DE102020115722A1 - Method for the additive production of at least one shaped body, in particular at least one vehicle component - Google Patents

Abstract

A method for the additive production of at least one molded body (1), in particular at least one vehicle component, in an additive manufacturing device (2) by successive selective solidification of a, in particular powdery, building material (3) to form the molded body (1) (1), comprising the following Method steps: - building up at least one shaped body (1) on a building board (3) of the additive manufacturing device (2), - removing unconsolidated building material (3) from the at least one shaped body (1) and / or from the building board (3), the Building board (3) comprises at least one channel (4, 4 '), - through which, during the removal of the unconsolidated construction material, the unconsolidated construction material is at least partially, in particular completely, discharged and / or through which a flushing fluid (5) for at least some sections, in particular complete removal of unconsolidated building material (2) from the molded body (1) and / or from the building board (3) w earth.

Description

The invention relates to a method for the additive production of at least one shaped body, in particular at least one vehicle component.

Corresponding methods for the additive production of at least one shaped body, in particular at least one vehicle component, are basically known from the prior art. So it is, for example, from the pamphlets DE 10 2007 059 865 A1 known to produce a vehicle component in the course of a metal powder-based additive assembly process. From the pamphlet DE 195 11 772 A1 the use of a substrate plate which is arranged on a carrier and on which building material is applied is known. After the additive manufacturing process, the unconsolidated building material applied to the substrate plate is typically removed from the molded body produced by means of a manually guided suction nozzle and thus by means of suction or by means of a brush. This is associated with a high, in particular manual, effort. It is also complex or even impossible to achieve residue-free removal of the unconsolidated building material from the shaped body. In certain areas, e.g. B. in engine technology, the purity of a component is of great importance, so it can happen that additive manufacturing processes are excluded as a manufacturing process due to the risk of contamination.

The invention is based on the object of specifying a method which, in particular with regard to a simple, quick and inexpensive measure, enables the production and removal of unconsolidated building material. The degree of automation of this process step should preferably be increased.

The object is achieved by a method for the additive production of at least one shaped body, in particular at least one vehicle component, 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 at least one shaped body, in particular at least one vehicle component, in an additive manufacturing device by successive selective solidification of a, in particular powdery, building material to form the shaped body, comprising the following process steps: (a) building at least one shaped body on a building plate the additive manufacturing device, (b) removing unconsolidated building material from the at least one molded body and / or from the building panel. The method is characterized in that the building board comprises at least one channel, (c) through which, during the removal of the unconsolidated construction material, the unconsolidated construction material is at least partially, in particular completely, discharged or can be discharged and / or (d) through which (the Channel) a flushing fluid for at least partially, in particular complete, removal of unconsolidated building material from the molded body and / or from the building board is passed or can be passed through. In other words, the building board is provided with a discharge and / or flushing channel which has a function during the removal of the unconsolidated building material from the molded body and / or from the building board, in particular during a powder removal step.

The building board can also be referred to as a base plate and is typically an element within an additive manufacturing device on which the solidified and thus the at least one molded body to be produced is attached or built up. For this purpose, the building board is typically displaced, in particular vertically, during the building process relative to an energy input device and / or relative to a building level to be supplied with a subsequent building material. As a result of the vertical displacement of the building board, for example, the recently produced molded body layer is moved or relocated from the building level and this building level is made available for the supply of further or “fresh” building material in order to carry out a subsequent solidification step through the action of energy radiation.

The building material used to produce the shaped body can, for example, be present at least partially, in particular completely, in liquid and / or in powder form within the additive manufacturing device. The unconsolidated building material can, for example, be in the form of a powdery building material, which is or can be used as a support for subsequent material layers during the additive build-up. After the molded body has reached its target geometry in the course of the additive build-up, the unconsolidated building material must be removed. According to the invention, this can be done by removing or letting at least part of the unconsolidated building material pass through at least one channel provided on the building board side and / or by rinsing away, for example, the unconsolidated building material adjacent to the molded body by its impact, by means of a through the at least one channel of the building board flushing fluids passed through. In an optional combined embodiment, at least part of the unconsolidated building material can be discharged through the building board-side channel and a further part of the unconsolidated building material by its impact with the building board through the channel flushing fluid passed through from the molded body and / or separated from the building board.

The building board can comprise one channel or several channels, in particular discharge and / or flushing channels. In the case of at least two channels, these can be distributed or present at least in sections, in particular completely, regularly and / or irregularly over the surface facing the molded body and / or within the main extension volume of the building board. The building board can, for. B. represent a component produced from an additive manufacturing process, so that the shape and / or the course of the at least one channel can be generated in a simple and convenient manner.

Because the volume of the building platform is used for the removal process of the unconsolidated building material, the degree of freedom of design for the molded body to be manufactured and / or for the arrangement of the at least one molded body within a volume of an additive manufacturing device can be increased, since an alternative and / or additional space is made available for the liquid building material removal process.

