DE102018213111A1 - Material system and method for manufacturing a component in an additive manufacturing process - Google Patents

Abstract

The invention relates to a material system for producing a component in an additive manufacturing process with at least a first group of particles (203, 301, 302, 303, 400, 401, 402, 500, 800, 802, 1002, 1003, 1200, 1201 , 1300), each of which has a defined geometric shape and size. This allows the individual particles to be placed optimally in a powder cake while achieving a high material density.

Description

The invention is in the field of production technology and relates in particular to layer construction techniques that are used in additive manufacturing processes. Such additive manufacturing processes are usually characterized by a layered structure of components, for example by successive addition of particles or drops and their selective binding.

Additive manufacturing methods are generally used in machine tools that are used for the production of prototypes or for one-off production. The additive manufacturing processes currently used are sometimes too complex, slow and expensive for use in production machines. Nevertheless, additive manufacturing processes could be used in the future both in the manufacture of individual products and in series production.

Machines for additive manufacturing that work according to the layer construction principle are usually called 3D printers. An example of the 3D printing process is the stereolithography process, in which a resin is hardened in layers by a laser beam ( US 4,575,330 ).

In addition, so-called fused deposition modeling methods are known, in which material is deposited on a construction platform in the form of an extrudate of a meltable mass in each case by means of a nozzle in accordance with a virtual sectional image of the object to be produced. The so-called multi-jet modeling processes work similarly, in which liquid droplets are joined together by means of a large number of nozzles. There, too, the material added in the manner mentioned is cured with radiation ( US 6,259,962 ).

The methods mentioned have the disadvantage that the added material initially remains deformable and has to be supported until it hardens.

In contrast to this, powder-based processes first allow the creation of a powder bed that surrounds the contour of the object to be manufactured. Only then are the areas of the total volume that make up the body to be manufactured connected and / or hardened. This can be done in layers or in larger volumes (cf. US 5 340 656 . US 5,155,324 ). The connection of the selected particles can be achieved, for example, by printing with an adhesive or by fusing with an energy-rich jet.

In principle, it is desirable for many production tasks to produce bodies that are as solid as possible and that have high stability. In many cases, the powder-based process poses the problem that only a limited amount of space can be achieved through the loose filling of the powder material. The space filling is only incompletely improved by fusing or connecting the particles using additional adhesives. In addition, deformations of the component to be produced cannot be ruled out in some manufacturing processes by sticking together with the shrinkage (polymerisation shrinkage) that usually occurs. Such a problem is, for example, in the EP 2 054 216 addressed.

Against the background of the prior art, the present invention is based on the object of improving the handling and processing of the powder material in an additive manufacturing process.

The problem is solved with a material system with the features of claim 1. Claims 2 to 10 represent advantageous configurations of such a material system. In addition, the invention relates to a method for producing a body with such a material system according to the features of claim 11 Claims 12 to 15 show advantageous implementations of such a method. Claim 16 relates to a device for producing a body with a material system according to the invention.

Accordingly, the invention relates to a material system for producing a component in an additive manufacturing process with at least a first group of particles, each of which has a defined geometric shape and size.

The currently known particle-based additive manufacturing processes (for example layer construction processes) are based on the fact that in planning a body to be produced is virtually broken down into different successive layers and these layers are produced in a sequential manner. For this purpose, a powder bed is first created on a construction platform, this powder bed is selectively solidified in sections and then the next particle layer is applied to the powder bed. The particles that form the body to be produced are thus connected to one another in layers and later remain as a solid body after the excess powder bed has been removed. By removing the excess powder, the body to be produced is exposed at the end of the process. The connection of the particles to one another can be achieved by methods known per se, such as printing with binders, activators or catalysts, and the like selective melting by radiation, for example laser radiation, or similar processes. It is also possible to selectively dissolve particles with a suitable solvent using a print head for selective processing of the particles. The added binders have the function in common that they are intended to bind neighboring particles to one another either by chemical reactions or by drying processes.

The techniques mentioned are characterized, inter alia, by the fact that during the actual solidification steps of the body to be produced there is a volume contraction of the binder or the melt. This volume contraction must be compensated for or taken into account or even compensated for. The size of such a shrinkage or deformation effect depends, among other things, on the layer thickness. The voids in the particle bed determine, for example, the amount of binder or melt added. It is therefore advantageous to optimize the bulk density in the powder bed or to prevent or minimize any deformation or change in the particles or their positions relative to one another. This is achieved by using a group or a plurality of particles, each of which has a defined geometric shape and size.

According to the prior art, powder materials are used for additive manufacturing technology, in which the individual particles of the powder vary in size and shape according to a statistical distribution and are indefinite. This is usually production-related and depends on the type of production of the powder particles. In the prior art, volume fillings in the powder bed of the order of 50% can be achieved.

The material system according to the invention allows particles to be assembled into a bed, which enables particularly good packing. For this purpose, particles with a special shape and size are to be used. Various forms are conceivable for this, which are explained in more detail below. Overall, however, characteristic of the invention is the idea of using particles with a defined geometric shape and size. This enables the degree of filling of the bulk of the powder bed to be predicted and optimized. In addition, a special design of the particles in many cases permits a targeted arrangement and / or orientation of the particles, which is useful for a further increase in the degree of filling.

The group of particles with a defined geometric shape and size enables the selection of suitable measures which can increase the packing density of the particles or the powder bed. These measures can include, for example, vibration of the powder bed, vibration of the particles added to the powder bed, orientation of the particles before they are deposited in the powder bed, or targeted positioning of each individual particle relative to the particles already in the powder bed and / or relative to those added at the same time Include neighboring particles. A defined geometric shape and size can be understood to mean, for example, a mathematically defined and reproducible shape which, for example, defines and describes the outer contour of the particles by means of a function or a mathematical approximation. It can also be understood to mean a shape and size that is determined by the production process to the usual tolerances. In this case, the term of the defined geometric shape and size should include the deviations in shape and / or size that are inevitable during the production process.

For example, it can be particularly advantageously provided that the particles of the first group each have the same geometric shape and size. A symmetrical and homogeneous distribution of the particles of the first group can thus be achieved in a simple manner. However, it is also conceivable that the particles of the first group have the same geometric shape, but a size distribution with different sizes. It is also possible that the particles of the first group each have the same size, measured for example by the volume of a particle, an edge length, the diameter or the greatest linear extent, but have different geometric shapes. The shape of the particles can be designed such that the particles can be arranged in a row or in a layer, for example, or stacked in the direction perpendicular to the individual layers. “Same” shape and size should also be understood to mean shapes and sizes that differ from a standard shape or standard size only by manufacturing tolerances.

