DE102020103255A1 - Process for the additive production of a molded body - Google Patents

Abstract

A method for the additive production of a molded body (1), in particular a vehicle component, wherein a liquid building material (2) in at least one solidification step (100) successively, preferably in layers, selectively by means of an energy radiation emitted from a radiation device (9), in particular UV radiation ( 6), is solidified, wherein during solidification of the liquid building material (2) on or on an exposed surface (12) of the liquid building material (2) a separating layer (14) formed from a separating layer material (13) is or is being arranged or formed.

Description

The invention relates to a method for the additive production of a molded body, in particular a vehicle component, wherein a liquid building material is gradually solidified in at least one solidification step, preferably in layers, selectively by means of an energy radiation emitted from a radiation device, in particular UV radiation.

Corresponding processes for the additive production of a shaped body are basically known from the prior art. Such methods are known under the terms rapid prototyping, rapid tooling and rapid manufacturing and are used in a wide variety of industries for the production of sample components, tools as well as prefabricated components or semi-finished products. Here, starting from possibly processed or modified design data, typically CAD data, control data are generated and used to control a device for executing an additive manufacturing process. The device produces the shaped body to be produced by consolidating a building material to be consolidated which is typically provided in layers. In this way, moldings such. B. jewelry, dental implants, tool molds, aircraft components are made.

The invention is based on the object of specifying a method which, in particular with regard to a simple, fast and inexpensive measure, allows the quality of the molded bodies to be produced to be increased. In particular, area-dependent material property values of the molded body should be able to be specified or manufactured in a more defined manner.

The object is achieved by a method for the additive production of a shaped body according to claim 1. The dependent claims relate to possible embodiments of the method.

The invention relates to a method for the additive production of a molded body, in particular a vehicle component, wherein a liquid building material is gradually solidified in at least one solidification step, preferably in layers, selectively by means of an energy radiation emitted from a radiation device, in particular UV radiation. The method is characterized in that during the solidification of the liquid building material, in particular during the solidification step, a separating layer formed from a separating layer material is or will be arranged or formed on or on an exposed surface of the liquid building material. In order to obtain a high-quality molded body and in particular to obtain a molded body having a homogeneous and / or specifically adjusted, area-dependently different material property, it is advantageous if the building material is homogeneous over the course of the solidification step. Thus, according to the invention, a liquid building material or a building material mixture consisting of several components can be present, which has a similar, in particular identical, component composition and / or component proportions during the solidification step or during the additive manufacturing process.

Experiments have shown that a change in the composition and / or the proportions of the components of the liquid building material can be determined during the additive manufacturing process or during the solidification step for creating a dimensionally stable molded body, in particular a green body of the molded body. Here it can happen that a component of the building material, in particular one which influences the viscosity of the building material, emerges or is removed at least partially from the building material during the solidification step, e.g. B. volatilized or evaporated. As a result, the viscosity of the liquid building material can change, in particular increase, over the course of the solidification step or the additive manufacturing process. In the case of the use of an additive manufacturing process that provides for post-flow of the building material, in particular due to gravity, this can lead to an undesirable different post-flow behavior of the building material over the solidification step. This change in the behavior of the building material can lead to an undesirable inhomogeneity of the physical and / or chemical material properties of different shaped body sections.

By providing a separating layer which is arranged or formed on an exposed surface of the liquid building material and is formed from a separating layer material, the building material can be shielded or closed off from an (e.g. adjoining) building space atmosphere or from an adjoining environment. For this purpose, the separating layer can be placed on the area of a building material liquid that is geodetically arranged at the top. In other words, the separating layer can rest on a building material mirror, for example. H. on a smoothed form of a free and largely undisturbed liquid building material surface, which occurs under the influence of gravity.

By means of the separating layer, the liquid building material can be removed from a partial volume of the building space or an environment, so that at least one diluent component contained in the building material cannot escape from the liquid building material or escape more slowly or with a delay, in particular evaporate or volatilize. With the separating layer, a transition of at least one component from the liquid building material to a building space part volume or the environment is delayed or prevented.

For example, the building material is arranged in a building container, the building container having a transparent and gas-permeable body on its bottom area. Such a body can for example be referred to as a so-called “permeable window”. The transparent property of the permeable window enables UV light, for example, to pass through, and the gas-permeable property of the permeable window enables the formation of an intermediate area in which the solidified building material does not adhere to the permeable window itself. This intermediate area is also known as the “dead zone”. The transparent property of the permeable window enables energy radiation, in particular UV radiation, to strike the bottom layer of the building material inside the container from below and solidification in certain areas can occur. In this case, a first layer or layer of the building material can be placed on a building board which is arranged between this layer and the permeable window and can be displaced in height. The solidified building material can form a bond on the building board or it adheres to it. The building board is then moved in a direction pointing away from the permeable window, the resulting free space between the solidified building material adhering to the building board and the permeable window being filled with liquid building material, in particular due to gravity. This subsequent flow of building material forms the next layer of building material made available for area-dependent solidification. The building material located in the building container can have the separating layer on its surface facing geodetically upwards or on its free surface area opposite the permeable window.