It is possible to use a building board which comprises at least one channel, preferably a discharge channel and / or a flushing channel, which extends at least in sections, in particular completely, within a main volume of the building board. The channel can, for example, be designed as a connection between two openings on different sides and / or surfaces of the building board. The channel can be designed at least in sections, in particular completely, as a closed channel, i. H. as a channel which extends exclusively from a first opening in the surface and / or side of the building board to a further opening in a further surface and / or side of the building board. In this way, the channel can, for example, be encompassed, in particular fully, by the material of the building board. Alternatively or additionally, the channel can be designed at least in sections, in particular completely, as a channel that is open through the material and / or through the structure of the building board itself, e.g. B. in the manner of an at least partially extending groove on the surface of the building board. For example, a channel formed at least in sections as a groove open on one side can preferably be closed off at least in sections, in particular completely, by solidified building material or another element at least during the process step of removing unconsolidated building material. It is thus possible for the channel section of the channel of the building board, which is open at least on one side, to be surrounded by a solidified building material in the course of the additive construction of the molded body in such a way that a “closed channel” is formed.

In a further advantageous embodiment it can be provided that a building board is used which comprises at least one channel, in particular a discharge and / or flushing channel, which extends from a surface facing the molded body to a further surface of the building board. It is thus possible for at least two openings in the channel to be arranged on the top and bottom of a building board. The at least one channel can preferably extend from a surface facing the molded body to an opposite surface and / or to a laterally arranged surface of the building board.

At least one opening of the at least one channel can be arranged or formed, for example, in the vicinity of at least one molded body built on the building board. In this context, the proximity area is to be understood as an arrangement and / or a structure of the molded body relative to the at least one opening of the channel facing the installation space, which is less than 15.0 cm, preferably less than 5.0 cm, particularly preferably less than 2, 5 cm, most preferably less than 1.0 cm, from the nearest interface or surface of the solidified building material of the shaped body. Alternatively or additionally, a maximum distance from a projection of the outer contour shape of the at least one molded body onto the surface of the building board facing the molded body to the opening building board can be understood as a close range, which is less than 15.0 cm, preferably less than 5.0 cm, particularly preferred is less than 2.5 cm, most preferably less than 1.0 cm. For example, the non-solidified building material, which, in particular directly, adjoins solidified building material forming the shaped body during the additive construction, is arranged or formed there or adheres there in the course of removal at least partially, preferably predominantly, particularly preferably completely, through at least one channel discharged and / or flushed away from the molded body and / or from the building board by a flushing fluid passed through the channel.

It is possible that (a) the channel is closed at least in sections in a first state, in particular before and / or during the additive construction of the molded body, and (b) is opened before and / or during the removal of the unconsolidated building material and / or is open. The channel can be closed, for example, by a closing means. Here, the closing means can be used during the manufacturing process and / or assembly process of the building board, for example in the In the course of an additive manufacturing process, to be built or assembled. Alternatively or additionally, the closing means can have been produced in the course of an additive manufacturing process for the production of the molded body (e.g. in situ with the molded body), the building board itself not or at least partially not being produced in one or not in the same additive manufacturing process. The closing means can, for example, be designed as a closing means, in particular as a closing layer, before and / or during the additive manufacturing process for producing the molded body in or on the building board for at least partial, in particular complete, formation of the closing means closing the channel. The closing means or closure means can, for. B. be applied as building material, especially with a generous dosage. The closing means or the closing layer can be formed at least in sections, in particular completely, by solidified and / or unsolidified building material, preferably in the course of an additive construction of the at least one shaped body. Since, in the case of unsealed channel openings on the building board, the building material applied first reaches the at least one channel via the at least one opening, a bead can form on the surface of the applied building material layer facing away from the building board. This bead formation can be compensated for by a defined additional application of building material.

Alternatively or additionally, the effective construction area can begin at an area which is so spaced from the opening and which is “built up” or “buried” by tilting a powdery building material in such a way that it falls into the sewer during the application of the first layers of building material no longer has an impact on the layers above or has no impact on the effective construction area. Furthermore, it is possible to provide a channel course relative to the opening in the end region of the channel facing the construction chamber or the construction site of the molded body, which allows the opening to be closed by the penetration of a defined amount or of little building material. For example, the course of the channel in the end area facing the construction site and thus in the vicinity of the opening facing the construction site has an angle and / or an, in particular L-shaped, step and / or a chicane that prevents the penetration of building material due to gravity limits the opening facing the building level.

In a further optional embodiment it can be provided that the opening of the channel takes place at least in sections, in particular completely, displacement and / or destruction of a closing means; the closing means itself or a connection point of the closing means with the channel preferably has a predetermined breaking area. In a first variant, at least one opening of a channel of the building board can be temporarily opened and / or closed via a movably mounted closing means. This makes it possible to use a building board multiple times for separately executed construction processes and to open and close the opening correspondingly frequently or reproducibly for this purpose. In a further variant, the closing means can be designed in such a way that the closing means can no longer be used after the opening has been opened.

