DE102021107720A1 - Process, device and system for producing a three-dimensional molded part - Google Patents

Abstract

The present invention relates to a method for producing a three-dimensional molded part from a structure (1), comprising the steps: A. Forming or providing the structure (1) from at least one tape structure, which tape structure contains at least one polymer;B. heating the structure (1) at least above a softening point of the polymer of the tape structure;C. forming and consolidating the structure (1) by means of a three-dimensional mold into the three-dimensional molded part; andD. Removing the molding from the mold, the three-dimensional shape being formed by a molding material (4) in a molding box (3) and a contour (5) of the three-dimensional shape on an open side (6) of the molding box (3) by contouring the molding material (4), in particular by embossing, removing or applying the molding material (4). The invention also relates to a device (20) such as a plant for producing a three-dimensional molded part from a structure (1).

Description

The present application relates to a method for producing a three-dimensional molded part from a structure according to claim 1 and a device for producing a three-dimensional molded part from a structure according to the preamble of claim 17. The application also relates to a system for producing a three-dimensional molded part from a structure according to claim 29.

The applications for fiber composite materials have continued to increase over the past decades, especially when they could be seen as a cheap alternative to metallic materials. The use of fiber composite materials goes hand in hand with the advantages of freedom of design and adaptation to the application-specific conditions, especially with regard to the formulation options. Fiber composites are characterized in particular by high strength and high structural rigidity, which is an important criterion in automotive and aircraft construction, so that the use of fiber composites has a very high potential for lightweight construction.

The automated production of molded parts made of fiber composite materials represents a key technology in the manufacturing process of continuous fiber reinforced fiber composite components for the realization of an efficient large-scale production with reproducible and stable component quality. Today, for the production of such continuous fiber reinforced components, mainly textile fiber semi-finished products are used, which are wetted with a binder (hot melt adhesive) and/or or with a matrix partially or completely impregnated fiber yarns and/or fabrics (so-called prepregs) such as fiber fabrics, fiber knits, fiber scrims or fiber mats. The matrix of fiber-reinforced plastic has the task of embedding the highly resilient fibers (support function) and completely filling the space between them (blocking function).

In principle, materials from the group of thermoplastics and optionally additional elasticizing components such as elastomers can be used as binder and/or matrix materials, which differ in terms of strength, maximum elongation, operating temperature, processing speed and chemical resistance.

It is also known to use a cutting process to produce blanks from semi-finished products that are available as rolls or sheets in standard formats, which blanks generally line the entire surface of the unshaped component.

In particular, however, continuous fiber-reinforced components can also be produced using fiber or also known as tape laying methods with significantly less waste or even without waste and thus more resource-efficiently. In particular, the use of tapes, preferably comprising unidirectional endless fibers in a thermoplastic or duromer matrix, has proven to be a very attractive process variant. In this context, a tape is understood to mean a web-like material, in particular a prepreg material, which has a width of between 3 mm and 200 mm, for example. A tape structure is produced from the individual tapes using a tape laying device known per se, the tape structure being designed in accordance with the requirements for absorbing forces on the respective molded part. In particular, the tape structure can be a full-surface structure which is designed essentially in accordance with the contour of the subsequent molded part. Alternatively, the tape structure can be designed in such a way that the molded part is reinforced by the tape structure only in certain areas when the tape structure is combined with other materials to construct the component.

In the present case, prepreg material means in particular fiber yarns (rovings), fiber scrims and/or fiber fabrics, which are wetted with a binder and/or partially or completely impregnated with a matrix, for example a thermoplastic matrix or duromer matrix , In particular are pre-impregnated. The fibers are in particular carbon fibers, but this can also be used in the same way for glass fibers or other fibers, in particular fibers produced artificially.

To process tapes to form a tape structure, it is known to remove these tapes from a spool or roll using tape laying devices, in particular what are known as fiber placement devices, to cut them to length and place them on a laying table or one that has already been placed on the laying table to lay down the tape. When a tape is laid down, it is fixed to an already existing tape layer, for example by pointwise connection using ultrasonic welding heads, so that the laid down tape is then connected in a stationary manner to the already laid down tape layer. To fix the first tape placed directly on the table, the table is equipped with a vacuum device so that the layer of tape lying directly on the table is fixed to the table by means of a vacuum. Exemplary tape laying devices are from WO 2014/083196 A1 and from the U.S. 8,048,253 known.

After the corresponding fiber composite structures have been laid or built up with a desired shape by laying individual tapes and/or by arranging cuts, it is also known, particularly when using tapes, to bond the fiber composite structures in a subsequent process step under the action of pressure and temperature to consolidate into a laminate, which is then brought into its final form in a corresponding process in a press.

The production of fiber composite structures, in particular those that contain tape structures, is overall very complex and time-consuming and costly due to the laying of the corresponding structures, the consolidation and the forming. In particular, the need for component-specific molds for the production of the molded parts and the consolidation of the fiber composite structures is very cost-intensive and a major cost driver, especially in the production of small series.

Methods for consolidating fiber composite structures, which in particular comprise at least one tape structure, are known, for example, from the document DE 10 2017 105 450 A1 or DE 10 2014 004 053 A1 known. In both cases, a fiber composite structure to be consolidated is placed between an essentially rigid base and an essentially rigid cover and heated by means of electromagnetic radiation. At the same time, the cavity formed between the rigid cover and the rigid base is evacuated via a port, which exerts pressure on the fiber composite structure during heating and consolidation occurs. In addition, it is also known for shaping fiber composite structures to arrange them between two membranes, then heat them up and mold them onto a shaped element arranged on a table.

It is therefore the object of the present invention to specify a method, a device and a system by means of which the production of molded parts from fiber composite structures can be carried out faster and more cost-effectively, in particular in a way that conserves resources.

A further object of the present invention is to specify a method, a device and a system for producing a molded part, by means of which a flexible, quickly adaptable and cost-effective possibility of shaping is achieved.

These objects and other objects are achieved by a method for producing a three-dimensional molded part according to claim 1, by a device for producing a three-dimensional molded part according to claim 17 and by a system for producing a three-dimensional molded part according to claim 29. Advantageous configurations for the production method of a three-dimensional shaped part are set out in the dependent claims 2-16. Further advantageous developments of the device for producing a three-dimensional shaped part are set out in the dependent claims 18-28.

The device is suitable in particular for carrying out a method for producing a three-dimensional molded part from a structure, in particular a preferred embodiment thereof.

The method for producing a three-dimensional molded part from a structure can be carried out in particular with a device for producing a three-dimensional molded part from a structure, in particular an advantageous embodiment thereof.