In addition, an implementation can provide that, in addition to the first group, at least one second group and in particular at least one further group of particles is provided, the particles of the second group and in particular of the further groups relating to one another and / or from the particles of the first group distinguish the geometric shape and / or size. The shape and / or size of the particles within one of the groups should, however, correspond in each case or should essentially agree up to tolerances. For example, the particles of the second group can be selected with regard to their shape and / or size so that they are in pairs or in larger groups match each other with the particles of the first group, in particular form-fitting. In connection with the particles of the first group, the particles of the second group can for example also fill gaps between the particles of the first group or vice versa. Overall, the particles of the first and second groups and in particular also further groups can be coordinated with one another in such a way that a periodic arrangement of the particles from different groups in alternation enables a high filling density.

In a further implementation it can be provided, for example, that the particles of the first group and / or the second group and / or at least one further group each have at least one, at least two or at least three straight edges and / or at least one or at least two or at least three have flat interfaces.

In the case of a space-saving arrangement of particles of a first group relative to one another or also of particles of a first and a further group relative to one another, the individual particles can be aligned such that the straight edges of respectively adjacent particles are aligned parallel to one another and in particular are positioned adjacent to one another. This then minimizes a space between the particles which abut each other on their straight edges. In extreme cases, the particles can at least partially have a prismatic shape or the shape of a cube or cuboid.

In this context, the term “prismatic” should be understood to mean a geometric volume shape, which is defined by the volume which is penetrated by moving a base area along a straight line in space.

With some prism shapes, 100% volume filling can be achieved, for example with triangular prisms, while with other prism shapes, such as cylinders, 100% volume filling cannot be achieved.

In one implementation it can also be provided that each particle of the first group and / or the second group and / or at least one further group has at least two, in particular at least three mutually parallel edges or at least two mutually parallel interfaces.

The provision of straight and / or mutually parallel interfaces in a group of particles or in a plurality of groups of particles can also be used to achieve a high volume filling by depositing the particles adjacent to one another in the powder bed such that the straight edges or Adjacent surfaces of adjacent particles. Theoretically, if certain prismatic shapes are used, for example cubes or cuboids, a volume fill of 100 percent can be achieved.

A further implementation can provide, for example, that each particle of the first group and / or the second group and / or at least one further group has a prismatic shape, in particular the shape of a triangular, quadrangular or polygonal prism or a circular or elliptical cylinder. This can also be achieved, for example, if only the first group or only a first and second group of particles is provided.

A further implementation of the material system can provide that each particle of the first group and / or the second group and / or at least one further group is produced from a base body by extrusion or by cutting or punching, the base body in particular having plane-parallel cover surfaces. This also applies if only the first group or only two groups of particles are provided. All particles can thus also belong to the same first group and be produced by extrusion or cutting or punching.

When producing particles by extrusion, it can be ensured that the individual particles have the shape of a cylinder or a prism in cross-section, and it is only necessary to ensure that all particles have the same size by being cut to length. By punching out the particles from a sheet or a flat plate it can be achieved, for example, that all particles have the same reproducible shape.

If, for example, the particles in the form of slugs, that is to say plane-parallel round plates, are produced by punching, each layer of such particles can be individually produced very homogeneously by placing the individual particles next to one another. The method of positioning the individual particles is discussed in more detail below.

Stamping is a possible manufacturing process for the targeted shaping of prismatic particles. Cylindrical sections can also be produced from wires. Different cross sections are also possible here.

Prismatic bodies can also be cut out of sheet metal with a laser. This gives great freedom of form and different shapes can be created in one production step.

The creation of prismatic bodies cannot only be done by cutting or separating. Such bodies can also be created constructively. An example is the screen printing of ceramic or metallic masses. The product produced in this way is then sintered and can be used in the layer-building process.

It is also possible to generate such particles by crystallization processes. The crystal growth is stopped at a certain size and thus a monodisperse distribution is achieved.

A further implementation of the invention can provide, for example, that each particle or part of the particles of the first group and / or of the second group and / or at least one further group has a coating and / or that all or some of the particles of the first group and / or the second group and / or at least one further group have a surface condition, in particular roughness, which differs from that of other particles. In this case, for example, the particles which are later to be selectively connected to one another for the production of the body can each be coated or can be specially designed with regard to their surface properties, so that these particles, in contrast to the neighboring particles which are to be removed later, are efficiently combined with one another can be connected. This can be done, for example, by a coating that can be selectively activated locally as a binder simply by added substances, or a roughness that enables the connection of appropriately pretreated particles by adding a binder, for example a catalyst, an activator or an adhesive. The coating itself may already have an adhesive, a solder, a binder, an activator or a catalyst, or the coating may develop binder properties by adding a further substance locally.

In addition, it can be provided, for example, that one or more particles have bores or recesses through which channels are formed within the component made from the particles. In this case, through the recesses / channels after the particles have been assembled to form the body to be produced, a system of openings / channels can be produced in a targeted manner, which produces a desired porosity and / or enables mass transport, for example gas transport, through the body to be produced.

In addition to a material system of the type described above, the invention also relates to a method for producing a body from such a material system, with provision being made for particles to be moved in succession by means of a first feed device and in particular by means of a second or further feed device, each through a feed channel of the respective Feeding device are supplied to their respective destination on a powder cake, the particles or a subset of the particles in particular having a predetermined orientation or being moved to their destination in a specific orientation.

With a suitable design of this device, particles can be conveyed exactly to their target position in the powder bed by means of a feed device. The feed device can also be designed such that in addition to the target position of the particle, the orientation of the particle can also be determined. In this way it is possible to achieve an optimized stacking and ranking of the particles in the powder bed. If several feed devices, in particular for particles from different groups, are used, the particles from different groups can also be positioned relative to one another in a targeted sequence and arrangement in the powder bed.

In this case, it can be provided, for example, that the particles are moved along the feed channel (s) by vibration or inconsistent supply of kinetic energy. This is to be understood to mean all conceivable forms of mechanical excitation, for example also excitation by means of sound or ultrasound waves.

It can also be provided that the particles are applied to the powder cake in layers, in particular in each case in a layer thickness of one particle.

It can further be provided that the particles which are to be connected to one another to form the body are selected from the available particles or particle groups in such a way that they have a property, for example a coating, which has an effective connectivity with the respectively adjacent ones Particles in the powder cake allows, or that the particles to be connected are connected at their destination in the powder cake by locally targeted addition of a substance, in particular an adhesive, a binder, an activator or a catalyst, or prepared for a connection. This step specifically ensures that the particles, each of which is intended to form part of the body to be produced, are selected such that they are set up for connection to neighboring particles. Other neighboring particles, which are arranged in the powder bed but do not belong to the actual body to be produced, do not have this quality and can be removed without further effort after the body has been produced.

Ultimately, the invention relates not only to a material system and a method for producing bodies, but also to a device for producing a body by means of a material system of the type explained above with one, two or more feed devices for particles to their respective destination on a powder cake with one each Feed channel along which the particles can each be moved to their destinations.

