JP2020519486A - 特に金属および/またはセラミックに適用可能な成形方法および成形装置 - Google Patents
特に金属および/またはセラミックに適用可能な成形方法および成形装置 Download PDFInfo
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- JP2020519486A JP2020519486A JP2019559325A JP2019559325A JP2020519486A JP 2020519486 A JP2020519486 A JP 2020519486A JP 2019559325 A JP2019559325 A JP 2019559325A JP 2019559325 A JP2019559325 A JP 2019559325A JP 2020519486 A JP2020519486 A JP 2020519486A
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- Manufacturing & Machinery (AREA)
- Chemical & Material Sciences (AREA)
- Materials Engineering (AREA)
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Abstract
Description
(1)鋳造の温度を、前の層から既に鋳造されたスラリーまたはペーストを凝固するのに十分低い温度に維持する。
(2)例えば、エポキシ樹脂および/またはアクリル系および/またはメタクリル系の架橋性モノマーを用いる熱硬化プロセスを用いて鋳造材料のスラリーまたはペーストを硬化する。
(3)重合反応を活性化するか、または場合によってはプロセスの他の部分からの熱を使用してスラリーの表面を硬化させる。
(4)赤外線照射等の乾燥プロセスで鋳造原料のペーストを硬化させる。
(5)結合材料、例えば溶剤または水を加熱して蒸発させる。
(1)温度を上げてワックスを溶融する。
(2)溶剤またはガスに浸漬してバインダーの一部を溶解または溶出する、または温度を上げてバインダー除去を行う。
(3)再度温度を上げて焼結する。
(4)材料および品質の要件に従い、必要に応じて熱プロセスを追加する。例えば、熱間等方圧加圧法により、部品の密度を高めることができる。アルミニウム部品には、焼き戻しや熟成等も可能である。
Claims (34)
- 成形積層製品の製造方法であって、
前記製品の1層を画定するために第1の型を印刷することと、
前記第1の型を鋳造材料で充填し、それにより第1の層を形成することと、
第2の層を画定するために前記第1の層の上に第2の型を印刷することと、
前記第1の層の上で、前記第2の層を鋳造材料で充填し、それにより成形積層製品を形成することと、
を含む、方法。 - 前記第1の層を、形成後かつ前記第2の型の印刷前に仕上げ、それにより前記第1の層の仕上げ表面に前記第2の層を形成することをさらに含む、
請求項1に記載の方法。 - 前記型は、型印刷材料を使用して印刷される、
請求項1または2に記載の方法。 - 前記型印刷材料の融点は、前記鋳造材料の融点よりも低い、
請求項3に記載の方法。 - 前記鋳造材料は、ワックス、バインダー、硬化材料、分散剤、消泡剤、モノマー、オリゴマー、開始剤、活性剤、安定剤、バインダー除去制御添加剤、および焼結制御剤からなる第1の群の中の1つと、セラミックおよび金属からなる第2の群の中の1つと、を含む、
請求項1〜4のいずれか一項に記載の方法。 - 前記型鋳造材料は、スリップ材料、またはゲルキャスト材料、またはペースト材料を含む、
請求項1〜5のいずれか一項に記載の方法。 - 前記型印刷材料の粘度は、前記鋳造材料の粘度よりも高い、
請求項6に記載の方法。 - 前記スリップ、またはゲルキャスト、またはペーストは、水ベースまたは有機溶媒ベースである、
請求項6または7に記載の方法。 - 前記鋳造材料は、親水性成分または疎水性成分を含む、
請求項1〜8のいずれか一項に記載の方法。 - 前記充填することは、前記鋳造材料を前記型に注入することを含む、
請求項1〜9のいずれか一項に記載の方法。 - 前記注入することは、注入ノズルから行われる、