The closing means can be converted from a state that closes the at least one channel to a state that opens the channel, for example by a mechanical and / or chemical and / or electrical and / or thermal and / or magnetic action. In the case of a mechanical action, for example, by introducing force by means of rigid traction and / or pressure means and / or by introducing force by means of fluid admission (gas admission and / or liquid admission), an at least section-wise break and / or an at least section-wise displacement of the closing means can be initiated. For example, a slide mechanism can be arranged or formed in or on the building board, which at least partially, in particular completely, displaces and / or at least partially, in particular completely, destroys the firing means. A chemical action in this context can include, for example, the application of a chemical to the closing means that changes the physical properties of the closing means in such a way that the closing effect of the closing means is at least partially, in particular completely, canceled and the building board-side channel can thus be released. Alternatively or additionally, in the course of exposure to thermal energy, e.g. B. heat, and / or by the action of current and / or an electric and / or magnetic field, a change in the properties of the locking means take place in such a way that its locking effect for the channel is canceled.

It is possible that, after the additive construction of the molded body, a corresponding media line for supplying a medium, in particular a flushing fluid, and / or for discharging unconsolidated building material is connected via a connection means arranged or formed on the building board. The connection means can, for example, form an interface to which a media line can be connected in a media-tight and releasable manner, ie, for example, non-destructively releasable. For this purpose, the media line and the connection means a structure, in particular provided with a sealing element, which enables a temporary and media-tight connection of the media line and the connection means on the building board side. For example, the connection of the media line and the connection means on the building board side can take place or be designed in a force-fitting and / or form-fitting manner.

Alternatively or additionally, it can be advantageous if the building board comprises centering means and / or holding means which enable simplified and / or functionally reliable assembly when the building board is brought together with a docking station and / or when connecting means and media line are brought together or coupled enable. A building board-side holding means can, for. B. facilitate an automated, in particular robot-assisted, holding and / or gripping of the building board.

In a coating process, a coating agent for building up a layer in or on the shaped body can be supplied, for example, for at least partially, in particular complete, coating of the at least one shaped body via the media line. The coating agent can, for example, be introduced as a liquid and / or in powder form into the interior and / or into an outer section of at least one shaped body, in particular at least one group of shaped bodies, via the channel on the building board and there, or as a Form layer. For example, the coating agent fed into an interior space and / or to an outer surface of the shaped body by means of the channel is used to powder coat an inner or outer surface section of the shaped body at least in sections.

It is possible that in the course of a test process at least one (a) dependent on at least the unconsolidated building material discharged via the channel (physical and / or chemical) variable and / or (b) one dependent on the execution of the flushing fluid through the (Physical and / or chemical) variable related to the channel and / or (c) a (physical and / or chemical) variable related to a test medium guided through the channel is detected. For example, a pressure change and / or a pressure value and / or a mass and / or a volume flow and / or a volume and / or a reaction to an electric or magnetic field is detected and compared with a reference value. For example, it is possible for the mass and / or the volume of the unconsolidated building material discharged through the channel to be recorded. By comparing the recorded size, in particular the mass or volume, of this recorded unconsolidated building material with a reference value, a statement can be made about the degree of removal or the purity of the shaped body. For example, the amount of residues or the degree of contamination of unconsolidated building material in a cavity or interior of the molded body can be determined and, if necessary, checked.

By flushing the channel and an interior of the shaped body by means of a gaseous and / or liquid flushing medium, a conclusion can be drawn about the degree of cleaning or the liberation of a section, e.g. B. an interior, the molded body are drawn. The flushing and its evaluation or observation, in particular the pressure values, can also provide a conclusion for the functioning of a physical and / or chemical property relevant in the intended use of the shaped body or the functioning of the shaped body for at least one technical aspect, e.g. B. a flow behavior can be checked. So the shaped body can, for. B. be designed as an aerosol separator, its functionality and / or its functional effectiveness (z. B. separation behavior) for separation can be checked and / or validated using the test process. Quality assurance can thus be carried out in a simple manner, since at least part of the test medium, in particular the complete test medium, is passed through a channel on the building board side. By using the building board or the building board-side channel for introducing a test medium, the functional test of at least one molded body designed as an aerosol separator, in particular by using at least one connecting means on the building board, can be simplified.

For example, a multiplicity of shaped bodies can be built up on the building board and in particular each connected to a channel on the building board side. Due to the connection means for connection to a media line, which is provided on the building board side, the test means can be guided in a targeted manner to at least one individual shaped body and / or in a targeted manner to a group of shaped bodies and / or to all shaped bodies. By detecting the pressure and / or a change in pressure, a conclusion about the fluidic properties and / or the purity (i.e., for example, the degree of probability of unconsolidated building material still adhering in or on a section of the molded body) of at least one section of the Shaped body and / or at least a section of at least one group of shaped bodies and / or for sections of all shaped bodies.

The measured variable can also be, for example, the proportion and / or the amount of residues (e.g. unconsolidated building material) retained in a filter element downstream of the test medium flowing through. For this purpose, z. B. on the building board side in the channel, a medium can be introduced or carried out, as first flows through the building board side channel and then z. B. an interior section of the molded body is flowed through, downstream of the interior section a filter element can be arranged or formed and flowed through, the filter element at least partially, in particular completely, retains or collects any residues of unconsolidated building material. By evaluating the collected residues or the filtrate on the filter element, conclusions can be drawn about the purity and / or the surface properties of the interior of the shaped body.