The solidification step encompasses all sub-steps for the formation of a molded body in the course of the additive manufacturing process and thus all solidification operations for the respective building material layers of the molded body.

The energy radiation used in the solidification step can, for example, strike the building material to be solidified flatly and / or linearly and / or point-like and solidify this area-dependently through the action of energy, preferably through polymerization, particularly preferably through photopolymerization. The building material is at least partially and / or at least partially, in particular completely, polymerizable, in particular photopolymerizable, in its areas to be solidified by the action or exposure of UV radiation or a UV beam. The UV radiation is generated by a radiation device and successively and selectively directed or directed onto the building material to be consolidated. By means of a targeted and selective solidification of the building material provided in layers or in layers by means of the UV ray, the dimensionally stable molded body can be formed or built up in layers in the course of the solidification step.

In this case, for example, by means of the UV beam, cured or polymerized areas of the building material can form a solid, which leads to dimensional stability of the building material and finally forms the geometrically determined solid. This shaped body can be (a) a green compact to be subjected to an aftertreatment step and / or (b) a prefabricated component, e.g. B. a semi-finished product, train or represent. The polymerization by means of UV radiation can comprise a photopolymerization. This means that a polymerization takes place that is initiated by the absorption of visible or ultraviolet light. For example, a building material is used which, when exposed to UV rays in the wavelength range from 200 to 400 nm, leads to polymerisation of the building material. The green compact state is to be understood as meaning a molded body that is not yet fully cured and is subjected to a, in particular thermal, post-consolidation step or which was completely cured in the course of the first consolidation step and undergoes further consolidation in a later post-consolidation process, possibly between the first Solidification step and the post-solidification step, an at least section-wise temporary softening, so that resolidification is achieved in the post-solidification step. After passing through the, in particular thermal, post-consolidation step, the shaped body can have its physical and / or chemical properties for its intended use.

A displacement reaction, also called chain extension reaction, of a chain extender (component B) with oligomers (component A) can be initiated by the thermal application or by the increased temperatures in the thermal aftertreatment or during the post-solidification step. Here, the chain extender and / or the oligomers form a component of the building material. This reaction also takes place at the contact surface of liquid and solidified building material, creating chain extenders of the solidified building material or the part molded body with oligomers of the liquid, in the receiving space 4th brought in building material and vice versa react. This creates cross-phase covalent bonds. The bonding of the phases can be additionally strengthened by further bonds such as hydrogen bonds and dipole-dipole interactions or Van-der-Waals bonds.

It is possible for the separating layer to be arranged or designed in such a way that the liquid building material is predominantly or completely separated from a partial volume of the building space, in particular the separating layer arranged or formed on the surface of the liquid building material separates the liquid building material in a gas-tight and / or airtight manner of a partial volume of the installation space. In other words, the separating layer and / or the separating layer material forming the separating layer can be designed or arranged in such a way that diffusion or penetration of at least one component of the building material, in particular a thinner component of the building material, is delayed or prevented. This can prevent the proportion of one, in particular volatile, component of the building material from being reduced due to the transfer of this component to the atmosphere of the building chamber or to the environment. Consequently, even without countermeasures, the proportion of one, in particular volatile, component of the building material can be kept constant.

A separating layer material can be used, for example, which is at least partially, in particular completely, in a liquid state during the solidification step for forming the shaped body. The liquid state of aggregation of the separating layer material, at least while the additive solidification step is being carried out, makes it possible to achieve a reliable closure of the liquid building material on its free surface. For example, in the advanced stage of the solidification step, the building board and / or at least a region of the already solidified shaped body can move or “emerge” from the exposed surface of the liquid building material. Because the free surface is interrupted or changed in shape by the elements passing through it, the liquid separating layer material can be used to evade and / or flow around the emerging elements, so that there is always a closure or a certain, in particular high, Degree of completion of the exposed surface of the liquid building material can be achieved or is achievable. In other words, the liquid separating layer material can be used to easily and reproducibly achieve a separating layer that is always or predominantly present during the additive solidification step on the exposed surface of the building material. Due to the liquid separating layer material, the separating layer can, for example, conform closely to elements passing through the exposed surface and, in particular, enable the exposed surface of the liquid building material to be sealed as air and / or gas-tight as possible.

It is possible that a separating layer material is used which has a lower density than the building material, at least during the consolidation step. Due to the lower density of the separating layer material, it is always arranged or placed on the exposed surface or on the geodetically highest area of the liquid building material. Here, the separating layer can at least partially, in particular completely, float on the liquid building material during the solidification step for forming the shaped body.

In an advantageous embodiment, it can be provided that before and / or during and / or after the solidification step to form the shaped body, separating layer material is introduced into and / or applied to the building material via a metering unit. In this case, separating layer material can be introduced into and / or applied to the building material within the additive manufacturing device via the metering unit or can be introduced and / or applied by the metering unit.