1. A. Bilden oder Bereitstellen der Struktur aus zumindest einer Tapestruktur, welche Tapestruktur zumindest ein Polymer enthält;
2. B. Aufheizen der Struktur zumindest über eine Erweichungstemperatur des Polymers der Tapestruktur;
3. C. Formen und Konsolidieren der Struktur mittels einer dreidimensionalen Form zu dem dreidimensionalen Formteil; und
4. D. Entnehmen des Formteils von der Form.

The method according to the invention for producing a three-dimensional molded part from a structure comprises the following steps:

1. A. Forming or providing the structure from at least one tape structure, which tape structure contains at least one polymer;
2. B. heating the structure at least above a softening point of the polymer of the tape structure;
3. C. Forming and consolidating the structure with a three-dimensional mold into the three-dimensional molded part; and
4. D. Removal of the molding from the mold.

The method is further characterized in that the three-dimensional shape is formed by a molding material in a molding box and a contour of the three-dimensional shape is formed on an open side of the molding box by contouring the molding material, in particular by embossing, removing or applying the molding material.

The method according to the invention now makes it possible through the use of a mold material in a mold box that the mold material can be contoured according to the contour of the molded part to be produced and the contouring can be carried out by processing the mold material. In particular, it is no longer necessary, individual cost-intensive molds, especially on a form correspondingly adapted upper and Lower tools to be kept ready or to be made accordingly as part of the production of a new molded part. Almost any contour can be flexibly formed in the molding box using the molding material, with the processing of the molding material, in particular the embossing, removal or application of the molding material, being carried out by a molding device. This flexibility now also makes it possible to produce small series without having to construct and provide a special lower tool and/or upper tool.

The method enables the production of a three-dimensional molded part from a structure, wherein a structure can preferably be formed from fiber scrims, fiber fabrics, fiber layers and/or organic sheets and/or other materials for the production of fiber-reinforced parts. Organo sheets are preferably thermoplastically impregnated fabrics.

The structure comprises at least one tape structure, which in the present case can be unconsolidated, at least partially consolidated or already consolidated.

In addition to the tape structure, the structure preferably comprises at least one further structural element.

The structure can particularly preferably be a structure made up of a number of structural elements, in which case the individual structural elements can be a tape structure, fiber scrim, fiber fabric, fiber layers and/or organic sheets.

The polymer of the tape structure is preferably formed by a thermoplastic polymer or a duromer polymer.

In a preferred embodiment, method step C takes place before method step B, in particular when using a tape structure and/or a further structural element of the structure with a duromer polymer.

Preferably, only the shaping of the structure in method step C takes place before method step B.

A preferred embodiment of the method is characterized in that the molding material is removed in the molding box to form the contour, with the removed molding material preferably being temporarily stored in a store and, if appropriate, fed to reuse. The molding material is partially removed from the molding box by removal, so that a corresponding contour can be formed inside the molding box without having to temporarily store or relocate the molding material inside the box. The store enables a modified mold to be produced quickly, since the mold material can be accessed directly and this can be fed back into the box from the store. In particular, resources can be saved through reuse.

Alternatively or preferably in addition, the molding material is applied in the molding box to form the contour and preferably solidified, with the molding material preferably being removed from the store. By applying the molding material in the molding box, molding material is thus added to the molding box in order to be able to reproduce the corresponding contour. What is achieved in particular by the strengthening is that the contour can be formed accordingly and has a corresponding stability.

The molding material is preferably embossed in the mold box to form the contour by means of a mold shell. The shell mold can in particular be a printed shell mold. The shell mold preferably already has the corresponding contour of the molded part to be produced, so that this contour is only correspondingly stamped into the mold material, with the mold material forming a contour corresponding to the shell mold and also supporting the shell mold.

The mold shell preferably closes the open side of the mold box and the mold box is preferably rotated after the mold shell has been placed on it, so that the mold material rests on the mold shell. Placing the mold shell on the mold box and rotating the mold box ensures that the mold material rests on the mold shell and, due to its own weight, clings to the contour of the mold shell and, in particular, is compressed. The molding box is rotated in particular in such a way that the weight of the mold material rests on the mold shell. Furthermore, the rotation of the molding box makes it possible to open the molding box on the side opposite the mold shell after the rotation, for example to compact the molding material or to fill in further molding material, so that the formation of the contour is correspondingly solidified, especially when the molding box is rotated back into an initial position .

In a preferred embodiment of the method, a binding agent is added to the molding material before and/or during the formation of the contour. The binder can be, for example, water or a glue or act similar. The binder is preferably supplied to the mold material once, at intervals or continuously, with supply taking place in particular by spraying the mold material with the binder. In particular, the process for producing the molded part can result in consumption of the binding agent in the mold, so that binding agent is fed in to ensure the stability of the molding material in the corresponding contour.

A stability of the contour formed on the surface of the molding material is preferably achieved by spraying the molding material. The surface or contour of the molding material is also the area in which an increased consumption of binding agent can occur, for example due to evaporation of the binding agent.

Alternatively or preferably in addition, the mold material is tempered. Temperature control of the mold material makes it possible to minimize the temperature differences between the structure and the mold material, for example to enable better clinging to the contour or to avoid premature solidification of the structure or significant cooling of the structure.

A preferred embodiment is characterized in that the molding material in the molding box is compressed by means of a vacuum via at least one opening in the molding box which is fluidically connected to a vacuum generator. The compression of the molding material also results in a solidification of the molding material, for example when there is air between the molding material.

Alternatively or preferably in addition, the molding box is shaken before and/or during the formation of the contour and/or the molding material is subjected to vibration before and/or during the formation of the contour, preferably by means of ultrasound. Both the shaking of the molding box via corresponding shaking devices on and/or in the molding box and the impingement of vibrations on the molding material can lead to compaction or hardening of the molding material, which in particular increases the service life and stability of the contour formed in the molding material. For example, air inclusions or lumps in the mold material can be broken up by shaking or subjecting the mold material to vibrations, in particular ultrasound. In particular, this prevents the contour formed from collapsing.

It is an advantageous embodiment of the method that an intermediate layer covering the molding material is placed on the open side of the molding box with, during and/or after the formation of the contour. The intermediate layer avoids direct contact between the structure and the mold material. Furthermore, the contour of the molding material is also stabilized by the intermediate layer, so that the contour is retained even when the structure is removed or demoulded and is not damaged, for example, by the molding material adhering to the structure.

The intermediate layer is preferably a film covering the molding material in the molding box, which preferably extends to the edge of the molding box or also beyond the edge of the molding box.

Alternatively or preferably in addition, the intermediate layer can be the shell mold itself, which is thus used on the one hand to form the contour and on the other hand also to separate the mold material and structure.