In order to create a layer with a high density, the particles should be able to be arranged within this layer. Vibrations can be used for such an arrangement. For this purpose, the particles are applied to a slightly inclined plane within a device for producing bodies. Due to the effect of the vibration, they run in the direction of gravity. They build up on the edge of the building container and condense. Cylindrical particles are particularly suitable for this type of processing. Due to their cylindrical shell, these form particularly lightly dense packings, since each space between two particles represents a potential sink, which the particles prefer to assume when vibrations are effective.

Cylindrical and cuboid particles can also be separated from the collective and applied to a layer under construction. For this purpose, for example, a feed device with a feed channel in the form of a nozzle can be used, which feeds individual particles as a strand of particles and can lay this strand on the already existing layer. Vibrations can in turn be used to produce the layer tightly.

To increase the assembly speed, several such nozzles can be used at the same time. Depending on the particle material, the nozzles for a single particle cannot be arranged next to one another, since the structure of a nozzle is wider than a particle itself. One way out is to arrange two rows of nozzles one above the other in the direction perpendicular to the layers to be applied and to let the particles converge on one plane.

The speed of the respective coating process can be a hindrance to the overall build rate of the layer construction process. It is therefore advisable not to create the layer in the device for the layer construction process, but outside and separately, and then to introduce this layer into the building container. In contrast to the construction in the device, a transfer step is necessary. This transfer step makes it necessary to temporarily bind the loose layer. This can be done, for example, using a switchable vacuum or, in the case of magnetic particles, using a magnetic field. The layer can then be transferred to a plate, which in turn transports the layer into the system and releases it again.

The temporary connection can also be based on a temporary binder. This binder is then removed from the powder cake after the entire construction process has been completed, thus releasing the actual component. Solving processes, melting, evaporation or sublimation can be used for removal. The means must be chosen so that the actual structure is not damaged.

The layers produced in the manner described above are characterized by a high density in the plane of a layer. The sorting process and the smallest inequalities of the particles can mean that the surface of a layer is not perfectly flat. In the further construction process, this leads to an imperfect packing and density in the vertical direction. This can also lead to packaging errors within a shift. It can therefore make sense to calibrate a new layer, whether created or placed online, in the device or beforehand outside. This can be done, for example, by pressing with a straight plate or rollers. If the particles are sufficiently firmly bonded to one another, grinding can also be an option. In this way, the surface can be leveled and the next particles can be placed safely and with a high density.

The use of cylindrical particles makes it possible, directly in analogy to the methods of the prior art, to solidify the particles by printing on a binder or using an energy beam. This is made possible because a prismatic defect remains open in a layer between the particles, through which the liquid of the binder or radiation can penetrate. The individual particles can not only be selectively solidified with one another, but also with one another.

For example, in order to distribute the liquid of the binder in the respective lower layer, it can be useful for the particles to have a structure on their surface. The structure can be channels into which the liquid of the binder is drawn by capillary forces. Likewise, such channels can point to radiation that are not directly in the Direction of penetration of the radiation source lie, to a certain extent direct.

Cuboid or cubic particles are more difficult to arrange as a dense layer than cylindrical particles. If a device with a vibration effect is used, the additional force effect can point in the direction of a corner of a cube already arranged in the layer. Since, in addition to the spatial positioning of the particles, it also has to be rotated, the energy requirement and the susceptibility to errors are higher overall.

With cubic systems, the effective access to the lower particle layers for binder or radiation is theoretically completely blocked with perfect packing. Thus, an energy input can only superficially influence particles in the layer or must penetrate the particle layer. It is therefore conceivable to realize other geometric features in addition to the global geometric shape when shaping the particles. These can be grooves which, similar to the system with cylindrical particles, direct an energy input or a substance to layers that are already hidden. However, holes can also pass through the particles. Such structures can be applied in a quasi-symmetrical manner on any surface of a cuboid. However, it is also possible to produce particles whose special characteristics are oriented. Such particles have to be correctly oriented again when the layer is created in order to function properly in the layer.

Such channels can be introduced in the manufacture of the particle using various methods. They can be created, for example, when punching using a suitably shaped tool. It is also possible to use a blank or sheet with a special surface texture that contains channels or knitted structures for a stamping process. This structure can be embossed, can be produced with an etching process or can also be applied with a laser structuring.

With the appropriate technology and sufficient throughput, the particles can also be processed individually. For example, holes can be drilled through the entire structure by a laser every millisecond.

The structuring can also introduce features that do not serve to connect the particles. Another example can be the drilling through the individual particles. For example, you can let gases escape through the generated body. Such a property is advantageous if the components are used as casting cores in a casting process.

Holes can also be drilled during the construction process. These can be used to enable an effect, such as a gas pipe. For this purpose, an already applied layer can, for example, be selectively provided with bores using a laser.

If oriented particles are used in a layer, it is possible to obtain a system using different particles and asymmetrical holes, which not only allows the layer just covered, but also, depending on the version, layers below with an effect, for example an energy input or a substance to achieve specifically. Such a structure makes it possible, for example, to prepare several layers one above the other and to selectively solidify them in a common step.

Provision can also be made to use specially shaped particles whose surface or regions close to the surface have a different composition or coating than the rest of the particle.

On the one hand, such a coating can modify the surface and make it wettable, for example, for liquids. This can be controlled in a targeted manner by applying hydrophilic or hydrophobic substances. Likewise, the surface treatment can influence the system solely through its geometric texture.

The surface can also be treated with other functional materials. In the case of chemical binders, catalysts for a solidification reaction could be deposited on the surface. For example, a solder could be applied to the surface for energy radiation-based processes.

If a layer generation method is used that separates particles and thus assembles the layer - even in a highly parallelized manner - different particles can be used in a targeted manner. This can be done in layers. So z. B. every second layer in a metallic system is a different metal to the first metal. However, it is also possible with such an arrangement to sort the particles completely individually.

Such an arrangement with specially shaped particles opens up the possibility of assembling the desired structure from the desired materials. This eliminates the need for selective consolidation, which is customary in prior art processes. The selectivity takes place in the process of building the layer. The powder cake produced in this way can, for example, be completely sintered after the build-up process.

In addition to the elimination of geometrically active units such as printheads and lasers, such an arrangement has the advantage that all layers can be built up in parallel and are only connected in a subsequent step. This makes it possible to carry out the process faster than all known processes and thus to massively increase the performance of the layer construction processes.