It is possible that (a) an unconsolidated building material (a1) located in a first interior space of a first shaped body is at least partially, in particular completely, discharged via a first channel of the building board and / or (a2) by means of a flushing fluid passed through a first channel is removed and (b) an unconsolidated building material located in a second, separate from the first interior space of the first shaped body or another shaped body, at least in sections, in particular completely, (b1) is discharged via a further channel and / or (b2) by means of a flushing fluid passed through a second channel is removed. Alternatively or additionally, during the coating process and / or during the testing process, a coating agent and / or a testing agent or a testing medium can be introduced into separate interiors of one or different molded bodies via at least sections, in particular completely, separately running channels in the respective interiors. In other words, different sections of the one shaped body or several shaped bodies can be supplied or charged with coating agent and / or test agent separately from one another via at least partially, in particular completely, separated channel sections or channels of the building board.

In a further advantageous embodiment it can be provided that (a1) at least two sections of a shaped body and / or (a2) at least two sections of a first and a further shaped body are built up so closely in the course of the additive construction and / or (a3) at least A cavity of a molded body can be built up in the course of an additive structure in such a way that (b) an unconsolidated building material lying between the two sections and / or in the cavity predominantly, in particular exclusively or completely, via a spatial connection to the channel of the building board, in particular in the non-separated state of the at least one shaped body from the building board, from the shaped body and / or the building board can be removed. In other words, after the additive construction of the at least one shaped body, at least some sections of unsolidified building material can be captured or enclosed by the at least one shaped body and the building board in such a way that it cannot be removed or can only be removed via the at least one building board-side channel. For example, this is the case when the distances between individual molded body sections and / or the building board are so small that the grain size of the powder does not fit through any gaps. So z. B. the gap size or the maximum clear width can be smaller than the grain size (z. B. the maximum grain size or the mean grain size or the minimum grain size) of the powder. Also due to a snagging and / or tilting, grain sizes, which z. B. 20%, preferably 15%, particularly preferably 10%, most preferably 5%, smaller than the gap size or the clear width of a gap section, if there is a certain length perpendicular to the opening area of the gap section, be unsuitable for passage or a Be prevented from stepping through.

An unconsolidated building material lying between the two sections and / or in the cavity means that the unconsolidated building material is trapped between the two sections and / or in the cavity. I. E. z. B. that the unconsolidated building material is trapped there at least in the state of the at least one molded body not separated or detached from the building board and cannot be removed from this assembly with the exception of the use of the at least one building board-side channel.

The additive process for producing the shaped body can, for example, be a stereolithography process (SL) and / or a laser sintering process (LS) and / or a laser beam melting process (LBM) and / or a selective laser melting process (SLM) and / or an electron beam melting process (EBM) and / or a fused layer modeling / manufacturing process (FLM / FFF) and / or a multi-jet modeling process (MJM) and / or a poly-jet modeling process (PJM) and / or a binder jetting process and / or a layer laminated manufacturing process (LLM) and / or a continuous liquid interface production process (CLIP) and / or a thermal transfer sintering process (TTS) and / or a digital light processing Process (DLP) and / or a Digital Light Synthesis Process (DLS). The, in particular liquid or powdery, building material processed in the additive method preferably comprises at least one partially, in particular completely, metal and / or plastic and / or synthetic resin.

In addition to the method for the additive production of at least one shaped body, the invention also relates to a building board for use in a method described herein. The invention also relates to at least one molded body, in particular at least one vehicle component, which is produced in a method described herein. The invention thus also encompasses a vehicle which has a vehicle component produced in the method described herein or in which such a vehicle component is installed. The vehicle can include, for example, a motor vehicle, in particular a multi-lane motor vehicle, or a road vehicle driven by an engine.

All advantages, details, designs and / or features of the method according to the invention can be transferred or applied to the building board according to the invention and the molded body according to the invention.

• 1 eine perspektivische Prinzipdarstellung einer mit einer Vielzahl an Formkörpers versehenen Bauplatte gemäß einem Ausführungsbeispiel;
• 2 eine Prinzipdarstellung einer mit Formkörpern versehen Bauplatte gemäß einem Ausführungsbeispiel, wobei Innenräume und Zwischenräume der Formkörper in einer Verbindung mit bauplattenseitigen Kanälen stehen;
• 3 eine Prinzipdarstellung einer mit Formkörpern versehen Bauplatte gemäß einem Ausführungsbeispiel, wobei die Verbindung der Innenräume und Zwischenräume der Formkörper mit bauplattenseitigen Kanälen mit einem Schließmittel verschlossen sind;
• 4 eine schematische Schnittdarstellung eines als Aerosolabscheider ausgebildeten Formkörpers gemäß einem Ausführungsbeispiel.