Alternatively or additionally, a quantity and / or a volume and / or a point in time and / or a period and / or a chronological sequence and / or an insertion or application location of the or applied separating layer material of the dosing unit can be controlled via a control device which controls the dosing unit. In other words, a control device can control the mode of operation of the metering unit. The metering unit can, for example, be movably mounted or movable within the additive manufacturing device and moved directly or indirectly to defined insertion and / or application locations of a building material bath and / or an exposed building material surface via the control device. As an alternative or in addition, the metering unit can have at least two, in particular a multiplicity of, outlet openings through which separating layer material can be introduced into and / or applied to the building material. The outlet openings of the metering unit can be arranged or formed above, to the side and / or within the liquid building material bath. If the separating layer material would be introduced into the building material, the separating layer material can, for. B. due to a lower density of even move upwards and connect there with the separating layer or form it there.

It can be provided, for example, that the control of the metering unit (a) as a function of at least one process parameter of the solidification step and / or (b) as a function of at least one physical and / or chemical property of the building material, in particular the diluent contained in the building material, and / or (c) as a function of at least one physical and / or chemical property, in particular a layer thickness, of the separating layer arranged on the surface of the building material or of the separating layer material of the separating layer. For example, based on empirical values, after a predefined duration of the solidification step or additive manufacturing process, a, in particular fresh, separating layer material can be applied or introduced by the metering unit.

A separating layer material feed depending on the type and / or scope of elements passing through the exposed surface of the building material or through the separating layer can, for example, prove to be advantageous. For example, at least a part of the separating layer material attaches itself to a surface of an element passing through the separating layer or remains adhered to it and thus removes separating layer material from the separating layer. This separating layer material removed from the separating layer can, for example, be fed back directly or indirectly to the separating layer by means of the metering unit.

For example, at least one building material comprising a photopolymerizable component can be used as the building material, in particular the building material consisting of at least partially a photopolymerizable material is photopolymerized by UV radiation during the solidification step to form the shaped body. For example, the building material used comprises at least one component based on resin, in particular based on synthetic resin. The building material can consequently at least partially, preferably predominantly, particularly preferably exclusively, comprise an, in particular photosensitive, synthetic resin. The photopolymerizable building material can be monomers and / or oligomers and / or other additives, such as. B. dyes or passive absorbers include. For example, at least one component of the building material may comprise a photoinitiator (PI), e.g., diphenyl (2,4,6-trimethylbenzoyl) phosphine oxide. The photoinitiator breaks down into radicals, which in turn can react with a monomer or an oligomer to form a polymer chain.

The building material can, for example, have at least one building material comprising a diluent component. In particular, a low molecular weight and / or reactive diluent component is used as at least one component of the building material. The building material can contain methacrylates and / or acrylates, for example, as the diluent component. The diluent component can be used to give the building material mixture a minimum flowability so that the building material can flow in, in particular in an additive manufacturing process that works according to the CLIP process principle (Continuous Liquid Interface Production process). Because the thinner component ensures that the building material can flow again, when the building board or the last solidified level of building material is raised in a CLIP process, the building material can flow reliably and reproducibly to form an at least regionally new building material layer to be solidified. The building material that flows in forms an intermediate zone, also known as the “dead zone”, in the immediate vicinity or directly at the permeable window. Sufficient flowability or a viscosity below a reference value is necessary for this. The diluent component can, for example, make up at least 20% by weight, preferably at least 35% by weight, particularly preferably at least 45% by weight, of the total mass of the building material. In the present sense, molecules with a low number of atoms can be described as “low molecular weight”. In particular, one or more low molecular weight and / or reactive diluent components can be used as ingredients of the building material.

A more extensive, optional process control can be achieved in that a pressure prevailing in an installation space is changed or can be changed by a pressure control device, in particular in a predeterminable manner. Since the pressure prevailing in the construction space and / or the temperature prevailing in the construction space (a) has an influence on the flowability of the construction material and / or (b) an influence on the leakage of a component, in particular a thinner component, from the construction material and / or (c ) can have an influence on the flowability of a separating layer material forming the separating layer, it can be advantageous if the pressure prevailing in the installation space and / or the temperature prevailing in the installation space can be changed by a pressure influencing device and / or by a temperature influencing device.

The change in the pressure prevailing in the installation space with regard to a pressure value and / or a point in time and / or a time period and / or carried out on the pressure-influencing device side or a time profile can be controlled or controllable, for example, via a control device which activates the pressure-influencing device. The control device can interact with a control device controlling the solidification process or form a part of this. The pressure influencing device can be designed as a compressor, for example. Similarly, alternatively or additionally, a temperature influencing device with regard to the pressure value and / or a point in time and / or a period and / or a time profile can be controlled via a control device for changing the temperature within the installation space.