• 1a-c eine schematische Abbildung eines pulverbettbasierten 3D-Druckprozesses nach dem Stand der Technik,
• 2a+b ein Schema einer realitätsnahen Schüttung aus natürlichem Partikelmaterial als zweidimensionale Projektion,
• 3a+b eine Darstellung beispielhafter Packungen,
• 4a+b eine Darstellung einer erfindungsgemäßen Packung aus Partikeln mit gezielter, determinierter Formgebung,
• 5a+b ein Schema einer Packung aus gleichförmigen Zylindern als Kompromiss zwischen Fertigungstechnik und Druckverfahren,
• 6a-d erfindungsgemäße geometrische Modifikationen an Partikeln mit gezielter Formgebung,
• 7a+b eine Modifikation an Partikeln mit gezielter Formgebung durch Werkstoffbeeinflussung in oberflächennahen Bereichen,
• 8 ein Beschichtungsverfahren mit Vibrationen zur Herstellung der dichten Packung,
• 9 ein Beschichtungsverfahren mit speziell ausgebildeter Düse zur Erzeugung der Packung,
• 10 eine dreidimensionale Ausprägung des Beschichtungsverfahrens mit speziell ausgebildeten Düsen,
• 11 eine Abbildung eines Partikels mit spezieller Formgebung mit Kanälen zur Verbindung der Partikel und Kanälen zur Leitung von Gasen beim späteren Einsatz als Formwerkstoff für Gießverfahren,
• 12 eine beispielhafte Darstellung von Partikeln mit einer Kodierung unterschiedlicher Lagen,
• 13a+b ein Schema eines Pulverkuchens mit zwei verschiedenen Partikelsorten und
• 14a-c verschiedene Partikel in prismatischen Formen.

In the following, the invention is shown with reference to figures of a drawing in exemplary embodiments and explained below. Show

• 1a-c 1 shows a schematic illustration of a powder bed-based 3D printing process according to the prior art,
• 2a + b a schematic of a realistic bed made of natural particle material as a two-dimensional projection,
• 3a + b an illustration of exemplary packs,
• 4a + b a representation of a packing according to the invention made of particles with targeted, determined shaping,
• 5a + b a diagram of a pack of uniform cylinders as a compromise between manufacturing technology and printing process,
• 6a-d Geometric modifications according to the invention on particles with targeted shaping,
• 7a + b a modification of particles with targeted shaping by influencing the material in areas near the surface,
• 8th a coating process with vibrations to produce the tight packing,
• 9 a coating process with a specially designed nozzle for producing the pack,
• 10 a three-dimensional version of the coating process with specially designed nozzles,
• 11 an image of a particle with a special shape with channels for connecting the particles and channels for guiding gases when later used as a molding material for casting processes,
• 12 an exemplary representation of particles with a coding of different layers,
• 13a + b a scheme of a powder cake with two different types of particles and
• 14a-c different particles in prismatic shapes.

Exemplary embodiments of the invention

Example 1: Binder jetting process with cylindrical punch slugs

A component is to be cast using the lost-shape process. For this, a mold made of connected particle material ( 2 ), which defines the inner and outer contours of the cast component and can be removed after the casting process. After removing the mold, the desired cast component remains. The shape should follow 1a-c with an additive manufacturing process, the so-called binder jetting process. This is based on a layered structure ( 1 . 107 ) a base material made of particle material ( 1 . 105 ), which is achieved by using a binder system ( 1 . 106 ) in defined areas ( 1 . 108 ) is connected to each other. By repeating this process, it is possible to produce three-dimensional components.

Within the scope of this exemplary embodiment, 1 . 105 ) Particles in the form of so-called punch slugs ( 5 . 500 ) be used. These are created by a stamping process, such as is used industrially when punching sheet metal. The punch slugs ( 5 . 500 ) have constant dimensions and roundness due to the cutting punch and die geometry. Compared to the use of naturally broken mold raw material in particle form, such as quartz sand ( 2 . 200 ) can be produced in a targeted manner in a specific form ( 2 . 203 ) an increased and above all predictable and defined packing density ( 2 . 204 ) will be realized. The practical implementation for introducing the artificially produced raw material ( 2 . 203 ) can, for example, be created using a slightly tilted construction platform or a printer that is tilted as a whole ( 8th ).

The punch slugs ( 5 . 500 ) of the same size and shape, which can consist of a metal, a plastic, a ceramic or another material, are vibrated ( 8th . 801 ) placed in the most energetically favorable arrangement. Particles standing on the edge are thus tilted and remain in their most energetically advantageous arrangement on their largest surface, which is defined by the diameter of the slugs ( 8th . 800 ). The arranged in a line and by vibration ( 8th . 801 ) sorted particles ( 8th . 800 ) are placed over an edge on the construction field in such a way that a surface with the densest possible and defined packing density and position is created. This property can be achieved by deliberately storing all others Layers can also be reached in the direction perpendicular to the layers ( 5 . 402 ). Using a visual check, unwanted geometry deviations and sorting errors of the slugs can be automatically recognized and assigned to local locations ( 10 ).

Due to the precisely defined surfaces and geometrical dimensions of the artificially created and specifically arranged particle material ( 2 . 500 ) any particle not lying flat or tilted ( 10 . 1004 ) can be recognized individually. Using a squeegee, slightly tilted particles or particles that are not in the correct position can be pushed away.

A special feature when using the specifically manufactured and geometrically defined punching slugs ( 5 . 500 ) The basic density is the defined density over the entire construction field. The density and position of individual particles can be predicted before the process is carried out and linked to the expected properties of the manufactured body.

While using naturally broken mold raw materials ( 2 . 200 ) If the powder cake is settled by post-compression and there are typical anisotropic properties in the powder cake, these effects can be achieved when using the geometrically defined basic molding material ( 5 . 500 ) be prevented. Furthermore, the processing is extremely stable due to the always the same particles.

Each layer of punched slugs arranged next to each other and defined in terms of orientation and position ( 5 . 500 ) is via a printing process ( 1 ) with a one-component water glass binder ( 1 . 106 ) wetted. The introduction of the binder can be adjusted in terms of volume via the volume flow during the printing process. Furthermore, the wetting can be controlled locally by positioning the pressure nozzles to ensure a desired wetting. In a further process step, the water glass binder is cured by water removal using an infrared lamp that sweeps over the construction area, and the metal particles are bonded to one another. After lowering the build platform ( 1 . 102 ) another layer ( 1 . 101 ) Punching slugs ( 5 . 500 ) which are independent of the existing layer ( 1 . 108 ) positioned and can also be wetted independently with water glass binder. Through constant repetition, it is possible to produce three-dimensional components with a unique particle structure and wetting arrangement for each component layer. As already described, the entire quality control process is monitored optically, and detected errors are eliminated immediately. This means that the layer thickness is always adjusted as required, and the printed metal form is documented for further process steps in each layer. This can be important, for example, for the virtual prediction of properties in downstream processes, such as coring after a casting process.

Once the three-dimensional component has been printed, the core is unpacked from the powder bed either manually or in an automated process, and the punching slugs that are not bound together with water glass are shaken off. Due to the defined geometry of the base material ( 5 . 500 ) and the safe process control there is no hooking and wedging of individual particles, and buildup can be avoided. This represents a decisive advantage over the conventional process with naturally broken mold raw materials ( 2 . 200 ), in which the process of unpacking and releasing the buildup on the molds poses a challenge for the required technical cleanliness of the molds. Particles that are not correctly attached would loosen during the casting process and can be trapped in the cast component. This can have an impact on the mechanical properties and surface defects.