The shell mold is preferably a shell mold which enables the contour to be formed precisely. In particular, the shell mold was produced using 3D printing. The shell mold is in particular formed from a material which, on the one hand, has sufficient stability for embossing the mold material and, on the other hand, is durable and stable when in contact with the structure that has been heated above the softening point of the thermoplastic polymer. The shell mold is preferably made of polyamide (PA), polyphthalamide (PPA), polyetheretherketone (PEEK), polyetherketoneketone (PEKK), polyaryletherketone (PAEK), polyetherimide (PEI), polytetrafluoroethylene (PTFE) or silicone plastics, each with or without fillers, educated. Compared to molds, the shell mold has the advantage that the shell mold takes up little space compared to a mold and can be produced correspondingly inexpensively in relation to the materials required for production.

In a preferred embodiment, the structure is placed on a lower membrane before method step B and at least one cover, in particular an upper membrane and/or a plate, is placed on the structure. Placing the structure between a membrane and a cover avoids direct contact of the structure with the molding material or shim or mold box, thus avoiding contamination of the structure which can adversely affect quality. Furthermore, the polymer of the tape structure is also prevented from adhering to the molding material or the intermediate layer.

Preferably two or more structures are placed on the lower membrane. In particular, with two or more structures on the lower membrane, a corresponding number of shell molds on the mold material are used, with a gap between the shell molds being covered by an intermediate element, in particular in the form of a film or a plate. Alternatively, the shell mold can already be designed in such a way that it can be used to produce a number of structures at the same time.

The cover preferably has an embossing, as a result of which the structure is correspondingly embossed. An embossing can be advantageous in particular when using the structure as a visible molded part in an object. Areas that are to be cut out later, for example, can also be embossed directly in the structure and marked accordingly by embossing, so that later handling is simplified.

In a further preferred embodiment, the lower membrane is sealed against the at least one cover arranged directly above the structure to form a cavity, in particular by means of a sealant, the cavity being evacuated at least before and/or during method step B. By sealing the lower membrane against the cover, the structure is not exposed to the influences of the environment, which does not reduce the quality and stability of the preferably thermoplastic polymer. Furthermore, the structure between the lower membrane and the cover is fixed or even compressed by the evacuation of the cavity, so that due to the pressure acting on the membrane and/or the cover from the outside, a force acts directly on the structure.

In a preferred embodiment, a device for transporting and/or depositing, which comprises at least the lower membrane and the cover, is introduced into a vacuum chamber, which is completely evacuated, with the cavity being formed only after the vacuum chamber has been evacuated. In particular, during the evacuation of the vacuum chamber, the cover is initially placed opposite the lower membrane or the sealing means in such a way that the cavity is not yet completely formed and sealed off from the environment. In this way, air inclusions in the cavity, for example due to the formation of bubbles between the membrane or cover and the structure, can be avoided.

After the cavity has been formed, the vacuum chamber is preferably vented and the device is removed from the vacuum chamber. The cavity is preferably further evacuated via the connection element in order to achieve a higher negative pressure in the cavity.

A preferred embodiment is characterized in that the lower membrane and/or the at least one cover are each clamped in a frame. The frame makes it easier to handle the lower membrane or the cover, which means that, for example when transporting or moving the membrane and/or the cover, there is direct contact with the lower membrane and/or the cover and thus a possible influence on the formation of the contour is avoided. Rather, the transport and handling of these devices can be done via points of attack on the frame.

In another preferred embodiment, at least the lower membrane or its frame is placed on the open side of the mold box in such a way that a mold cavity, in particular a mold cavity sealed off from the environment, is formed between the lower membrane and the contour of the mold material. In particular, the lower membrane can be placed on the molding box together with the at least one cover. By generating a negative pressure in the mold cavity and/or by applying pressure to a side facing away from the mold cavity, the structure is moved into the mold cavity and can be molded to the contour of the mold material. The structure or the structure resting on the lower membrane is thus drawn into the mold cavity or moved into it by applying pressure on the side facing away from the mold cavity, whereby the structure is molded onto the contour. In particular, this form of molding to the contour makes it possible to dispense with upper tools, which are to be designed in accordance with the contour of the lower tools and thus also contribute to correspondingly high costs for the production of molds.

A flexible material, in particular silicone foam or polyurethane, is preferably used for the lower membrane and/or the at least one cover. A flexible material enables the structure to be molded directly onto the contour of the molding material and thus enables the molded part to be formed correspondingly to the contour. The use of a flexible material for the cover means that the cavity between the lower membrane and the cover can be maintained during molding to the contour, especially if this cavity has been evacuated, so that the corresponding pressure of the cover or one from the outside pressure applied to the cover is maintained on the structure.

In a further preferred embodiment of the method, a multi-layer film is used for the lower membrane and/or the at least one cover. The multi-layer film is characterized in particular by the fact that a layer of the multi-layer film facing the structure consists of a first, preferably thermoplastic polymer, preferably the polymer of the tape structure, in particular polypropylene or polyamide, and a layer of the multi-layer film facing away from the structure consists of a further polymer, in particular Polyamide or polyphthalamide is formed. The further polymer preferably has a higher melting temperature than the first polymer. The layer of the multilayer film facing the structure preferably bonds to the structure, but the layer of the multilayer film facing away from the structure does not bond to the structure. The use of multi-layer films thus enables the surface of the structure to be influenced in a targeted manner, it being possible to achieve a better surface of the structure or even passivation by connecting the structure to the layer of the multi-layer film facing the structure. In particular, a multi-layer film can only be used for the lower membrane or the at least one cover, depending on which part of the molded part is later visible in the molded part produced, for example.

A preferred embodiment of the method is characterized in that the lower membrane and/or the at least one cover is formed in such a way that it has a low tendency to stick to the structure. A low tendency to stick improves demolding and separating the structure from the lower membrane and/or the at least one cover, so that damage can be avoided in particular. Preferably, a separating agent is applied to a surface facing the structure or to the structure itself on the lower membrane before the structure is placed and/or on the at least one cover before it is placed on the structure. The separating agent likewise achieves a low tendency to adhere between the structure and the lower membrane and/or the at least one cover. The separating agent can preferably be applied to the respective membrane or cover or also directly to the structure.

In method step B, the structure is preferably heated by means of a heating device from one or both surface sides, preferably by means of infrared radiation, ultraviolet radiation, microwave radiation, induction, contact heat and/or thermal radiation. By heating the structure on both sides of the surface, uniform heating is achieved so that local overheating can be avoided.

The molded part is preferably tempered in the mold before process step D, in particular cooled. The temperature of the molded part is preferably controlled by contact temperature control via the mold material, by thermal radiation and/or by convection. Temperature control of the molded part allows the polymer of the tape structure to cool below its softening temperature and thus harden the structure according to the contour, so that the molded part can be removed with its shape.