The control of the pressure influencing device and / or the temperature influencing device can, for example, be (a) depending on at least one process parameter of the solidification step and / or (b) depending on at least one physical and / or chemical property of the building material, in particular the diluent component contained in the building material, and / or (c) take place as a function of at least one physical and / or chemical property, in particular a layer thickness, of the separating layer arranged on the surface of the building material or of the separating layer material of the separating layer. For example, in the event that the thickness of the separating layer falls below a minimum setpoint, the pressure in the installation space can be increased by means of the pressure-influencing device so that, despite a small layer thickness of the separating layer, a component of the liquid construction material, in particular a thinner component, is reduced or prevented from crossing into the adjacent installation space partial volume can.

It is possible that the physical and / or chemical property of the building material, in particular the diluent component, and / or the physical and / or chemical property, in particular the layer thickness, of the separating layer is or can be detected via a detection device during the process of building the shaped body. By monitoring the separating layer and / or the separating layer material, its functionality or the prevention of the outdiffusion of at least one component, in particular a diluent component, of the liquid building material can be monitored. Alternatively or additionally, the installation space atmosphere can be monitored so that, for example, a content of the component, in particular the thinner component, of the construction material in the installation space atmosphere is recorded. In the event of a deviation in the physical and / or chemical properties of the separating layer and / or if the content of the component of the building material in the building space atmosphere exceeds a reference value, a countermeasure can be initiated, for example, in order to maintain the separating function of the separating layer during the solidification step. From exceeding the reference value of the content of the component of the building material in the building space atmosphere, it can be concluded that the separating layer is not functioning adequately and therefore a reinforcement, ie. H. an addition of release liner material to the release liner is to be performed.

The detection device can, for example, information on z. B. transmit the layer thickness of the separating layer to a control device and / or to a dosing unit, so that if the layer thickness for the separating layer falls below a defined target value, in particular "fresh" separating layer material is applied by the dosing unit and the separating layer is thus filled or removed. can be reinforced.

During or after the construction of the shaped body, for. B. at least one solidified portion of the shaped body, in particular the entire solidified shaped body, are subjected to a cleaning process. During the cleaning process, the molded body can be freed of any separating layer material adhering to this, in particular superficially. The cleaning process preferably takes place before, during or after a thermal aftertreatment step for the shaped body. For example, it can be provided that parts of the surface of the molded body are specifically not cleaned, so that separating layer material adhering there can remain at defined points on the surface of the molded body and act as a protective layer and / or as an area-dependently effective influencing layer during the, in particular thermal, post-treatment step. For example, thermal energy is applied to the shaped body in an aftertreatment step, in particular in an oven, in order to achieve further solidification of the shaped body. The surfaces of the molded body provided with separating layer material have a different thermal influence during the aftertreatment step than the surface sections of the molded body provided without separating layer material. In this way, through a targeted or defined arrangement of separating layer material on the surface of the shaped body, a targeted area-dependent influencing of the shaped body can take place in the course of the post-treatment step.

It is possible that while the shaped body passes through the separating layer, at least a part of the separating layer material on at least one surface section of the Molded body adheres. In this case, for example, at least a part of the separating layer material can form a component of the molded body in a green compact state and / or in a finished part state. During the additive manufacturing process or during the solidification step, solidified areas of the molded body can move out of the exposed surface of the building material bath, so that separating layer material can be applied to the surface sections of the molded body and at least partially remain there. The separating layer material adhering to surface sections of the shaped body can form a surface coating of the shaped body that partially or completely surrounds the shaped body. In particular, if the molded body initially forms a green compact after its solidification step or after the additive, shaping manufacturing process, which is influenced in a subsequent post-treatment step, in particular an application of thermal energy, the separating layer material can serve as a protective layer of the green compact. This protective layer prevents, for example, an unwanted reaction and / or aging of solidified areas of the molded body due to its contact with the atmosphere surrounding it. Even during a possible relocation of the shaped body or the shaped body present as a green compact from the additive manufacturing device to a further location, e.g. B. to a post-treatment step device, the separating layer material adhering to the surface of the molding can serve as a protective layer against chemical and / or mechanical influences or reactions.

The separating layer material lying on the surface of the shaped body can, for example, at least in sections move into the interior of the shaped body.

It can be provided that the molded body is manufactured or provided with a predefined porosity or geometric and / or chemical absorption capacity at least in sections, in particular completely, in the course of the additive manufacturing process in order to at least partially draw in or at least partially absorb separating layer material to achieve in internal areas of the molded body.

The molding can, for example, after its shaping structure in the course of the solidification step by means of an additive manufacturing device, be in a green compact state B. a temperature control device (z. B. an oven), post-treated, in particular temperature controlled, to achieve a finished part state. The aftertreatment can serve to further consolidate the shaped body, for example polymerisation of the component, in particular to form a green compact, is achieved in the consolidation step, and thermal post-consolidation of the shaped body is achieved in the aftertreatment step.