The inorganically bonded molds are set to the desired strengths by a post-curing process in the furnace before being used in a casting process and can then be poured off according to the prior art. Particular advantages of the method according to the invention are the improved dimensional stability and the good predictability of anisotropy and surface properties. The surface properties can be controlled in all dimensions depending on the process, and the anisotropy, if intended, only occurs in the direction of the layer structure. Since the anisotropy is predictable due to the defined geometry and wetting of the particles, this can be taken into account due to the process. As a result, compared to the prior art, as already described, improved dimensional stability and surface quality are possible while increasing the process stability.

Instead of cylindrical punch slugs, longer cylindrical prisms can also be used, for example 1401 ( 14a) , Triangular prisms 1402 ( 14b) or prisms with a square cross section 1403 ( 14c ) be used.

Unbound material can be easily recycled. The immediately reusable punching slugs ( 5 . 500 ) fed to a storage container and are available for another print. After casting, the bound particles can be mechanically separated and binder residues can be removed. Due to the higher melting point of the particles compared to the cast light metal, the particles are not damaged, continue to be true to size and can be reused. Removing the brittle water glass ( 1 . 106 ) of the individual particles can be accomplished, for example, by the action of a mechanical force via a baffle plate, so that the water glass flakes off the particles and can then be separated using wind views.

Example 2: Laser sintering on cubic packing

To produce a functional component with increased requirements regarding dimensional accuracy and strength properties, cubic particles ( 4 . 400 ) connected to each other by means of a laser sintering process. The initially stochastically oriented cubic individual particles ( 4 . 400 ) are over vibration ( 8th . 801 ) energized on a vibrating plate and come to rest in the most energetically favorable arrangement. The energy introduced by the vibrating plate is not sufficient to pry the particles out of this energetically favorable position again. By tilting the vibrating plate in two dimensions, the particles can be positioned side by side ( 8th . 802 ) or placed precisely on a construction platform using a vibrating trough that defines a feed channel ( 8th . 800 ). Consistent application of this principle enables the formation of a closed particle layer on the construction platform with cubic particles lined up ( 4b) , A high-density layer packing is created. As a result of positionally accurate energy input by means of a laser beam, individual particles are then specifically connected to one another within the powder bed formed in the volume of the body to be produced by fusing the contact surfaces between two particles. Certain contact areas or interfaces 700 . 701 ( 7 ) of particles 400 can be coated or roughened to facilitate sintering, gluing or soldering by local laser exposure or to make it possible in the first place.

This process is further improved by using specially prepared particles with grooves or guide channels for the passage of the laser beam ( 6b . 6c . 6d ). The intelligent positioning and lining up of guide channels and grooves enables the laser beam to be guided and guided in a targeted manner. It is therefore also possible to introduce energy to desired conventionally inaccessible connection points that are concealed by the particles lined up in a row. If required, the laser introduces further geometric features into a component layer after the individual particles have been connected in one plane. For example, cooling channels can be created by laser-cutting grooves using this process ( 6b) ,

By consistently using the layer structure, three-dimensional components with almost 100% packing density are produced. Due to the high packing density, these have strengths that can only be achieved with conventional 3D printing methods with randomly shaped base bodies while accepting residual stresses and distortion. Another effect caused by the increased packing density is the improved thermal conductivity, which in turn increases the possible power density for use in functional components, for example for foundry technology.

After completion of the 3D component, it is unpacked, and unbound particles are fed to a collecting container after the component has been removed from the construction platform. The fact that unbound particles have not undergone any thermal stress or chemical modification during the printing process means that they can be used again without any recycling effort. The component is immediately ready for use without any cleaning effort and can be used directly for any subsequent operations. For example, due to the small tolerance bands that can be achieved, threads that are imprinted in bores can be used immediately without mechanical rework.

Example 3: Sorted particle continuum with block sintering

A lost mold is required for use in foundry technology. This is done using a sorted particle continuum ( 4b) . d , H. several groups of particles with groups of different shape and / or size, which is connected by a thermal process at defined contact points, so that a compact geometry with high dimensional accuracy ( 4b . 5b) and a high surface quality that is suitable for the subsequent casting process.

To create the complex geometry with undercuts, both cubic Particles ( 4 . 400 ) with a thin coating ( 13 . 1300 ) from a low-melting solder as well as uncoated particles ( 13 . 400 ) used. The particles present in a defined position via a vibrating trough are conveyed via two separating rails. The two separating rails are arranged in a line with the opposite conveying direction. The conveying direction of the two separating rails is directed towards each other, and the individual particles ( 4 . 400 ) are positioned on a conveyor belt running at right angles to it. This ensures that targeted conveyor impulses on one of the two conveyor rails on the conveyor belt ensure that individual particles ( 8th . 800 ) is possible from one of the two conveyor rails. By juxtaposing line-shaped particle strands of a defined length, a flat particle continuum / particle arrangement with coated and uncoated particles is built. Each particle that is in direct contact with a neighboring particle with a solder coating is connected to it in the subsequent thermal process. Both the process of generating the particle lines and the stringing together of the individual particle lines to form a surface are parallelized. The individual surfaces, consisting of individual particles, are placed one above the other in a defined order, and a three-dimensional powder cake is created that already contains the desired body, albeit unbound ( 13b) ,

The powder cake is heated in an oven to a temperature just above the melting temperature of the solder coating. Any particle that is in direct contact with a coated particle is connected to it by this process. All uncoated particles ( 13 . 400 ) that are not in direct contact with a coated particle ( 13 . 1300 ) remain unaffected by the heat input far below the melting temperature of the particles themselves. Since the thermal expansion of the coated ( 13 . 1300 ) and the uncoated particles ( 13 . 400 ) Due to the fact that the coating is very thin in relation to the volume of the particles, it can be assumed to be the same.

In the subsequent unpacking process, the unbound particles ( 13 . 400 ) by lifting the mold body away from the build platform. By swiveling and rotating in all spatial directions of the form, unbound individual particles trickle ( 13 . 400 ) and collect in a collection container. As it is possible that unpacked particles (such as coated particles ( 13 . 1300 ) and they can mix with uncoated particles, all the dissolved particles are then subjected to a sorting process.

The cleaned and thermally bonded mold is now filled with melt. The hot casting material quickly cools down at the contact surface with the mold due to the very good thermal conductivity of the mold and very quickly forms a solid edge shell. This process runs faster than the melting of the bonds between the individual particles of the mold. Due to the constant heat input through the cast component into the mold, the temperature in the mold rises steadily, and the solder connections between the individual particles become detached. This effect is desired and leads to an automatic coring effect in the course of the casting process, which has to be followed up in a complex process using conventional methods.