The invention is explained in more detail using exemplary embodiments in the drawings. It shows:

• 1 a perspective basic representation of a building board provided with a plurality of shaped bodies according to an exemplary embodiment;
• 2 a schematic diagram of a building board provided with molded bodies according to an exemplary embodiment, the interiors and spaces of the molded bodies being in connection with channels on the building board side;
• 3 a schematic diagram of a building board provided with molded bodies according to an embodiment, the connection of the interior spaces and spaces between the molded bodies with channels on the building board being closed with a closing means;
• 4th a schematic sectional view of a shaped body designed as an aerosol separator according to an embodiment.

The molding shown and described below 1 is exemplarily designed as an aerosol separator, in particular as an oil mist separator, cf. 4th . The molded body 1 can be designed as any other vehicle component. For example, the shaped body 1 be designed as an injection nozzle, battery cell cooler, control unit cooler, liquid-liquid heat exchanger (e.g. for setting different temperature levels between an electrical energy store and an internal combustion engine of a hybrid vehicle) or as a hydraulic valve. The shaped body can 1 for example, when used as intended, perform a fluidic task or contribute to the fulfillment of such a task.

A method for the additive production of at least one shaped body is provided 1 , in particular at least one vehicle component, in an additive manufacturing device. Here, through successive selective solidification of a building material, in particular in powder form 2 a shaped body 1 built or formed. The method comprises the following method steps: a) Building up at least one shaped body 1 on a building board 3 the additive manufacturing device, b) removing unconsolidated building material 2 of the at least one shaped body 1 and / or from the building board 3 , with the build plate 3 at least one channel 4th , 4 ' comprises, (I) by which during the removal of the unconsolidated building material 2 the unconsolidated building material 2 is at least partially, in particular completely, discharged and / or (II) through which a flushing fluid 5 for at least partial, in particular complete, removal of unconsolidated building material 2 from the molded body 1 and / or from the building board 3 is passed through. That in between 6th between the moldings 1 and / or indoors 7th any unsolidified building material 2 can pass through the at least one channel 4th , 4 ' the building board 3 be removed or, starting from one, through the at least one into a channel on the building board 4th , 4 ' flushing fluid passed through 5 from the molded body 1 and / or the build plate 3 washed away or removed.

A building board can be used for this 3 used that at least one channel 4th , 4 ' , preferably a discharge channel and / or a flushing channel, which extends at least in sections, in particular completely, within a main volume of extension of the building board 3 extends. In other words, the building panel is within the main extension volume 3 a circumferentially closed channel 4th , 4 ' formed, which has openings 8th , 9 , 13th the building board to the at least one molded body 1 and / or to at least one gap 6th at least two shaped bodies 1 on the one hand and on the other hand to an interface for the targeted derivation of unconsolidated building material 2 and / or to an interface for the targeted introduction of a flushing fluid 5 and / or a coating agent and / or a cleaning agent.

It can also, for example, be a building board 3 used that at least one channel 4th , 4 ' comprises, which extends from one of the molded body 1 facing surface 10 to another surface 11th the building board 3 extends. The at least one channel preferably extends 4th , 4 ' of one of the molded body 1 facing surface 10 to a opposite surface 11th and / or to a laterally arranged surface (not shown) of the building board 3 . One channel 4th can for example have three connection points or more than two connection points, so that a first connection point or opening 8th to an interior 7th of the molded body 1 , a second opening 9 to an interface for a media line 12th and a third opening 13th to a space in between 6th at least two shaped bodies 1 across the canal 4th are interconnected or connectable (not shown). In 2 is a first channel 4th with three openings 8th , 9 provided, with two openings 8th to interiors 7th two moldings 1 and another opening 9 to the connection point for the media line 12th leads. An opening on the building level 8th , 13th the building board can also only have a single connection point-side opening 9 for a media line 12th be connected, see channel 4 ' according to 2 .

It is possible to have at least one opening 8th , 9 , 13th of at least one channel 4th , 4 ' in a close range 14th of at least one on the build plate 3 built-up molded body 1 is arranged or formed. For example, unconsolidated building material is used 2 , the solidified adjacent to the molded body 1 forming building material is arranged or formed during the course of the removal at least partially, preferably predominantly, particularly preferably completely, through at least one channel 4th , 4 ' discharged and / or by a through the channel 4th , 4 ' guided flushing fluid 5 from the molded body 1 and / or from the building board 3 washed away or removed.

The channel 4th , 4 ' can for example be closed at least in sections in a first state and before and / or during the removal of the unconsolidated building material 2 be opened. In the 3 are closing means 15th , 15 ' shown schematically. So z. B. opening the channel 4th , 4 ' by relocating and / or destroying a locking means at least in sections, in particular completely 15th , 15 ' respectively. The closing means preferably has 15 ' itself or a connection point of the locking means 15 ' with the channel 4th , 4 ' a predetermined breaking range 16 or a predetermined breaking point. Such a predetermined breaking range 16 can e.g. B. as a tapered and / or in its strength weakened area of a closing means 15 ' (see 3 ) and break in the event of a force (e.g. application of pressure force) and thus the channel 4th , 4 ' release. Because the predetermined breaking range 16 or the closing means 15th , 15 ' during the additive build-up of the molded body 1 is closed, powdery building material can trickle into it 2 into sections of the at least one channel 4th , 4 ' during the application of building materials 2 onto the build plate 3 be prevented.