A further solution to the aforementioned objects is provided by a device for producing a three-dimensional molded part from a structure, the structure comprising at least one tape structure comprising at least one polymer. The device further comprises a heating device for heating the structure at least above a softening point of the polymer of the tape structure, in particular a thermoplastic polymer or duromer polymer of the tape structure, and a device for transporting and/or depositing the heated structure on or in a three-dimensional form. The device is further characterized in that the mold comprises a molding box in which a molding material is arranged, the molding material being contourable to form a contour of the three-dimensional shape on an open side of the molding box by means of a molding device.

The polymer of the tape structure is preferably a thermoplastic polymer or a duromer polymer.

Advantageously, the molding device is designed as a material application and/or material removal element, with the device preferably further comprising a store for temporarily storing and reusing the removed molding material. The molding device designed as a material application and/or material removal element allows the three-dimensional shape to be formed from the molding material with a corresponding contour; in particular, the molding material can be removed and/or molding material, in particular intermediately stored molding material, can be applied to form the contour.

Alternatively or preferably in addition, a mold shell can be placed on the mold material by means of the mold device and the mold material can be embossed with the mold shell. In particular, the shell mold can be a printed, preferably 3D-printed shell mold. through the Mold shell, the contour of the three-dimensional shape is already specified accordingly, so that it only embosses the mold material or, if the mold shell remains on the mold material during the manufacturing process, the mold shell is supported by the mold material.

Preferably, the mold box is designed to be rotatable about an axis parallel to the open side of the mold box. The rotation of the molding box makes it possible, in particular, for a mold shell to first be placed on the open side of the molding box and fixed to the molding box, with the molding material being able to be deposited on the mold shell by rotating the molding box by preferably 180°. Because the mold material rests on the mold shell as a result of the rotation of the molding box, the mold material nestles against the mold shell, so that a contour corresponding to the course of the mold shell is formed. At the same time, the molding box can be opened on the side opposite the open side and the molding material can be compacted if necessary and/or further molding material can be backfilled, so that the corresponding embossing is retained when the molding box is rotated 180° back to the starting position.

A preferred embodiment of the device is characterized in that an intermediate layer, which preferably completely covers the molding material, is arranged on the molding material designed as a three-dimensional shape. The intermediate layer preferably covers the mold material completely and optionally goes as far as an edge of the mold box or possibly even beyond it.

The intermediate layer covering the mold material can in particular be the mold shell, as explained above, or a film.

The device advantageously comprises a lower membrane, on which the structure can be placed, and at least one cover, which is arranged above the structure. The entire structure is thus transported via the device, comprising a lower membrane and a cover, and possibly formed into a three-dimensional molded part within the device, in particular with the device.

The lower membrane and the at least one cover preferably form a cavity in relation to one another, with sealing means surrounding the structure optionally being arranged between the lower membrane and the at least one cover. The formation of a cavity within the device therefore makes it possible, for example, for the cavity to be evacuated.

In a preferred embodiment, the device comprises a vacuum chamber into which the device for transporting and/or depositing can be introduced and which can then be evacuated. In particular, during the evacuation of the vacuum chamber, the cover is initially placed opposite the lower membrane or the sealant in such a way that the cavity is not yet completely sealed off from the environment. In this way, air inclusions in the cavity, for example due to the formation of bubbles between the membrane or cover and the structure, can be avoided.

Advantageously, the lower membrane and/or the at least one cover is clamped in a respective frame. The frame can simplify the handling of the membrane or the cover as part of the device and direct contact of the membrane or the cover, which can have a negative impact on the structure, for example due to the ingress of dirt, can be directly avoided.

Alternatively or preferably in addition, the at least one cover is formed at least partially, in particular over the entire surface, from a material that is transparent or translucent for radiation assigned to the heating device, in particular for infrared radiation. In this way it can be ensured that the radiation emitted by the heating device can be introduced into the structure.

The structure preferably comprises at least one tape structure and/or a further structural element which has high radiation absorption. The tape structure or the further structural element can preferably comprise carbon fibers or be colored, for example by mixing the polymer with carbon black. Furthermore, the tape structure or the further structural element can be formed from materials with bipolar or electromagnetic properties.

The cover preferably has an embossing or shaped geometry. By means of an embossing or shape geometry, the structure can already be assigned an embossing or shape geometry when it is introduced into the device and the cover is placed on it.

In a further preferred embodiment, the lower membrane and/or the at least one cover are made of a flexible material or a multi-layer film. The flexible material can in particular be silicone foam or polyurethane.

In particular, the multilayer film comprises at least one layer facing the structure, which is formed from a first, preferably thermoplastic polymer, preferably the polymer of the tape structure, in particular polypropylene or polyamide, and a layer facing away from the structure, which is made from another polymer, in particular polyamide or Polyphthalamide is formed. The further polymer preferably has a higher melting point than the first polymer.

In an even more preferred embodiment, the lower membrane and/or the at least one cover has a low tendency to stick to the structure. The low tendency to stick to the structure enables the structure to be separated gently from the membrane and/or the cover without the structure sticking or being fixed to the membrane and/or the cover. In particular, a surface of the lower membrane and/or the cover that faces the structure and/or a surface of the structure that faces the lower membrane and/or the cover has a release agent. The release agent also achieves a low adhesion tendency between the structure and the lower membrane and/or the cover, so that demolding can take place smoothly.

The device can advantageously be placed on one open side of the molding box in such a way that a mold cavity that is closed off from the environment is formed between the lower membrane of the device and the molding material, with preferably in the mold cavity via a connecting element in the molding box and/or in the Device a negative pressure can be generated and / or a pressure on the opposite side of the mold cavity surface of the cover can be exerted.

In an even more preferred embodiment, the heating device is arranged on one or both surface sides of the structure and preferably comprises at least one radiation source, in particular an infrared, ultraviolet and/or microwave radiation source, and/or induction coils and/or channels for conducting a heating medium as a heating medium. The structure can be heated by the heating device on one or both surface sides, in particular also depending on the thickness of the structure. By means of a heating device on both surface sides of the structure, overheating of the structure on the surface side of the structure facing the heating device can be avoided and, overall, faster heating of the structure can be achieved.

An advantageous embodiment of the device is characterized in that an opening is formed in the molding box, which is connected to a vacuum generator for compressing the molding material in the molding box via a fluidic connection. The molding material in the mold box can be compressed through the opening by means of the vacuum generator, so that in particular a structure that has been formed is also retained during the manufacturing process and, for example, does not collapse.

A filter element is also preferably arranged in the fluidic connection between the vacuum generator and the molding box and/or at the opening. The filter element prevents the mold material from penetrating into the fluidic connection and thus into the vacuum generator, as a result of which the wear and tear and service life of the vacuum generator can be increased and the consumption of mold material can be prevented.

Another preferred embodiment is characterized in that means for tempering and/or means for shaking the molding box and/or means for subjecting the molding material to vibrations are arranged in and/or on the molding box.