Aspects of the Invention

• 1. Materialsystem zur Herstellung von komplexen 3D-Bauteilen mit Partikeln, deren Gestalt über mathematische Funktionen eindeutig beschreibbar und/oder determinierbar ist.
• 1a. Materialsystem zur Herstellung von 3D-Bauteilen mit Partikeln, dadurch gekennzeichnet, dass Partikel verwendet werden, deren Gestalt und/oder Größe durch einen Herstellungsprozess determiniert ist.
• 2. Materialsystem zur Herstellung von 3D-Bauteilen mithilfe eines Schichtbauprozesses, dadurch gekennzeichnet, dass Partikel verwendet werden, deren Gestalt durch eine Konstruktionsprozess oder Herstellungsprozess bestimmt ist.
• 3. Materialsystem zur Herstellung von 3D-Bauteilen mithilfe eines Schichtbauprozesses, dadurch gekennzeichnet, dass zylindrische Partikel verwendet werden.
• 4. Materialsystem zur Herstellung von 3D-Bauteilen mithilfe eines Schichtbauprozesses, dadurch gekennzeichnet, dass kubische Partikel verwendet werden.
• 5. Materialsystem zur Herstellung von 3D-Bauteilen mithilfe eines Schichtbauprozesses, dadurch gekennzeichnet, dass Partikel mit hexagonalem Grundriss verwendet werden.
• 6. Materialsystem zur Herstellung von 3D-Bauteilen mithilfe eines Schichtbauprozesses mit Partikeln, dadurch gekennzeichnet, dass die Partikel oberflächliche geometrische Modifikationen aufweisen.
• 7. Materialsystem zur Herstellung von 3D-Bauteilen mithilfe eines Schichtbauprozesses mit Partikeln, dadurch gekennzeichnet, dass die Partikel gezielt geformte Bohrungen aufweisen.
• 8. Materialsystem zur Herstellung von 3D-Bauteilen mithilfe eines Schichtbauprozesses mit Partikeln, dadurch gekennzeichnet, dass die Partikel künstliche Erhöhungen auf der Oberfläche aufweisen.
• 9. Materialsystem zur Herstellung von 3D-Bauteilen mithilfe eines Schichtbauprozesses mit Partikeln, dadurch gekennzeichnet, dass die Partikel oberflächlich werkstoffbeeinflusst sind.
• 10. Materialsystem zur Herstellung von 3D-Bauteilen mithilfe eines Schichtbauprozesses mit Partikeln, dadurch gekennzeichnet, dass die Partikel oberflächlich beschichtet sind.
• 11. Materialsystem zur Herstellung von 3D-Bauteilen mithilfe eines Schichtbauprozesses mit Partikeln, dadurch gekennzeichnet, dass die Partikel aus der Werkstoffgruppe Metalle, Kunststoffe, Keramik, Naturstoffe, Salze und Mineralien oder Mischungen daraus bestehen.
• 12. Materialsystem zur Herstellung von 3D-Bauteilen mithilfe eines Schichtbauprozesses mit Partikeln, dadurch gekennzeichnet, dass die Partikel eine maximale Kantenlänge von 10 um bis 50 cm aufweisen.
• 13. Materialsystem zur Herstellung von 3D-Bauteilen mithilfe eines Schichtbauprozesses mit Partikeln, dadurch gekennzeichnet, dass die Partikel im Inneren weitere Funktionalstrukturen aufweisen.
• 14. Materialsystem zur Herstellung von 3D-Bauteilen mithilfe eines Schichtbauprozesses mit Partikeln, dadurch gekennzeichnet, dass die Partikel im Inneren elektrisch besonders leitfähige Bereiche aufweisen.
• 15. Verfahren zur Herstellung von 3D-Bauteilen mit Partikeln, dadurch gekennzeichnet, dass Partikel verwendet werden, deren Gestalt und Größe über mathematische Funktionen eindeutig beschreibbar ist.
• 15a. Verfahren zur Herstellung von 3D-Bauteilen mit Partikeln, dadurch gekennzeichnet, dass Partikel verwendet werden, deren Gestalt durch einen Herstellungsprozess bestimmt wird.
• 16. Verfahren zur Herstellung von 3D-Bauteilen mit Partikeln, dadurch gekennzeichnet, dass die Partikel einzeln räumlich zusammengestellt werden.
• 17. Verfahren zur Herstellung von 3D-Bauteilen mit Partikeln, dadurch gekennzeichnet, dass die Partikel schichtweise auf eine Bauplattform oder auf eine schon erstellte Schicht aufgelegt werden.
• 18. Verfahren zur Herstellung von 3D-Bauteilen mit Partikeln, dadurch gekennzeichnet, dass die Partikel zu einem kompletten Pulverkuchen zusammengestellt werden.
• 19. Verfahren zur Herstellung von 3D-Bauteilen mit Partikeln, dadurch gekennzeichnet, dass die Partikel während eines Schichtbauprozesses zusammengestellt werden.
• 20. Verfahren zur Herstellung von 3D-Bauteilen mit Partikeln, dadurch gekennzeichnet, dass die Partikel parallel zu einem Schichtbauprozess zusammengestellt werden und schichtweise verwendet werden.
• 21. Verfahren zur Herstellung von 3D-Bauteilen mit Partikeln, dadurch gekennzeichnet, dass die Partikel gezielt selektiv miteinander verbunden werden.
• 22. Verfahren zur Herstellung von 3D-Bauteilen mit Partikeln, dadurch gekennzeichnet, dass die Partikel miteinander verklebt werden.
• 23. Verfahren zur Herstellung von 3D-Bauteilen mit Partikeln, dadurch gekennzeichnet, dass die Partikel selektiv verschmolzen werden.
• 24. Verfahren zur Herstellung von 3D-Bauteilen mit Partikeln, dadurch gekennzeichnet, dass die Partikel selektiv verlötet werden.
• 25. Verfahren zur Herstellung von 3D-Bauteilen mit Partikeln, dadurch gekennzeichnet, dass die Partikel über einen Verbindungsprozess als gesamter Pulverkuchen verbunden werden.
• 26. Verfahren zur Herstellung von 3D-Bauteilen mit Partikeln, dadurch gekennzeichnet, dass die Partikel über einen Verbindungsprozess als gesamter Pulverkuchen versintert werden.
• 27. Verfahren zur Herstellung von 3D-Bauteilen mit Partikeln, dadurch gekennzeichnet, dass die Partikel über einen Verbindungsprozess als gesamter Pulverkuchen verlötet werden.
• 28. Verfahren zur Herstellung von 3D-Bauteilen mit Partikeln, dadurch gekennzeichnet, dass die Partikel über einen Verbindungsprozess als gesamter Pulverkuchen verklebt werden.
• 29. Vorrichtung zur Herstellung von 3D-Bauteilen mit Partikeln, dadurch gekennzeichnet, dass in der Vorrichtung Partikel verwendet werden, deren Gestalt über mathematische Funktionen eindeutig beschreibbar ist.
• 29a. Vorrichtung zur Herstellung von 3D-Bauteilen mit Partikeln, dadurch gekennzeichnet, dass in der Vorrichtung Partikel verwendet werden, deren Gestalt durch einen Herstellungsprozess bestimmt wird.
• 30. Vorrichtung zur Herstellung von 3D-Bauteilen mit Partikeln, dadurch gekennzeichnet, dass die Partikel über Vibrationen angeordnet werden.
• 31. Vorrichtung zur Herstellung von 3D-Bauteilen mit Partikeln, dadurch gekennzeichnet, dass die Partikel über Vibrationen zu Schichten innerhalb eines Schichtbauprozesses angeordnet werden.
• 32. Vorrichtung zur Herstellung von 3D-Bauteilen mit Partikeln, dadurch gekennzeichnet, dass die Partikel über Vibrationen zu Schichten parallel zu einem Schichtbauprozess zusammengestellt werden und schichtweise verwendet werden.
• 33. Vorrichtung zur Herstellung von 3D-Bauteilen mit Partikeln, dadurch gekennzeichnet, dass die Partikel über Vibrationen und gerichtete Kräfte angeordnet werden.
• 34. Vorrichtung zur Herstellung von 3D-Bauteilen mit Partikeln, dadurch gekennzeichnet, dass die Partikel über Vibrationen und/oder magnetische oder gravitative Kräfte angeordnet werden.
• 35. Vorrichtung zur Herstellung von 3D-Bauteilen mit Partikeln, dadurch gekennzeichnet, dass die Partikel über Absonderung von speziellen Düsen angeordnet werden.
• 36. Vorrichtung zur Herstellung von 3D-Bauteilen mit Partikeln, dadurch gekennzeichnet, dass verschiedene Partikel über Absonderung aus speziellen Düsen gezielt relativ zueinander angeordnet werden.
• 37. Vorrichtung zur Herstellung von 3D-Bauteilen mit Partikeln, dadurch gekennzeichnet, dass mehrere Düsensysteme gleichzeitig und parallel den Pulverkuchen aufbauen.
• 38. Vorrichtung zur Herstellung von 3D-Bauteilen mit Partikeln, dadurch gekennzeichnet, dass die Partikel selektiv auf einer Plattform abgelegt werden können und die selektive Anordnung verwendet wird, um verschiedene Partikelsorten in einer Ebene anzuordnen.