If for at least one to the molded body 1 directional opening 8th , 13th the building board 3 no locking means 15th , 15 'is provided, it can prove to be advantageous if in the construction space or construction level 17th directed half, preferably third, particularly preferably quarter, most preferably eighth, (of the length) of the channel 4th , 4 ' a channel course is formed in such a way that one of the building level 17th out in the canal 4th , 4 ' falling or penetrating building material 2 there a chicane “finds” which, due to gravity, continues a movement of the incident or penetrating, in particular powdery, building material 2 inhibits or makes it difficult. For example, the course of the channel can include a step on which any incident or penetrating building material 2 comes to rest, so that in distant sections of the channel 4th , 4 ' not or not to the extent or not so easily penetrating construction material due to gravity 2 can reach, cf. 3 . Alternatively or additionally, a channel section or a channel-side baffle can be designed in a siphon-like manner.

Furthermore, the closing means 15th , 15 ' for example by a mechanical and / or chemical and / or electrical and / or thermal and / or magnetic action of one of the at least one channel 4th , 4 ' closing state in a the channel 4th , 4 ' to be transferred to the opening or releasing state.

It is possible that after the additive structure of the shaped body 1 via one on the build plate 3 arranged or formed connection means 18th one of the connection means 18th assigned and / or corresponding media line 12th for feeding a medium, e.g. B. a flushing fluid 5 and / or a cleaning agent and / or a coating agent, and / or for discharging unconsolidated building material 2 is connected. The connection means 18th can be designed in the manner of a coupling in such a way that a temporary, in particular media-tight, connection between the duct on the building board 4th , 4 ' and a media line 12th can be produced. Thus, via the media line 12th via the connection means 18th a medium through the channels 4th , 4 ' in or on a shaped body 1 be transported to unconsolidated building material 2 from the molded body 1 and / or from the building board 3 to solve.

In a coating process, for example, coating can be carried out at least in sections, in particular completely 27 of the at least one shaped body 1 via the media line 12th a, in particular liquid and / or powdery, coating agent for building up a layer 27 in or on the molded body 1 are fed. For example, a powder coating on an inside and / or outside of at least one shaped body can be achieved in this way 1 are executed.

In the course of a test process, for. B. at least one depending on at least that over the channel 4th , 4 ' discharged unconsolidated building material 2 standing (e.g. physical and / or chemical) quantity can be measured. A pressure change and / or a pressure value through at least one channel is preferred 4th , 4 ' guided test medium, in particular a test liquid, detected and compared with a reference value. The course of the pressure value or the course of a pressure drop can give an indication of the extent to which z. B. an interior of a molded body 1 of unconsolidated building material 2 has been freed and / or which fluidic or fluidic properties at least one section of the shaped body 1 having. If the molded body 1 performs a fluidic function in the intended use, this can be used for quality control or for functional testing (e.g. differentiation between good part and bad part). In particular, the at least one connection means held on the building board side 18th can perform a simplified test by connecting a media line 12th and enable transmission of the test medium.

In 2 is the media management 12th shown as a hose-like element, which is based on the connection point 18th extends to a media source. In contrast, the 3 an alternative to this is shown, according to which it can be advantageous for the building board to include centering means and / or holding means (not shown), which make it possible when the building board is brought together with a docking station and / or when the connecting means and media line are brought together or coupled to enable simplified and / or functionally reliable assembly. In other words, the media line can 12th be formed at least partially in a console or in a solid body as a channel section, the console making it possible to have a plurality of media lines in a simple and convenient manner 12th at the same time with different connection points 18th connect to. An example is in 3 the media management 12th designed as a channel, which has several outlets to the respective connection means 18th having. Alternatively, a console can have several media line sections that are separated from one another 12th have, which each run separately from further media lines and to different connection means on the building board side 18th to lead.

One in a first interior 7th a first shaped body 1 any unsolidified building material 2 can for example via a first channel 4th the building board 3 at least in sections, in particular completely, are discharged and one in a second, from the first interior 7th separate interior 7 ' of the first shaped body 1 or another shaped body 1 any unsolidified building material 2 at least in sections, in particular completely, via a further channel 4 ' , preferably in at least sections or completely separated from one another within the building board 2 running channels 4th , 4 ' removed or derived, cf. 3 .

It is possible that a1) at least two sections of a shaped body 1 and / or a2) at least two sections of a first and a further shaped body 1 be built up so closely in the course of the additive structure, and / or a3) at least one interior space 7th or cavity of a molded body 1 In the course of an additive structure, it is built up in such a way that b) an unconsolidated building material lying or arranged between the two sections and / or in the interior space or cavity 2 predominantly, in particular exclusively, via a spatial connection to the sewer 4th , 4 ' the building board 3 , preferably in the non-separated state of the at least one shaped body 1 from the build plate 3 , of the molded body 1 and / or is removable from the building panel. So z. B. the one with the arrow 19th labeled unconsolidated and in the space 6th at least two shaped bodies 1 arranged or captured building material 2 , especially exclusively, about the one with arrow 20th marked section of the building board-side channel 4th , 4 ' from the building board-molded body assembly without prior separation of the molded body 1 from the build plate 3 be released or removed.