It is possible for at least one section of the molded body to adhere or allow to adhere to the molded body in a targeted manner, depending on the area, in order to achieve a target material property in a targeted manner and / or as a function of a target material property, in order to effect its area-dependently different influencing in the course of the thermal aftertreatment.

The building material can, for example, comprise several components, in particular homogeneously distributed within the component, with a first component, preferably predominantly, particularly preferably exclusively, light-reactively solidified and a second component, preferably predominantly, particularly preferably exclusively, thermally at and / or from a reaction start temperature solidified. The light-reactive solidification takes place in the course of the solidification step during the additive manufacturing process and the thermal solidification can take place during the post-treatment step.

The additive manufacturing process for producing the shaped body, in particular a green compact, can be carried out, for example, at least in sections, completely, by means of polymerization. A digital light synthesis method (DLS), in particular a continuous liquid interface production method (CLIP) and / or a stereolithography method (SLA) and / or a digital light processing method (DLP) can be used here. In other words, the concept of the invention can be applied to any liquid bath process for building materials, in particular a resin bath process.

In addition to the method for the additive production of a molded body, the invention also relates to a molded body produced by a method described herein and a device for carrying out a method described herein.

All advantages, details, designs and / or features of the method according to the invention can be transferred or applied to the molded body according to the invention and / or to the device according to the invention for carrying out the method.

• 1: eine schematische Prinzipdarstellung einer CLIP-Vorrichtung gemäß einem Ausführungsbeispiel;
• 2: einen schematischer Verfahrensablauf zur Herstellung eines Formkörpers gemäß einem Ausführungsbeispiel.

The invention is explained in more detail by means of exemplary embodiments in the drawings. It shows:

• 1 : a schematic representation of the principle of a CLIP device according to an embodiment;
• 2 : a schematic process sequence for producing a molded body according to an embodiment.

The invention relates to a method for the additive production of a molded body 1 , in particular a vehicle component, wherein a hardenable, in particular polymerizable, building material under the action of energy 2 in a solidification step 100 successively, preferably in layers, selectively by means of one of a radiation device 9 emitted energy radiation, in particular UV radiation 6th , is solidified.

In 1 is an example of a device or an additive manufacturing device 3 for carrying out a method for the additive production of a molded body 1 shown using a CLIP process. In addition to the CLIP method, the method according to the invention can also be applied to other additive construction methods that use a liquid building material 2 use to be applied. The following is based on a CLIP procedure, for example. The CLIP process can provide that in a solidification step 100 , in particular in a polymerization step, a building material that can be solidified or solidified under the action of energy, in particular under the action of UV light 2 successively, preferably in layers, selectively by means of one of a radiation device 9 emitted energy radiation, in particular UV radiation 6th or light radiation, is solidified.

The illustrated additive manufacturing device 3 can be one, preferably optionally detachable, in the additive manufacturing device 3 attached or attachable building container 4th have, the building container 4th with a liquid building material, in particular consisting of plastic and / or synthetic resin 2 is filled. The floor 5 of the container 4th is light and gas permeable, or with a light and gas permeable body 26th - also referred to as a permeable window - provided, so that the energy radiation, in particular the UV radiation 6th , the ground 5 of the building container 4th penetrate and in an intermediate area 10 - also referred to as "dead zone" - hit or in an intermediate area 10 and the building material located there 2 can solidify depending on the area. The light and gas permeable body 26th enables energy radiation, in particular UV radiation, to pass through 6th , and a gas medium (not shown). The UV radiation 6th gets to the building material 2 and hardens it, the gas medium reaches the building material 2 and prevents the building material from sticking 2 to the ground 4th of the building container 4th and thus contributes to the functioning of the intermediate area 10 at. The UV radiation 6th emerges from the radiation device 9 or a light source and is supported by at least two mirror elements 7th , 7` having mirror device 8th so deflected that the UV radiation 9 in the intermediate area 10 selectively area-dependent, for example also at least in sections over an area, the intensity and / or exposure time of the UV radiation 6th within the impact area in the intermediate area 10 can be different or can be controlled in a targeted manner. This can be used in the intermediate area 10 a solidified or partially solidified shaped body 1 , in particular with area-dependent (depending on e.g. the intensity of the UV radiation 6th ) different material properties.

The intensity and / or exposure time of the UV radiation 6th is achieved, for example, by a control (a) of the mirror elements that move, particularly in terms of frequency 7th , 7` a mirror device 8th and / or (b) the radiation device 9 set. As a radiation device 9 For example, at least one UV LED light source can be used. The mirror device 8th can for example be designed as a micromirror array.