請求項10に記載の方法。 - 充填される前記型内のスペースのサイズに応じて前記注入ノズルを選択することを含む、
請求項11に記載の方法。 - 前記充填することは、前記型への前記鋳造材料の射出成形を含む、
請求項1〜9のいずれか一項に記載の方法。 - 前記充填することは、前記型に押し付けられたスキージを使用して前記鋳造材料を前記型の中に押し広げることを含む、または、前記充填することは、前記型の表面から離間したブレードを使用して前記鋳造材料を前記型の中に押し広げることを含む、
請求項1〜9のいずれか一項に記載の方法。 - 少なくとも2つの異なる鋳造材料を別々の層に使用することを含む、
請求項1〜14のいずれか一項に記載の方法。 - 前記鋳造材料は、少なくとも2つの異なる構成材料または少なくとも2つの異なるサイズの粒子を含む、
請求項1〜15のいずれか一項に記載の方法。 - 加熱、溶解、ならびに、加熱および溶解の組合せを含む群の中の1つを使用して、鋳造後に前記型を除去することを含む、
請求項1〜16のいずれか一項に記載の方法。 - 型を印刷し、前記型を充填するための3D印刷装置であって、
第1の型材料を用いて前記型を3D印刷するための、第1のサイズを有する第1のノズルと、
材料を注入して前記型を充填するための、前記第1のサイズとは異なる第2のサイズを有する第2のノズルと、
を備える、3D印刷装置。 - 前記第2のノズルは、取り外し可能である、
請求項18に記載の3D印刷装置。 - 前記第2のノズルは、交換可能であり、それにより、様々な充填速度が様々なサイズの型に対して提供される、
請求項18または19に記載の3D印刷装置。 - 前記第1のノズルは、熱溶解積層方式(FDM:Fused Deposition Modeling)の押出機である、
請求項18〜20のいずれか一項に記載の3D印刷装置。 - 前記第1のノズルは、インクジェットノズルまたはインクジェットノズルアレイである、
請求項18〜21のいずれか一項に記載の3D印刷装置。 - 型を印刷し、前記型を充填するための3D印刷装置であって、
型材料を用いて前記型を3D印刷するためのノズルと、
充填材料を塗布して前記型を充填するためのスキージと、
を備える、3D印刷装置。 - 型を印刷し、前記型を充填するための3D印刷装置であって、
型材料を用いて前記型を3D印刷するためのノズルと、
前記型を封止するための封止キャップと、
充填材料を射出して前記型を充填するための射出成形ユニットと、
を備える、3D印刷装置。 - 積層成形製品の製造方法であって、
前記積層成形製品の設計図を作成することと、
前記設計図を複数の層にスライスすることと、
層ごとに、型を設計することと、
連続した層ごとに、設計された型を3D印刷することと、
連続した層ごとに、前記型の形成後に鋳造材料を前記型に注入して前記層を形成することと、
次層の型を、それぞれの先行する層の上に3D印刷することと、
を含む、製造方法。 - 各層の上に次層の型を印刷する前に該各層を硬化することをさらに含む、
請求項25に記載の製造方法。 - 各層の上に後続層を形成する前に該各層を研磨することを含む、
請求項25または26に記載の製造方法。 - 前記鋳造材料は、流動して前記型を充填するレオロジー特性、および前記型の内面に付着するレオロジー特性を有するように選択される、
請求項25〜27のいずれか一項に記載の製造方法。 - 前記製品の全層が形成された後、前記製品を安定化するために熱を使用することを含む、
請求項25〜28のいずれか一項に記載の製造方法。 - 各型の層を除去することを含む、
請求項25〜29のいずれか一項に記載の製造方法。 - 加熱して、または溶媒を使用して前記鋳造材料から犠牲材料を除去することを含む、
請求項25〜30のいずれか一項に記載の製造方法。 - 前記鋳造材料は粉末を含み、熱処理を適用して前記粉末を焼結することを含む、
請求項25〜31のいずれか一項に記載の製造方法。 - 熱間等方圧加圧法(HIP:Hot Isostatic Pressing process)を使用して前記鋳造材料の密度を高めることをさらに含む、
請求項25〜32のいずれか一項に記載の製造方法。 - 請求項1〜16または請求項25〜33のいずれか一項に記載の方法に従って金属またはセラミックで作られた成形部品または成形製品。
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