The means for tempering the molding box are used in particular for tempering the mold material, whereby heat can be withdrawn from the heated structure after molding to the contour and thus the formation of a three-dimensional molded part can be accelerated. During tempering, the molding material does not necessarily have to be cooled below the ambient temperature; it is only necessary for the temperature to be below the softening point of the at least one thermoplastic polymer of the tape structure, so that the structure as a whole can solidify. in particular, it is possible that the molding material is also heated compared to the ambient temperature of the device. The means for tempering can also prevent the structure from cooling down too quickly.

Irregularities in the molding material, such as air pockets, bridging or clumping, can be loosened by means for shaking the molding box, which can be arranged on and/or in the molding box, which enables better compression of the molding material and thus improved formation of the contour of the three-dimensional shape becomes. Such irregularities affecting the molding material can also be solved by the means for impinging the molding material directly with vibrations.

Furthermore, the present invention relates to a system for producing a three-dimensional molded part from a structure, the system comprising a device for producing a three-dimensional molded part, in particular an advantageous embodiment thereof, and at least one additional molding box in which an additional molding material is arranged. The molding device for contouring the molding material is also designed for contouring the other molding material.

A further molding box with a further molding material can be used, for example, to form a further contour in the further molding box, so that a product changeover to a further molded part can be carried out quickly and without any problems. In addition, the mold material removed from the molding box can be used in the other molding box or also stored temporarily. In particular, it is also possible to use the further molding material for use in the molding box in order to form a corresponding contour and vice versa. It can also be advantageous, in particular when the structure cools down until it solidifies to form the three-dimensional molded part, to carry out the production of a further three-dimensional molded part in the further molding box with the further molding material using a further device.

Further advantageous features of the preferred embodiments are explained below using exemplary embodiments and the figures.

• 1A bis 1C eine Vorrichtung zur Herstellung eines dreidimensionalen Formteils zu verschiedenen Verfahrensschritten;
• 2A und 2B eine weitere Ausführungsform einer erfindungsgemäßen Vorrichtung zur Herstellung eines dreidimensionalen Formteils zu verschiedenen Verfahrensschritten;
• 3A bis 3C eine Einrichtung zum Transportieren und/oder Ablegen einer Struktur zu verschiedenen Verfahrensschritten; und
• 4A und 4B die Vorrichtung zur Herstellung eines dreidimensionalen Formteils zu weiteren Verfahrensschritten.

Show it:

• 1A until 1C a device for producing a three-dimensional molded part for various process steps;
• 2A and 2 B a further embodiment of a device according to the invention for the production of a three-dimensional molded part for various process steps;
• 3A until 3C a device for transporting and/or depositing a structure to various method steps; and
• 4A and 4B the device for producing a three-dimensional molded part to further process steps.

The figures show schematic representations that are not true to scale. The same reference symbols in the figures denote the same or equivalent elements.

In the 1A until 1C First, the mold 2 is shown as part of a device 20 for producing a three-dimensional molded part at different points in time. In the 1A Form 2 shown here shows a molding box 3 which is filled with a molding material 4 . In the present case, the molding material 4 is sand, which is mixed with water in order to achieve a certain binding effect between the individual grains of sand. The water acts here as a binder for the sand as the molding material 4.

The molding box 3 also has an open side 6 at its vertical upper end, via which the molding material 4 can be filled in and processed. In addition, the molding box 3 also has an opening 9 to which a fluidic connection 12 is connected, which connects the opening 9 to a vacuum generator (not shown), for example a vacuum pump. Air present in the molding material 4 is thus initially sucked off via the opening 9 and the molding material 4 is compressed. Furthermore, a filter element 10 is arranged in the fluidic connection 12 between the opening 9 and the vacuum generator and prevents the molding material 4 from being sucked out of the molding box 3. The filter element 10 protects the vacuum generator from penetration of the molding material 4, which extends its service life . The filter element 10 can be removed from the fluidic connection 12 for cleaning purposes, with the filter element 10 being reinserted after cleaning. Alternatively, the filter element 10 can also be replaced by a new filter element 10 . The cleaning or changing of the filter element 10 ensures that there is always a corresponding negative pressure at the opening 9 and the filter element 10 is not clogged, in particular by the mold material 4 .

In 1B the molding box 3 with the molding material 4 is shown at a later point in time, at which a negative pressure is present at the opening 9 via the fluidic connection 12 and the molding material 4 is compressed. As in 1B shown, the molding material 4 is processed on the open side 6 of the molding box 3 with a molding device 27, the molding device 27 being designed as a material application/material removal element. The molding device 27 removes molding material 4 from the molding box 3 by suction, so that the molding material 4 is formed on the open side 6 of the molding box 3 in accordance with a desired contour 5 . The molding material 4 removed or sucked off by the molding unit 27 is fed to a store 28 in which the molding material 4 is temporarily stored for later use. If to form the contour 5 not only a removal of molding material 4 from the mold box, but also an additional introduction of molding material 4 in the Mold box 3 is necessary, the required mold material 4 is removed from the store 28 and fed to the mold box 3 via the mold unit 27. The molding material 4 is removed from the molding box 3 primarily by sucking off the molding material 4 via the molding unit 27, forming a specific contour 5.

In a further step, as in 1C , shown after forming the contour 5 on the open side 6 of the molding box 3, an intermediate layer 8 in the form of a substantially gas-tight film placed on the mold material 4. The intermediate layer 8 nestles against the contour 5 of the molding material 4 due to the negative pressure still present at the opening 9 and the contour 5 is thereby reproduced. The intermediate layer 8 is designed in such a way that it completely covers the molding material 4 on the open side 6 of the molding box 3 and closes the molding box 3 on the open side 6 . When the molding box 3 is closed on the open side 6, the vacuum generator is separated from the fluidic connection 12 after a run-on time has elapsed and the opening 9 or the fluidic connection 12 is closed, for example by a check valve, whereby the vacuum in the molding box 3 and the correspondingly designed Contour 5 is retained with reduced energy use. The intermediate layer 8 also serves to separate the molding material 4 from the structure 1 (in 1B not shown) so that the structure 1 is not contaminated by the mold material 4.

Before and also during the formation of the contour 5 on the molding material 4, the molding box 3 is vibrated by means 32 for shaking, as a result of which air pockets in the molding material 4 are broken up and the molding material 4 is further compressed. The highest possible compression ensures that the formed contour 5 is retained and does not change during use. The means 32 for shaking the molding box 3 are here arranged on the outside of the molding box 3, but can also be arranged in the molding box 3 itself. Alternatively, the molding material 4 can be subjected to vibrations via other means, which also causes inclusions and agglomerations in the molding material 4 to be broken up. Here, the molding material 4 is subjected to ultrasound.

Furthermore, means 33 for tempering the molding material 4 are also arranged in the molding box 3, by means of which the molding material 4 is heated or cooled, depending on the area of application and the progress of the method for producing the three-dimensional molded part.