The ones in the building material 2 Due to the energetic action of the UV radiation, the photo-initiators present trigger a radical polymerization, in which monomers grow into polymers through a chain cleavage of the double bond. The building material 2 hardens along the exposed area. This creates a connection to a height-adjustable (see arrow 20th ) Building platform or building plate 11 , which are successively or continuously by the action of an actuator (not shown) to one layer height upwards (i.e. from the radiation device 9 away) to create a space for building material to flow in and to be solidified depending on the area 2 to build. With the CLIP procedure, the intermediate area usually remains 10 or that of UV radiation 6th facing area of the molded body 1 and the floor 5 of the building container 4th always with liquid building material during the construction process 2 covered (with the exception of the after running, a free space below the raised building board 11 or below the raised molding 1 filling liquid building material 2 ) caused by UV radiation 6th in turn can be solidified. By repeating this process several times, a layered shaped body is successively created 1 . After the desired shape of the molded body 1 is achieved by this process, the molded article 1 entirely from the bath of liquid building material 2 or from the liquid building material 2 filled container 4th , especially synthetic resin, moved out and finally from the building board 11 separated or solved.

By changing individual or several process parameters of at least two process parameter sets, the material properties of the molded body can be affected 1 during its manufacture in the course of the additive manufacturing process or during the solidification step 100 Influence. Thus, the shaped body shown in the figures 1 a first area 24 and a second area 25th on. The first area 24 is here as an area without filling, the second area 25th on the other hand, as an area with a dark, regular filling (horizontal stripes) provided within the contour line of the molded body 1 shown. The two areas 24 , 25th can differ in their material and / or component properties, in particular the two sections or areas differ 24 , 25th of the molded body 1 through their physical and / or chemical properties.

During the solidification of the liquid building material 2 is on or on an exposed surface 12th of the liquid building material 2 one made from a release liner material 13th formed separating layer 14th arranged or formed or such is applied. The separation layer 14th closes the exposed surface 12th of the liquid building material 2 compared to an installation space part volume 15th or an installation space atmosphere.

The separation layer 14th is arranged or designed in such a way that the liquid building material 2 predominantly or completely from a partial volume of the installation space 15th is separated, in particular separates the on or on the surface 12th of the liquid building material 2 arranged or formed separating layer 14th the liquid building material 2 gastight and / or airtight from a part volume of the installation space 15th . It can, for example, release layer material 13th can be used, at least partially, in particular completely, during the solidification step 100 to form the molded body 1 has a liquid state. This allows the separating layer 14th to a changing free surface 12th of the liquid building material 2 to adjust.

The release liner material 13th can have a lower density than the building material 2 , at least during the solidification step 100 , exhibit. The separating layer preferably floats 14th at least partially, in particular completely, during the solidification step 100 to form the molded body 1 on the liquid building material 2 . The separation layer 14th extends over the free or geodetically overlying surface 12th of the building material 2 .

Before and / or during and / or after the solidification step 100 can be used to form the molded body 1 Release material 13th via a dosing unit 16 in and / or on the building material 2 be applied and / or applied. The dosing unit 16 can with a control device 17th be connected in such a way that control signals of the control device 17th to the dosing unit 16 are transferable.

(A) a quantity and / or (b) a volume and / or (c) a point in time and / or (d) a period of time and / or (e) a chronological sequence and / or (f) a place of introduction or application of the in and / or on the building material 2 separating layer material to be introduced and / or applied or applied 13th the dosing unit 16 can for example use the dosing unit 16 controlling control device 17th to be controlled. The control of the dosing unit 16 can for example (a) as a function of at least one process parameter of the solidification step 100 and / or (b) depending on at least one physical and / or chemical property of the building material 2 , especially one in building materials 2 contained thinner component, and / or (c) depending on at least one physical and / or chemical property, in particular a layer thickness 18th that is on the surface 12th of the building material 2 arranged separating layer 14th or the separating layer material 13th the separating layer 14th respectively. A detection device 19th be provided which z. B. (a) a layer thickness 18th the separating layer 14th and / or (b) a composition of the release liner material 13th and / or (c) a content or a proportion of the diluent component in the partial volume of the installation space 15th and / or (d) a content or a proportion of the diluent component in the building material 2 recorded.

As building material 2 can at least one building material comprising a photopolymerizable component 2 may be used, particularly during the solidification step 100 to form the molded body 1 the building material consisting at least partially of a photopolymerizable material 2 by UV radiation 6th photopolymerized and thus at least predominantly cured.

As building material 2 can at least one building material comprising a diluent component 2 be used. In particular, a low molecular weight and / or reactive diluent component is used as a component of the building material 2 used.

A diluent component comprising methacrylates and / or acrylates is particularly preferably used. In this way, for example, a reactive diluent, which is significantly smaller in comparison to the oligomer molecules, can form a low molecular weight component. In particular, one or more low molecular weight and / or reactive diluent components can be used as a component of the building material.