In the following, aspects of the invention are mentioned, each of which on its own or in combination with other aspects or with features of the claims form an embodiment of the invention or can develop the invention:

• 1. Material system for the production of complex 3D components with particles, the shape of which can be clearly described and / or determined using mathematical functions.
• 1a. Material system for the production of 3D components with particles, characterized in that particles are used, the shape and / or size of which is determined by a manufacturing process.
• 2. Material system for the production of 3D components using a layer construction process, characterized in that particles are used, the shape of which is determined by a construction process or manufacturing process.
• 3. Material system for the production of 3D components using a layer-building process, characterized in that cylindrical particles are used.
• 4. Material system for the production of 3D components using a layer construction process, characterized in that cubic particles are used.
• 5. Material system for the production of 3D components using a layer building process, characterized in that particles with a hexagonal floor plan are used.
• 6. Material system for the production of 3D components using a layer-building process with particles, characterized in that the particles have superficial geometric modifications.
• 7. Material system for the production of 3D components using a layer-building process with particles, characterized in that the particles have specifically shaped bores.
• 8. Material system for the production of 3D components using a layer construction process with particles, characterized in that the Particles have artificial elevations on the surface.
• 9. Material system for the production of 3D components using a layer construction process with particles, characterized in that the particles are influenced by the surface of the material.
• 10. Material system for the production of 3D components using a layer-building process with particles, characterized in that the particles are coated on the surface.
• 11. Material system for the production of 3D components with the aid of a layer building process with particles, characterized in that the particles consist of the material group of metals, plastics, ceramics, natural substances, salts and minerals or mixtures thereof.
• 12. Material system for the production of 3D components using a layer-building process with particles, characterized in that the particles have a maximum edge length of 10 to 50 cm.
• 13. Material system for the production of 3D components with the aid of a layer construction process with particles, characterized in that the particles have further functional structures in the interior.
• 14. Material system for the production of 3D components with the aid of a layer construction process with particles, characterized in that the particles have electrically particularly conductive areas in the interior.
• 15. A method for producing 3D components with particles, characterized in that particles are used, the shape and size of which can be clearly described using mathematical functions.
• 15a. Method for producing 3D components with particles, characterized in that particles are used, the shape of which is determined by a manufacturing process.
• 16. A method for producing 3D components with particles, characterized in that the particles are individually spatially compiled.
• 17. A method for producing 3D components with particles, characterized in that the particles are placed in layers on a construction platform or on a layer that has already been created.
• 18. Process for the production of 3D components with particles, characterized in that the particles are put together to form a complete powder cake.
• 19. A method for producing 3D components with particles, characterized in that the particles are put together during a layer-building process.
• 20. Process for the production of 3D components with particles, characterized in that the particles are put together in parallel to a layer building process and are used in layers.
• 21. A method for producing 3D components with particles, characterized in that the particles are selectively connected to one another.
• 22. A method for producing 3D components with particles, characterized in that the particles are glued together.
• 23. Process for the production of 3D components with particles, characterized in that the particles are selectively fused.
• 24. Process for the production of 3D components with particles, characterized in that the particles are selectively soldered.
• 25. Process for the production of 3D components with particles, characterized in that the particles are connected as a whole powder cake via a connection process.
• 26. Process for the production of 3D components with particles, characterized in that the particles are sintered as a whole powder cake via a connection process.
• 27. Process for the production of 3D components with particles, characterized in that the particles are soldered as a whole powder cake via a connection process.
• 28. Process for the production of 3D components with particles, characterized in that the particles are glued together as a whole powder cake via a connecting process.
• 29. Device for producing 3D components with particles, characterized in that particles are used in the device, the shape of which can be clearly described using mathematical functions.
• 29a. Device for producing 3D components with particles, characterized in that particles are used in the device, the shape of which is determined by a manufacturing process.
• 30. Device for producing 3D components with particles, characterized in that the particles are arranged via vibrations.
• 31. Device for the production of 3D components with particles, characterized in that the particles are arranged into layers within a layer building process via vibrations.
• 32. Device for the production of 3D components with particles, characterized in that the particles are combined to form layers via vibrations in parallel to a layer building process and are used in layers.
• 33. Device for producing 3D components with particles, characterized in that the particles are arranged via vibrations and directed forces.
• 34. Device for producing 3D components with particles, characterized in that the particles are arranged via vibrations and / or magnetic or gravitational forces.
• 35. Device for producing 3D components with particles, characterized in that the particles are arranged by means of special nozzles.
• 36. Device for the production of 3D components with particles, characterized in that different particles are specifically arranged relative to one another by being secreted from special nozzles.
• 37. Device for producing 3D components with particles, characterized in that several nozzle systems build the powder cake simultaneously and in parallel.
• 38. Device for producing 3D components with particles, characterized in that the particles can be deposited selectively on a platform and the selective arrangement is used to arrange different types of particles in one plane.