In the 2A and 2 B an alternative embodiment for forming a contour 5 in the molding box 3 is shown. The starting point here is to the in 1A shown position identical. A molding material 4 is again present in a molding box 3, with the molding box 3 again having an opening 9 with a fluidic connection 12 to a vacuum generator and means 32 for shaking the molding box 3.

The contour 5 is formed as in 2 B shown, in this embodiment by means of a mold shell 7, over which the material 4 in the molding box 3 is embossed on the open side 6. The molding device 27 has gripping devices which receive the mold shell 7 and insert it into the mold box 3 for embossing the mold material 4 accordingly. As a result, a contour 5 corresponding to the shape of the shell mold 7 is formed on the open side 6 of the mold box 3 .

Further molding material 4 can be added to or removed from the molding box 3 via the molding unit 27 and the molding material 4 can be distributed accordingly in the molding box 3 . By distributing or adding or removing the molding material 4, the molding material 4 is formed close to the contour. However, in this embodiment, the final formation of the contour 5 takes place by embossing the molding material 4 with the mold shell 7. Pre-contouring the molding material 4 ensures that there is no excess molding material 4 in the mold box 3 and the molding material 4 is embossed by the mold shell 8 done more easily.

In an embodiment that is not shown, the mold box 3 can be rotated after the mold shell 7 has been placed in order to improve the formation of the contour 5 by embossing, so that the molding material 4 rests with its gravity on the mold shell 7, which in this case is held by the mold device 27 or is fixed to the mold box 3 by connecting elements. In addition, the molding box 3 can be shaken using the means 32 so that air pockets in the molding material 4 or agglomerations are dissolved accordingly and the molding material 4 is compressed to the maximum.

In the 3A , 3C a device 21 for transporting and/or depositing a structure 1 is shown. The structure 1 here comprises at least one tape structure and further structural elements in the form of fiber fabrics or further tape structures, the structural elements and the tape structure having been brought together beforehand in a laying device (not shown). A merging of the tape structure and the other structure However, structural elements of the structure 1 can also take place in the device 21 .

The device 21 comprises a flexible membrane 22 which is clamped in a frame 25 or is at least held by it. The structure 1 is placed on the flexible membrane 22 or, as explained above, formed by combining the tape structure with the other structural elements. The frame 25 only supports the membrane 22 on its outer circumference, the membrane 22 having a certain elasticity and being arranged on the frame 25 in such a way that the membrane 22 can be guided or slide off. A connection element 31 is also formed on the lower frame 25 and is connected to a vacuum generator. To generate the negative pressure, the connecting element 30 and the fluidic connection 12 can be connected to the same negative pressure generator. Alternatively, separate vacuum generators can also be used in each case.

Furthermore, at least one sealant 29 is arranged on the membrane 22, through which a cavity 24 is formed after placing a cover 23 on the structure 1 or the sealant 29, in which the structure 1 is arranged. The sealing means 29 is a sealing cord running around the structure 1 . At least one connecting element 30 is also integrated in the sealing means 29 and is also connected to a vacuum generator, so that after the cavity 24 has formed, it can be evacuated. The connection element 31 can be connected to the same vacuum generator as the connection element 30 or the fluidic connection 12 or to a separate vacuum generator.

As in 3B shown, the device 21 also comprises an upper frame 25', by means of which the cover 23 is held or clamped into it. In the present case, the cover 23 is also a flexible membrane, which is designed analogously to the membrane 22 . The membrane 22 as well as the cover 23 are made of polyurethane. Alternatively, the membrane 22 and the cover 23 can also be made of silicone foam.

In order to avoid air inclusions in the cavity 24 during the evacuation via the connection element 30, the cover 23 is first placed on the sealing means 29 in such a way that the cavity 24 is not yet completely formed and is not yet sealed off from the environment. In a further step (not shown), the device 21 is evacuated in a vacuum chamber, after which the cover 23 is completely laid down on the sealing means 29 and the cavity 24 is thus formed. These steps of evacuating the entire device 21 in a vacuum chamber ensure that larger air inclusions in the cavity 24, for example due to the formation of bubbles between the membrane 22 or cover 23 and the structure 1, cannot arise in the first place. After the cavity 24 has been formed, the cavity 24 is further evacuated via the connection element 30 in order to achieve a higher negative pressure in the cavity 24 . After the cavity 24 has been formed, the vacuum chamber is vented again and the device 21 is removed from the vacuum chamber, with the negative pressure in the cavity being maintained. Alternatively, the cavity 24 can be evacuated with its formation by placing the cover 23 on the structure 1 or the sealant 29 via the connection element 30 .

Before the structure 1 is laid down in the three-dimensional form of the molding box 3, it is heated by means of a heating device 26, as shown in FIG 3C shown. The heating device 26 is arranged both above and below the structure 1, so that the structure 1 is heated evenly from both sides. Alternatively, the heating device 26 can also only be arranged on one side of the structure 1, in particular on the surface side above the structure 1.

The structure 1 is heated via infrared radiation, which is emitted by the heating device 26 and infrared radiators arranged therein. The cover 23 and the membrane 22 are made of a material that is transparent or translucent to infrared radiation, so that heat is introduced into the structure 1 essentially directly.

The membrane 22 and the cover 23 have a lower tendency to stick to the structure 1, which means that the membrane 22 and the cover 23 can be easily detached from the molded part after the production of the three-dimensional molded part without damaging the surface structure of the molded part. A low tendency to stick is achieved for the membrane 22 and the cover 23 in that the membrane 22 and the cover 23 are formed from a special material, for example polyamide, or are coated with a special material, for example Teflon. Alternatively or additionally, the membrane 22 as well as the cover 23 can have a separating agent which is already applied as a coating to the membrane 22 and the cover 23 or is applied before contact with the structure 1 . Furthermore, the structure 1 can also be wetted with a separating agent before it is placed on the membrane 22 and before the cover 23 is placed on the structure 1 .

In an alternative embodiment, the membrane 22 and the cover 23 are each designed as multi-layer films, with the layer of the multi-layer film facing the structure 1 being made of a first, thermoplastic polymer of the tape structure, in this case polyamide, and the layer of the multi-layer film modified from the structure 1 being made of a further polymer is formed, which has a higher melting point than the first polymer of the tape structure. Due to the construction of the membrane 22 and the cover 23 as multi-layer foils, the layer of the multi-layer foil facing the structure 1 is bonded to the structure 1 during the heating by the heating device 26, since these are made of the same material. This improves the surface quality of the structure 1 or of the three-dimensional molded part formed from it, which is particularly desirable when the three-dimensional molded part is used as a visible component.