A pressure prevailing in an installation space can, for example, be achieved by a pressure influencing device 21 , in particular in a specifiable manner, be changed or be changeable. The pressure influencing device 21 can be designed, for example, as a fan and / or as a compressor. The change in the pressure-influencing device-side implemented in the installation space and thus in the installation space part volume 15th The prevailing pressure can, for example, with regard to a pressure value and / or a point in time and / or a period and / or a time profile via a pressure-influencing device 21 controlling control device 17th controlled or controllable. The pressure-influencing device is preferably controlled 21 (a) as a function of at least one process parameter of the solidification step 100 and / or (b) depending on at least one physical and / or chemical property of the building material 2 , especially that in building materials 2 contained thinner component, and / or (c) depending on at least one physical and / or chemical property, in particular a layer thickness 18th that is on the surface 12th of the building material 2 arranged separating layer 14th or the separating layer material 13th the separating layer 14th .

The physical and / or chemical property of the building material 2 , in particular the thinner component, and / or the physical and / or chemical property, in particular the layer thickness 18th , the separating layer 14th can during the additive manufacturing process or solidification step 100 of the molded body 1 via a detection device 19th be recorded or be detectable. The detection device 19th can, for example, as an optical sensor and / or as thermal sensor values, which draw conclusions, in particular area-dependent, about property values of the separating layer 14th or the separating layer material 13th and / or the building material 2 permitted.

During or after the construction of the molding 1 can at least one solidified portion of the molded body 1 , in particular the entire solidified molding 1 , a cleaning process or a cleaning step 101 be subjected. The cleaning process preferably takes place before, during or after an, in particular thermal, aftertreatment step 102 of the molded body 1 .

While the shaped body is passing through 1 through the separating layer 14th , can be at least a portion of the release liner material 13th on at least one surface section 22nd of the molded body 1 adhere to or arrange themselves on this, in particular at least a part of the separating layer material forms 13th a component of the molded body 1 in a green compact state 103 and / or in a precast state 104 .

According to the in 2 The flow chart shown is initially in a solidification step 100 or a molded body in an additive manufacturing process 1 in a green compact state 103 educated. In this green compact state, the molded body has 1 an essentially or predominantly, in particular complete, dimensionally stable shape. However, the molded body 1 in the green compact state do not have at least one desired property (ie physical and / or chemical properties) for its intended use. The molded body is then connected 1 optionally a cleaning step 101 or subjected to a cleaning process in which the molded body 1 at least in sections, in particular completely, of impurities and / or of separating material adhering to this 13th is released. Then a molded body 1 in an intermediate state 105 present, which is characterized in that the shaped body 1 is present in a green compact state and at the same time at least in sections of impurities and / or separating material 13th is exempt. Then the molded body 1 a post-treatment step 102 or subjected to a post-treatment process in which it undergoes post-curing or further curing. For example, the molded body 1 charged with thermal energy in order to further solidify the molded body 1 to reach. In other words, in the course of an aftertreatment step 102 post-curing can be carried out; the not yet fully cured and in the green compact state can be used for this 103 present molded body 1 be post-crosslinked in, for example, an oven by means of the action of thermal energy.

After going through the post-treatment step 102 is the shaped body 1 in a precast state 104 before, in which the molded body 1 has the material and / or component properties intended for its intended use.

The molded body 1 can, for example, according to its shaping structure in the course of the solidification step 100 by means of an additive manufacturing device 3 in a green compact state 103 are present and in an, in particular thermal, aftertreatment step 102 at least in sections, in particular completely, by an aftertreatment device, in particular by a temperature control device, to achieve a finished part state 105 post-treated, in particular tempered, are.

The molded body 1 can in particular form a vehicle component. The additive manufacturing device 3 can be used to produce a molded article by a method described herein 1 to manufacture. In particular, the additive manufacturing device comprises 3 a dosing unit 16 for the introduction or application of separating layer material 13th in or on the liquid building material 2 .

The control device 17th can use data connections 23 with the mirror device 8th and / or the radiation device 9 and / or the dosing unit 16 and / or the build plate 11 or with the building board 11 controlling actuators (not shown) and / or a detection device 19th be connected for the transmission of control signals and / or status signals and / or detection information. The data connections 23 can be used as unidirectional or as bidirectional data connections 23 be designed and are not limited to the data exchange directions shown in the drawings.

List of reference symbols

1

Moldings

2

Building material

3

Manufacturing device

4th

Construction container

5

Floor of 4

6th

UV radiation

7, 7 '

Mirror element

8th

Mirror device

9

Radiation device

10

Intermediate area ("dead zone")

11

Building board

12th

exposed surface

13th

Release material

14th

Separating layer

15th

Installation space part volume

16

Dosing unit

17th

Control device

18th

Layer thickness

19th

Detection device

20th

arrow

21

Pressure influencing device

22nd

Surface section

23

Data Connection

24

Range from 1

25th

Range from 1

26th

light and gas permeable body (permeable window)

100

Solidification step

101

Cleaning step

102

Post-treatment step

103

Green compact condition from 1

104

Precast condition from 1

105

Intermediate state from 1

Claims (17)