Although in the 2 and 3 between the molded body 1 a continuous space (here tapering towards the top) 6th shown, which is basically for the implementation or derivation of unconsolidated building material 2 could be used, but with a critical ratio of the minimum distance to the length of such a gap it is found that, in particular, powdery, non-solidified building material cannot flow off or be diverted. In other words, unconsolidated building material can be trapped in an intermediate space and / or in an interior space of a shaped body, provided the ratio of the minimum gap size to gap length does not exceed a limit value. The method according to the invention can preferably be used to remove unconsolidated building material even with gap ratios of a gap length to minimum gap width ratio of greater than 4: 1, preferably greater than 5: 1, particularly preferably greater than 7: 1, most preferably greater 9: 1. This is due to the fact that it can be removed via the at least one channel on the building board side 4th , 4 ' and / or by the possibility of pressurization through the channel on the building board side 4th , 4 ' supplied flushing fluids 5 justified.

The additive process for the production of the molded body 1 For example, a stereolithography process (SL) and / or a laser sintering process (LS) and / or a laser beam melting process (LBM) and / or a selective laser melting process (SLM) and / or an electron beam melting process (EBM) and / or a fused layer modeling / manufacturing process (FLM / FFF) and / or a multi-jet modeling process (MJM) and / or a poly-jet modeling process (PJM) and / or a binder jetting process and / or a layer laminated manufacturing process (LLM) and / or a continuous liquid interface production process (CLIP) and / or a thermal transfer sintering process (TTS) and / or a digital light processing process (DLP) and / or be a digital light synthesis process (DLS). Alternatively or in addition, it comprises the, in particular liquid or powdery, building material processed in the additive method 2 Metal and / or plastic and / or synthetic resin or contains at least components of the substances mentioned.

The invention also extends to a building panel 3 for use in a method described herein and also on a shaped body 1 , in particular a vehicle component that was manufactured in a method described herein.

In 3 is over part of the molded body 1 a filter element 21 arranged or formed. Via the at least one connection means 18th A test medium can be introduced and via the at least one channel 4th , 4 ' to the interior 7th , 7 ' at least one, a filter element 21 associated molded body 1 be forwarded. The filter element 21 is here downstream of the interior 7th of the molded body 1 arranged or designed so that any residues of dirt and / or unconsolidated building material from the building board 3 and / or from the interior 7th of the molded body 1 in the filter element 21 be held during the passage of the test medium. That in the filter element 21 remaining filtrate can provide information on the degree of purity of the building board and / or the interior 7th of the molded body 1 represent.

4th shows an example of a molded body designed as an aerosol separator 1 , being in the interior 7th of the molded body 1 several with openings 24 provided partition walls 25th are arranged or formed, which in the intended use of the molded body 1 fulfill a fluidic task. Via the at least one channel on the building board side 4th , 4 ' can the flushing fluid 5 over that of an opening 8th of the duct on the building board side 4th , 4 ' associated opening 26th of the molded body 1 in the interior 7th of the molded body 1 penetrate and especially areas of unconsolidated building material that are difficult to access 2 (e.g. the passage openings 24 and / or the corner areas of the partition walls 25th ) in a simple and comfortable way. Analog can be done through the opening 26th of the molded body 1 a coating 27 of the interior 7th and / or a test process using a test medium can be performed.

List of reference symbols

1

Moldings

2

Building material

3

Building board

4, 4 '

channel

5

Irrigation fluid

6th

Space

7, 7 '

Interior of 1

8th

Opening from 3

9

Opening from 3

10

first surface of 3

11th

further surface from 3

12th

Media management

13th

Opening from 3

14th

Close range

15, 15 '

Locking means

16

Predetermined breaking range

17th

Building level

18th

Connection means

19th

arrow

20th

arrow

21

Filter element

22nd

minimal gap

23

Gap length

24

Passage opening

25th

Partition

26th

Opening from 1

27

Coating

QUOTES INCLUDED IN THE DESCRIPTION

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

Patent literature cited

• DE 102007059865 A1 [0002]
• DE 19511772 A1 [0002]

Claims (15)