In the 4A and 4B the shaping process for the structure 1 into a three-dimensional molded part in the device 20 is shown in more detail. As in 4A shown, the device 21 lies directly on the mold box 3 so that a mold cavity 11 is formed between the membrane 22 and the contour 5 of the mold material 4 in the mold box 3 . The contour 5 of the molding material 4 was here as to 1B shown formed and there is an intermediate layer 8 on the mold material 4. Alternatively, the contour 5, as in 2 B shown, are formed with a mold shell 7 by embossing.

While the device 21 rests on the molding box 3 , the structure 1 is further heated by the heating device 26 , which is arranged above the structure 1 and above the molding box 3 . The heating of the structure 1 ensures that the structure 1 does not harden prematurely and thus the shaping of the structure 1 into a molded part is made more difficult or prevented.

To mold the structure 1 to the contour 5 of the molding material 4, the mold cavity 21 is evacuated via the connection element 31 in the frame 25 of the device 21, as a result of which the structure 1 together with the flexible membrane 22 and the flexible cover 23 is drawn into the mold cavity 11 and finally on the contour 5 of the molding material 4 nestles against it and is formed in accordance with the contour 5 . Alternatively or additionally, a connection element can also be arranged in the mold box 3 above the mold material 4, via which the mold cavity 11 can be evacuated.

In addition to the passive drawing of the structure 1 into the mold cavity 11 by negative pressure, pressure can also be exerted on the cover 23, by which the package of membrane 22, structure 1 and cover 23 is moved in the direction of the mold material 4. To apply pressure to the cover 23, a stamping member or a rolling member is used. In particular, the rolling movement of the rolling element on the cover 23 additionally supports the structure 1 clinging to the contour 5 and air inclusions can be avoided. In the event that at least one stamping element or one rolling element is used to better fit the structure 1 to the contour 5, the heating device 26 above the cover 23 is removed. The stamping element or also the rolling element can be heated in order to prevent the structure 1 from cooling down prematurely.

After the structure 1 has been formed in the molding box 3 according to the contour 5 of the molding material 4, the structure 1 remains in this position until the thermoplastic material has cooled below its melting temperature or has already hardened. Cooling elements are arranged above the cover 23 for faster cooling of the structure 1 . The cooling elements can be fans, blowers or cold plates, whereby the convection above the cover 23 is increased. Spraying the cover 23 with a coolant is also possible.

In addition, means 33 for cooling the molding material 4 are arranged below the molding box 3, as a result of which the molding material 4 and thus also the structure 1 are cooled from the lower membrane 22 side. For this purpose, 3 cooling elements can be arranged both in the molding box 3 and on the molding box. After the structure 1 has cooled down, resulting in the three-dimensional molded part, it is removed from the molding box with the device 21 and transported to a demolding station in which the structure 1 or the three-dimensional molded part is demolded from the cavity 24 .

Further three-dimensional molded parts are then produced in the mold box 3 . As soon as a piece number of the one three-dimensional molded part has been reached, the mold material 4 is reshaped by the mold unit 27 to form a further contour 5 .

In a system for the production of three-dimensional molded parts, in addition to the process described above with a molding box 3, other molding boxes are used in parallel, so that during the production of a three-dimensional molded part in a molding box 3, a further contour 5 is formed in the molding material 4 in the at least one additional molding box , which enables a quick production changeover.

Reference List

1

structure

2

shape

3

molding box

4

mold material

5

contour

6

open side

7

molded shell

8th

liner

9

opening

10

filter element

11

mold cavity

12

fluidic connection

20

contraption

21

furnishings

22

membrane

23

cover

24

cavity

25, 25`

frame

26

heating device

27

molding facility

28

Storage

29

sealant

30

connection element

31

connection element

32

Middle

33

Middle

QUOTES INCLUDED IN DESCRIPTION

This list of documents cited 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

• WO 2014/083196 A1 [0008]
• US8048253 [0008]
• DE 102017105450 A1 [0011]
• DE 102014004053 A1 [0011]

Claims (29)