A method for the additive production of a molded body (1), in particular a vehicle component, wherein a liquid building material (2) in at least one solidification step (100) successively, preferably in layers, selectively by means of an energy radiation emitted from a radiation device (9), in particular UV radiation ( 6), is solidified, characterized in that during solidification of the liquid building material (2) a separating layer (14) formed from a separating layer material (13) is arranged or formed on or on an exposed surface (12) of the liquid building material (2) or will. Procedure according to Claim 1 , characterized in that the separating layer (14) is arranged or designed in such a way that the liquid building material (2) is predominantly or completely separated from a partial building space volume (15), in particular separating the on or on the surface (12) of the liquid building material ( 2) arranged or formed separating layer (14) the liquid building material (2) gas-tight and / or airtight from a building space part volume (15). Procedure according to Claim 1 or 2 , characterized in that a separating layer material (13) is used which is at least partially, in particular completely, in a liquid state during the solidification step (100) for forming the shaped body (1). Method according to one of the preceding claims, characterized in that a separating layer material (13) is used which has a lower density than the building material (2), at least during the solidification step (100), preferably the separating layer (14) floats at least partially, in particular completely, during the solidification step (100) for forming the shaped body (1) on the liquid building material (2). The method according to any one of the preceding claims, characterized in that before and / or during and / or after Solidifying step (100) for forming the shaped body (1) separating layer material (13) is introduced into and / or applied to the building material (2) via a metering unit (16). Method according to one of the preceding claims, characterized in that a quantity and / or a volume and / or a point in time and / or a period and / or a chronological sequence and / or a place of introduction or application of the in and / or on the building material (2) to be applied and / or applied or applied separating layer material (13) of the metering unit (16) is controlled via a control device (17) controlling the metering unit (16), the metering unit (16) is preferably controlled - depending on at least one Process parameters of the solidification step (100) and / or - depending on at least one physical and / or chemical property of the building material (2), in particular the diluent contained in the building material (2), and / or - depending on at least one physical and / or or chemical property, in particular a layer thickness (18), of the separating layer (14) or of the Tre on the surface (12) of the building material (2) Inlayer material (13) of the separating layer (14). Method according to one of the preceding claims, characterized in that at least one building material (2) comprising a photopolymerizable component is used as the building material (2); Material existing building material (2) photopolymerized by UV radiation (6). Method according to one of the preceding claims, characterized in that at least one building material (2) comprising a diluent component is used as the building material (2), in particular a low molecular weight and / or reactive diluent component is used as the component of the building material (2), particularly preferably one Methacrylates and / or acrylates containing diluent component used. Method according to one of the preceding claims, characterized in that a pressure prevailing in a construction space is changed or can be changed by a pressure influencing device (21), in particular in a predeterminable manner. Procedure according to Claim 9 , characterized in that the pressure-influencing device-side change in the pressure prevailing in the installation space with regard to a pressure value and / or a point in time and / or a period and / or a time profile is controlled or controllable via a control device (17) which activates the pressure-influencing device (21) is, the pressure influencing device (21) is preferably controlled - depending on at least one process parameter of the solidification step (100) and / or - depending on at least one physical and / or chemical property of the building material (2), in particular that in the building material (2 ) contained thinner component, and / or - depending on at least one physical and / or chemical property, in particular a layer thickness (18), of the separating layer (14) or the separating layer material (13) arranged on the surface (12) of the building material (2) ) the separating layer (14). Procedure according to Claim 6 or 10 , characterized in that the physical and / or chemical property of the building material (2), in particular the thinner component, and / or the physical and / or chemical property, in particular layer thickness (18), of the separating layer (14) during the solidification step (100) of the shaped body (1) is detected or can be detected via a detection device (19). Method according to one of the preceding claims, characterized in that during or after the construction of the molded body (1) at least one solidified section of the molded body (1), in particular the entire solidified molded body (1), is preferably subjected to a cleaning step (101) the cleaning step (101) before, during or after an, in particular thermal, aftertreatment step (102) of the molded body (1). Method according to one of the preceding claims, characterized in that while the shaped body (1) passes through the separating layer (14), at least part of the separating layer material (13) adheres, in particular forms, to at least one surface section (22) of the shaped body (1) at least part of the separating layer material (13) is a component of the molded body (1) in a green compact state (103) and / or in a finished part state (104). Method according to one of the preceding claims, characterized in that the shaped body (1) is in a green compact state (103) after its shaping structure in the course of the solidification step (100) by means of an additive manufacturing device (3) and in an, in particular thermal, post-treatment step ( 102) at least in sections, in particular completely, by an aftertreatment device, is post-treated, in particular tempered, in particular by a temperature control device in order to achieve a finished part state (105). Method according to one of the preceding claims, characterized in that at least the solidification step (100), which takes place in particular by means of polymerization, for solidifying the building material (2) to form a molded body (1) within a digital light synthesis method (DLS), in particular a Continuous Liquid Interface Production process (CLIP) and / or a stereolithography process (SLA) and / or a digital light processing process (DLP) takes place. Shaped body (1), in particular a vehicle component, produced by a method according to one of the preceding claims. Device for carrying out a method according to one of the Claims 1 until 15th .

Images