A method for the additive manufacture of at least one shaped body (1), in particular at least one vehicle component, in an additive manufacturing device by successive selective solidification of a, in particular powdery, building material (2) to form the shaped body (1), comprising the following process steps: building at least one shaped body (1) on a building board (3) of the additive manufacturing device, - removal of unconsolidated building material (2) from the at least one molded body (1) and / or from the building board (3), characterized in that the building board (3) has at least one Channel (4, 4 '), - through which, during the removal of the unconsolidated building material (2), the unconsolidated building material (2) is at least partially, in particular completely, discharged and / or - through which a flushing fluid (5) for at least some sections, in particular complete removal of unconsolidated building material (2) from the molded body (1) and / or from the construction plan atte (3) is passed through. Procedure according to Claim 1 , characterized in that a building board (3) is used which comprises at least one channel (4, 4 '), preferably a discharge channel and / or a flushing channel, which extends at least in sections, in particular completely, within a main volume of the building board (3 ) extends. Procedure according to Claim 1 or 2 , characterized in that a building board (3) is used which comprises at least one channel (4, 4 ') which extends from a surface (10) facing the molded body (1) to a further surface (11) of the building board (3 ), the at least one channel (4, 4 ') preferably extends from a surface (10) facing the molded body (1) to an opposite surface (11) and / or to a laterally arranged surface of the building board (3). Method according to one of the preceding claims, characterized in that at least one opening (8, 9, 13) of the at least one channel (4, 4 ') in a close region (14) of at least one molded body (1 ) is arranged or formed, preference is given to unconsolidated building material (2) which is arranged or formed adjacent to solidified building material forming the molded body (1) during the additive build-up in the course of removal at least partially, preferably predominantly, particularly preferably completely, by at least a channel (4, 4 ') discharged and / or flushed away from the molded body (1) and / or from the building board (3) by a flushing fluid (5) passed through the channel (4, 4'). Method according to one of the preceding claims, characterized in that the channel (4, 4 ') is at least partially closed in a first state and is opened before and / or during the removal of the unconsolidated building material (2). Method according to one of the preceding claims, characterized in that the channel (4, 4 ') is opened by at least some sections, in particular complete, displacement and / or destruction of a closing means (15, 15'); 15 ') itself or a connection point of the closing means (15, 15') with the channel (4, 4 ') has a predetermined breaking area. Procedure according to Claim 6 , characterized in that the closing means (15, 15 ') by a mechanical and / or chemical and / or electrical and / or thermal and / or magnetic action from a state that closes the at least one channel (4, 4') to a Channel (4, 4 ') opening state is transferred. Method according to one of the preceding claims, characterized in that, after the additive structure of the molded body (1), a media line (12) for supplying a medium and / or for draining off via a connection means (18) arranged or formed on the building board (3) unconsolidated building material (2) is or is connected. Procedure according to Claim 8 , characterized in that in a coating process for at least partially, in particular complete, coating (27) of the at least one shaped body (1) via the media line (12), a coating agent for building up a layer of a coating (27) in and / or on the shaped body (1) is supplied. Method according to one of the preceding claims, characterized in that in the course of a test process at least - one variable depending on at least the unconsolidated building material (2) discharged via the channel (4, 4 ') and / or one depending on the implementation of the flushing fluid (5) through the channel (4, 4 ') and / or a variable that is dependent on a test medium passed through the channel (4, 4') is detected, the detected variable is preferably compared with a reference value . Method according to one of the preceding claims, characterized in that an unconsolidated building material (2) located in a first interior space (7) of a first molded body (1) is discharged via a first channel (4) of the building board (3) at least in sections, in particular completely and an unconsolidated building material (2) located in a second interior (7 ') of the first shaped body (1) or of a further shaped body (1), which is separate from the first interior (7), at least in sections, in particular completely, via a further channel ( 4 ') is discharged. Method according to one of the preceding claims, characterized in that - at least two sections of a molded body (1) are built up so closely in the course of the additive build-up and / or - at least two portions of a first and a further molded body (1) are built up so closely in the course of the additive structure and / or - at least one interior (7, 7 ') of a molded body (1) is built in the course of an additive structure that - one between the two sections and / or in the interior (7, 7') Laying unconsolidated building material (2) predominantly, in particular exclusively, via a spatial connection to the channel (4, 4 ') of the building board (3), in particular when the at least one shaped body (1) is not separated from the building board (3) the molded body (1) and / or from the building board (3) is removed or is removable. Process according to one of the preceding claims, characterized in that the additive process for producing the molded body (1) is a stereolithography process (SL) and / or a laser sintering process (LS) and / or a laser beam melting process (LBM) and / or a selective laser melting process (SLM) and / or an electron beam melting process (EBM) and / or a fused layer modeling / manufacturing process (FLM / FFF) and / or a multi-jet modeling process (MJM) and / or a Poly-Jet Modeling Process (PJM) and / or a Binder Jetting Process and / or a Layer Laminated Manufacturing Process (LLM) and / or a Continuous Liquid Interface Production Process (CLIP) and / or a Thermal Transfer Sintering Method (TTS) and / or a digital light processing method (DLP) and / or a digital light synthesis method (DLS), preferably comprises the building material (3) processed in the additive method, in particular liquid or powdery, metal and /O the plastic and / or synthetic resin. Building panel (3) for use in a method according to one of the preceding claims. Molded body (1), in particular a vehicle component, produced in a method according to one of the Claims 1 until 13th , The molded body (1) is preferably designed as an aerosol separator or injection nozzle or as a battery cell cooler or as a control unit cooler or as a liquid-liquid heat exchanger or as a hydraulic valve or as a component of the aforementioned vehicle components.

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