LIST OF REFERENCE NUMBERS

100

printhead

101

coaters

102

building platform

104

building container

105

particulate matter

106

drops

107

freshly produced layer

108

printed / solidified layer

200

Particles with an irregular shape

201

fill-related cavity

203

round or spherical particle

204

Tight packing area

301

spherical particle in the first level

302

spherical particle in the second level

303

spherical particle in the intermediate plane

400

Particles with a special shape

400a, 400b, 400c

edge

401

Particles of the first layer / level

402

Particles of the second layer

402a, 402b, 402c

edge

500

cylindrical particle (butze)

601

Effective channel for layer connection

602

Wirkverteilstruktur

603

Action channel through the particle

604

artificial increase

605

Normal level / surface / recess

700

continuously influenced boundary layer

701

local influence

800

Particle integrated into the pack

800a, 800b

interfaces

801

vibration

802

particle running towards the bed

802a, 802b

interfaces

901

Zippered cavity area

902

guide rail

1000

Particle nozzle at basic level

1001

Particle nozzle at a raised level

1002

Particle level particles

1003

Particles at a raised level

1004

Lowering point for fitting the particles into the bed

1200

Particles with two action channels for selective height effect - upper layer

1201

Particles with active channels - lower layer

1202

Effective channel for connection between the upper and lower layer

1203

Effective channel for connection downwards

1300

Particles with a special shape and material properties

QUOTES INCLUDE IN THE DESCRIPTION

This list of documents listed by the applicant has been generated automatically and is only included for better information for 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.

Patent literature cited

• US 4575330 [0003]
• US 6259962 [0004]
• US 5340656 [0006]
• US 5155324 [0006]
• EP 2054216 [0007]

Claims (16)

Material system for manufacturing a component in an additive manufacturing process with at least a first group of particles (203, 301, 302, 303, 400, 401, 402, 500, 800, 802, 1002, 1003, 1200, 1201, 1300), each have a defined geometric shape and size. Material system according to Claim 1 , characterized in that the particles (203, 301, 302, 303, 400, 401, 402, 500, 800, 802, 1002, 1003, 1200, 1201, 1300) of the first group each have the same geometric shape and size. Material system according to Claim 1 or 2 , characterized in that in addition to the first group at least one second group and in particular at least one further group of particles (203, 301, 302, 303, 400, 401, 402, 500, 800, 802, 1002, 1003, 1200, 1201 , 1300) is provided, wherein the particles of the second group and in particular of the further groups differ from one another and / or from the particles of the first group with regard to the geometric shape and / or size. Material system according to Claim 1 . 2 or 3 , characterized in that the particles (203, 301, 302, 303, 400, 401, 402, 500, 800, 802, 1002, 1003, 1200, 1201, 1300) of the first group and / or the second group and / or at least one further group each at least one, at least two or at least three straight edges (400a, 400b, 400c, 402a, 402b, 402c) and / or at least one or at least two or at least three flat interfaces (800a, 800b, 802a, 802b) exhibit. Material system according to one of the Claims 1 to 4 , characterized in that each particle of the first group and / or the second group and / or at least one further group has at least two, in particular at least three mutually parallel edges (400a, 400b, 400c, 402a, 402b, 402c) or at least two mutually parallel Interfaces (800a, 800b, 802a, 802b). Material system according to one of the Claims 1 to 5 , characterized in that each particle (500, 1401, 1402, 1403) of the first group and / or the second group and / or at least one further group has a prismatic shape, in particular the shape of a triangular, square or polygonal prism or a circle - Or elliptical cylinder. Material system according to one of the Claims 1 to 6 , characterized in that each particle of the first group and / or the second group and / or at least one further group is produced by extrusion or by cutting or punching from a base body, the base body in particular having plane-parallel cover surfaces. Material system according to one of the Claims 1 to 7 , characterized in that each particle or part of the particles of the first group and / or the second group and / or at least one further group has a coating (700, 701) and / or that all or some of the particles of the first group and / or the second group and / or at least one further group have a surface condition, in particular roughness, which differs from that of other particles. Material system according to Claim 8 , characterized in that the coating comprises an adhesive, a solder, a binder, an activator or a catalyst. Material system according to one of the Claims 1 to 9 , characterized in that one or more particles have bores or recesses (601, 602, 603) through which channels are formed within the component made from the particles. Method for producing a body from a material system according to one of the Claims 1 to 10 , characterized in that particles (203, 301, 302, 303, 400, 401, 402, 500, 800, 802, 1002, 1003, 1200, 1201, 1300) in succession by means of a first feed device (902, 1000, 1001) and in particular by means of a second or further feed device through a feed channel of the respective feed device to its respective destination on a powder cake, the particles or a subset of the particles in particular having a predetermined orientation or being moved to their destination in a certain orientation. Procedure according to Claim 11 , characterized in that particles (203, 301, 302, 303, 400, 401, 402, 500, 800, 802, 1002, 1003, 1200, 1201, 1300) of different nature, in particular different groups, by means of different feeding devices (902, 1000 , 1001) are moved to their respective destination. Procedure according to Claim 11 or 12 , characterized in that the particles are moved by vibration or discontinuous supply of kinetic energy along the supply channel (s). Procedure according to Claim 11 . 12 or 13 , characterized in that the particles (203, 301, 302, 303, 400, 401, 402, 500, 800, 802, 1002, 1003, 1200, 1201, 1300) in layers, in particular each in a layer thickness of one particle, are applied to the powder cake. Procedure according to one of the Claims 11 to 14 , characterized in that the particles (203, 301, 302, 303, 400, 401, 402, 500, 800, 802, 1002, 1003, 1200, 1201, 1300), which are to be connected to form the body, such can be selected from the available particles or particle groups in such a way that they have a property, for example a coating (700, 701), which enables effective connection to the respectively neighboring particles in the powder cake, or that the particles to be connected are located at their destination in the powder cake by locally targeted addition of a substance, in particular an adhesive, a binder, an activator or a catalyst, or prepared for a connection. Device for producing a body by means of a material system according to one of the Claims 1 to 10 , characterized by one, two or more feed devices (902, 1000, 1001) for particles to their respective destination on a powder cake, each with a feed channel, along which the particles can each be moved to their destinations.

Images