the laser device 16 at. The multi-material powder material consists of the individual powder particles 40 from 5 , In the first area 46 become the powder particles 40 of the multi-material powder material with a first laser parameter and in a second range 48 edited with a second laser parameter. As the laser device 16 is not aligned above the corresponding areas, are the individual powder particles 40 still in their original condition.

6B shows a state of powder particles 40 of the multi-material powder material after treatment with a laser device 16 , where now the laser device 16 relative to the image plane from left to right was guided over the material. This is again indicated by a block arrow. The individual powder particles 40 were exposed to the effect of the two laser parameters, leaving an electrically insulating area 50 and an electrically conductive area 52 were manufactured. Here, the material of the shell 42 in the electrically conductive region 52 connected together so that it is now electrically conductive. In the electrically insulating area 50 Again, the material has the shell 42 such with the material from the core 44 connected, that the resulting and fused together alloy is electrically insulating.

LIST OF REFERENCE NUMBERS

10

powder particles

12

shell

14

core

16

laser device

18

first area

20

second area

22

electrically insulating area

24

electrically conductive area

26

other powder particles

28

shell

30

core

32

first area

34

second area

36

electrically insulating area

38

electrically conductive area

40

further powder particles

42

shell

44

core

46

first area

48

second area

50

electrically insulating area

52

electrically conductive area

QUOTES INCLUDE IN THE DESCRIPTION

This list of the documents listed by the applicant has been generated automatically and is included solely for the better information of the reader. The list is not part of the German patent or utility model application. The DPMA assumes no liability for any errors or omissions.

Cited patent literature

• DE 102014007562 A1 [0009]
• DE 102015101430 A1 [0010]
• DE 202015103801 U1 [0011]

Claims (10)

Method for producing a component by means of powder-based 3D printing with at least one electrically conductive region (24, 38, 52) and at least one electrically insulating region (22, 36, 50), comprising the following steps: aligning a laser device (16) over one Multi-material powder material, wherein the laser device (16) is designed to have at least two different laser parameters, processing the multi-material powder material by means of the laser device (16) for producing the component, wherein a defined use of the two laser parameters is used, characterized in that the multi-material powder material is made of at least two materials, wherein the at least two materials have different melting and boiling points, so that when editing due to the action of the various laser parameters on the multi-material powder material at least one electrically conductive Area (24, 38, 52) and the an electrically insulating region (22, 36, 50) is produced in the component. Method according to Claim 1 wherein the multi-material powder material is particulate and all powder particles (10, 26, 40) of the multi-material powder material have substantially the same structure. Method according to Claim 2 wherein a core (14) of at least one powder particle (10) comprises an electrically conductive material and a shell (12) of the powder particle (10) comprises an electrically insulating material. Method according to Claim 2 wherein a core (30) of at least one powder particle (26) comprises an electrically insulating material and a sheath (28) of the powder particle (26) comprises an electrically conductive material. Method according to Claim 2 in which a sheath (42) of at least one powder particle (40) comprises an electrically conductive material and a core (44) of the powder particle (40) comprises an electrically insulating material, the laser device (16) being influenced by a first laser parameter. the shell (42) is at least partially melted so that the materials of the shell (42) and the core (44) form a composite material, whereby a first region (46) is transformed, which is based on its electrical conductivity of a second Area (48), which is processed by a second laser parameter of the laser device (16), different. Method according to Claim 2 in which a sheath (42) of at least one powder particle (40) comprises an electrically conductive material and a core (44) of the powder particle (40) comprises an electrically insulating material, the laser device (16) being influenced by a first laser parameter. the material from the sheath (42) chemically reacts with the material from the core (44) to form a new material, thereby transforming a first region (46) having a second region relative to its electrical conductivity (48) which is processed by a second laser parameter from the laser device (16) differs. Method according to Claim 2 wherein a sheath (42) of at least one powder particle (40) comprises an electrically conductive material and a core (44) of the powder particle (40) comprises an electrically insulating material, wherein by means of one of the laser parameters of the laser device (16) the material of the sheath (42) is alloyed with the material of the core (44), thereby transforming a first region (46) having a second region (48) with respect to its electrical conductivity and a second region (48) Laser parameter of the laser device (16) is processed differs. Method according to one of the preceding claims, wherein the electrically conductive material is a metal and the electrically insulating material is a polymer or sand or ceramic. Method according to Claim 8 wherein the electrically conductive material is aluminum and the electrically insulating material is silicon. Component, which with a method according to one of Claims 1 to 9 will be produced.

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