Method for producing a three-dimensional molded part from a structure (1) , characterized by the steps: A. Forming or providing the structure (1) from at least one tape structure, which tape structure contains at least one polymer; B. heating the structure (1) at least above a softening point of the polymer of the tape structure; C. shaping and consolidating the structure (1) by means of a three-dimensional mold (2) into the three-dimensional shaped part; and D. removing the molding from the mold (2), wherein the three-dimensional shape (2) is formed by a molding material (4) in a molding box (3) and a contour (5) of the three-dimensional shape on an open side (6) of the molding box (3) by contouring the molding material (4), in particular by embossing, removing or applying the molding material (4). procedure after claim 1 , characterized in that the polymer of the tape structure is formed by a thermoplastic polymer or a duromer polymer, and/or that method step C takes place before method step B, in particular when using a tape structure and/or a further structural element of the structure (1). a thermoset polymer. Procedure according to one of Claims 1 or 2 , characterized in that the molding material (4) is removed in the molding box (3) to form the contour (5), the removed molding material (4) preferably being temporarily stored in a store (28) and, if necessary, being reused, and/or that the mold material (4) is applied and preferably solidified in the mold box (3) to form the contour (5), the mold material (4) removed preferably being removed from the store (28). Method according to one of the preceding claims, characterized in that the molding material (4) in the molding box (3) is embossed to form the contour (5) by means of a mold shell (7), in particular a printed mold shell, the mold shell (7) preferably the open side (6) of the mold box (3) closes and the mold box (3) is preferably rotated after the mold shell (7) has been placed, so that the mold material (4) rests on the mold shell (7). Method according to one of the preceding claims, characterized in that the molding material (4) is mixed with a binder, for example water, before and/or during the formation of the contour (5), the binder preferably being added to the molding material (4) once, in Is supplied at intervals or continuously, in particular by spraying the molding material (4) with the binder, and / or that the molding material (4) is tempered. Method according to one of the preceding claims, characterized in that the molding material (4) in the molding box (3) is compressed by means of a vacuum and/or via at least one opening (9) in the molding box (3) which is in fluid communication with a vacuum generator that the molding box (3) is vibrated before and/or during the formation of the contour (5) and/or that the molding material (4) is subjected to vibration, preferably by means of ultrasound, before and/or during the formation of the contour (5). . Method according to one of the preceding claims, characterized in that on the open side (6) of the molding box (3) with, during and/or after the formation of the contour (5), an intermediate layer (7, 8) covering the molding material (4) is placed, which is preferably designed as a film or the mold shell (8). Method according to one of the preceding claims, characterized in that the structure (1) is placed on a lower membrane (22) before method step B and at least one cover (23), in particular an upper membrane and/or a plate, is placed on the structure ( 1) is placed, the cover (23) preferably having an embossing. procedure after claim 8 , characterized in that the lower membrane (22) is sealed off from the at least one cover (23) arranged directly above the structure (1) to form a cavity (24) and the cavity (24) is sealed at least before and/or during the Process step B is evacuated. Procedure according to one of Claims 8 or 9 , characterized in that the lower membrane (22) and/or the at least one cover (23) are each clamped in a frame (25, 25'). Procedure according to one of Claims 8 until 10 , characterized in that the lower membrane (22) or the frame (25) on the one open side (6) on the mold box (3) is stored in such a way that between the lower membrane (22) and the contour (5) of the molding material (4) forms a mold cavity (11), in particular a mold cavity (11) that is sealed off from the environment, whereby by generating a negative pressure in the mold cavity (11) and/or by applying a the mold cavity (11) facing away from the tape structure with pressure the structure (1) is formed on the contour (5). Procedure according to one of Claims 8 until 11 , characterized in that a flexible material, in particular silicone foam or polyurethane (PU), is used for the lower membrane (22) and/or the at least one cover (23). Procedure according to one of Claims 8 until 12 , characterized in that a multi-layer film is used for the lower membrane (22) and/or the at least one cover (23), wherein in particular a layer of the multi-layer film facing the structure (1) is made of a first, preferably thermoplastic polymer, preferably the polymer the tape structure, in particular polypropylene (PP) or polyamide (PA), and one of the structure (1) facing away layer of the multi-layer film of a further polymer, in particular of polyamide (PA) or polyphthalamide (PPA), is formed, the further polymer a has a higher melting point than the first polymer and wherein the layer of the multilayer film facing the structure (1) preferably connects to the structure (1). Procedure according to one of Claims 8 until 13 , characterized in that the lower membrane (22) and / or the at least one cover (23) is formed in such a way that it has a low tendency to adhere to the structure (1), in particular that on the lower membrane (22) before laying of the structure (1) and/or on the at least one cover (23) before being placed on the structure (1), a release agent is applied to a surface facing the structure (1) and/or to the structure (1) itself. Method according to one of the preceding claims, characterized in that the structure (1) is heated in method step B by means of a heating device (26) from one or both surface sides, preferably by means of infrared radiation, ultraviolet radiation, microwave radiation, induction, contact heat and/or thermal radiation. Method according to one of the preceding claims, characterized in that the structure (1) or the molded part is tempered, in particular cooled, before method step D in the mold (2), preferably by contact tempering via the mold material (4) and/or by thermal radiation and /or by convection. Device (20) for producing a three-dimensional molded part from a structure (1), in particular for carrying out the method according to one of Claims 1 until 16 , wherein the structure (1) comprises at least one tape structure comprising at least one polymer, with a heating device (26) for heating the structure (1) at least above a softening point of the polymer of the tape structure, and with a device (21) for transporting and /or depositing the heated structure (1) on or in a three-dimensional mold (2), characterized in that the mold (2) of the device (20) comprises a molding box (3) in which a molding material (4) is arranged, wherein the molding material (4) can be contoured by means of a molding device (27) to form a contour (5) of the three-dimensional shape on an open side (6) of the molding box (3). Device (20) after Claim 17 , characterized in that the polymer of the tape structure is a thermoplastic polymer or a duromer polymer. Device (20) according to one of claims 17 or 18 , characterized in that the shaping device (27) is designed as a material application and/or material removal element, the device (20) preferably further comprising a store (28) for temporarily storing and reusing the removed shaping material (4), and/or that by means the molding device (27) has a mold shell (8), in particular a printed mold shell (8), on which the mold material (4) can be placed and the mold material (4) can be embossed with the mold shell (8), the mold box (3) preferably being designed to be rotatable is. Device (20) according to one of claims 17 until 19 , characterized in that an intermediate layer (7, 8), in particular the mold shell (8) or a film, preferably completely covering the mold material (4), is arranged on the mold material (4) designed as a three-dimensional shape. Device (20) according to one of claims 17 until 20 , characterized in that the device (21) comprises a lower membrane (22) on which the structure (1) can be placed, and at least one cover (23) which is arranged above the structure (1), preferably the the lower membrane (22) and the at least one cover (23) form a cavity (24) in relation to one another, and sealing means (29) surrounding the structure (21) being arranged in particular between the lower membrane (22) and the at least one cover (23). Device (20) after Claim 21 , characterized in that the lower membrane (22) and/or the at least one cover (23) is clamped in a respective frame (25, 25') and/or that the at least one cover (23) consists at least partially, in particular over the entire surface a transparent or translucent material for one of the heating device (26), in particular infrared radiation, and preferably has an embossing or shaped geometry. Device (20) according to one of Claims 21 or 22 , characterized in that the lower membrane (20) and/or the at least one cover (23) are formed from a flexible material, in particular silicone foam or polyurethane (PU), or a multi-layer film, with the multi-layer film in particular having at least one of the structure ( 1) facing layer made of a first, preferably thermoplastic polymer, preferably the polymer tape structure, in particular polypropylene (PP) or polyamide (PA), and a layer of the multilayer film facing away from the structure (1) made of another polymer, in particular polyamide (PA) or polyphthalamide (PPA), wherein the further polymer has a higher melting temperature than the first polymer. Device (20) according to one of Claims 21 until 23 , characterized in that the lower membrane (22) and/or the at least one cover (23) has a low tendency to adhere to the structure (1), in particular that a surface facing the structure (1) of the lower membrane (22) and/or or the cover (23) has a release agent. Device (20) according to one of Claims 21 until 24 , characterized in that the device (21) can be placed on one open side (6) of the molding box (3) in such a way that a mold cavity (11) that is closed off from the environment between the lower membrane (22) in the device (21) and the mold material (4), wherein a negative pressure can be generated preferably in the mold cavity (11) via a connection element (31) in the mold box (3) and/or in the device (21). Device (20) according to one of Claims 21 until 25 , characterized in that the heating device (26) is arranged on one or both surface sides of the structure (1) and preferably at least one radiation source, in particular an infrared, ultraviolet radiation and/or microwave radiation source, and/or induction coils and/or Having channels for the passage of a heating medium as heating means. Device (20) according to one of Claims 21 until 26 , characterized in that in the molding box (3) an opening (9) is formed, which is connected to a vacuum generator for compressing the molding material (4) in the molding box (3) via a fluidic connection (12), preferably in the fluidic connection (12) a filter element (10) is arranged between the vacuum generator and the molding box (20) and/or at the opening (9). Device (20) according to one of Claims 21 until 27 , characterized in that means (33) for tempering and/or means (32) for shaking the molding box (3) and/or means for subjecting the molding material (4) to vibration are arranged in and/or on the molding box (3). Plant for the production of a three-dimensional molded part, comprising a device (20) according to one of claims 17 until 28 , and at least one further molding box, in which a further molding material is arranged, the molding device (27) preferably being designed for contouring the further molding material.

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