JP2022537561A - マルチマテリアルワークピースの製造方法並びに製造装置 - Google Patents
マルチマテリアルワークピースの製造方法並びに製造装置 Download PDFInfo
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Abstract
Description
Claims (16)
- 三次元のワークピース(12)を製造する方法であって:
(i)第1の原材料粉末(50)からなる原材料粉末層を形成するために、支持体(18)上に第1の原材料粉末(50)を塗布するステップと、
(ii)第1の原材料粉末(50)からなる硬化された第1のワークピース層セクション(52)を形成するために、第1の原材料粉末(50)からなる原材料粉末層を電磁放射又は粒子放射によって選択的に照射するステップと、
(iii)硬化されていない第1の原材料粉末(50)を支持体(18)から除去するステップと、
(iv)第1のワークピース層セクション(52)に隣接して、第2の原材料粉末(54)からなる原材料粉末層セクションを形成するために、支持体(18)上に第2の原材料粉末(54)を塗布するステップと、
(v)第1のワークピース層セクション(52)に隣接して、第2の原材料粉末(54)からなる硬化された第2のワークピース層セクション(56)を形成するために、原材料粉末層セクションを電磁放射又は粒子放射によって選択的に照射するステップと、
(vi)第1のワークピース層セクション(52)と第2のワークピース層セクション(56)に隣接して、第2の原材料粉末(54)からなるつながり合った多孔の焼結層セクション(58)を形成するために、硬化されていない第2の原材料粉末(54)を加熱するステップと、
を有する、三次元のワークピースを製造する方法。 - ステップ(i)から(iii)が、ステップ(iv)の実施の前に複数回実施され、ステップ(i)から(iii)の各繰り返しにおいて、特に異なる第1の原材料粉末(50)が使用され、及び/又は
前記ステップ(iv)から(v)が、前記ステップ(vi)の実施の前に複数回実施されて、ステップ(vi)において、複数の重なりあって配置された原材料粉末層セクションからなるつながり合った多孔の焼結層セクション(58)が形成され、及び/又は
前記ステップ(iv)において、第1のワークピース層セクション(52)と第2のワークピース層セクション(56)に隣接して、第2の原材料粉末(54)からなるつながりあった多孔の焼結層セクション(58)を形成するために、硬化されていない第2の原材料粉末(54)の一部のみが加熱される、
請求項1に記載の方法。 - 第2の原材料粉末(54)の材料が、第1の原材料粉末(50)の材料よりも、低い溶融温度及び/又は高い熱伝導率を有しており、及び/又は
第2の原材料粉末(54)の材料が、第1の原材料粉末(50)の材料よりも、安価である、
請求項1又は2に記載の方法。 - 硬化されていない第2の原材料粉末(54)が、焼結層セクション(58)を形成するために、第2の原材料粉末(54)の溶融温度を下回る温度に加熱され、及び/又は
硬化されていない第2の原材料粉末(54)が、焼結層セクション(58)を形成するための、所望の期間の間加熱され、及び/又は
硬化されていない第2の原材料粉末(54)が、焼結層セクション(58)を形成するために、第2の原材料粉末(54)の材料の、その溶融温度への加熱をもたらす溶融エネルギ投入よりも小さい、エネルギ投入によって加熱される、
請求項1から3のいずれか1項に記載の方法。 - -焼結層セクション(58)が、10から20%、の多孔率、特に10から15%の多孔率を有し、及び/又は
-第2のワークピース層セクション(56)が、0から5%の多孔率、特に0から2%の多孔率を有し、及び/又は
-焼結層セクション(58)が、その表面の領域内に互いに結合された粉末粒を含み、前記粉末粒の形状と大きさが、第2の原材料粉末(54)の粉末粒の形状と大きさに、実質的に相当する、
請求項1から4のいずれか1項に記載の方法。 - 硬化されていない第2の原材料粉末(54)が加熱装置(40)によって加熱され、前記加熱装置が硬化されていない第2の原材料粉末(54)に、硬化されていない第2の原材料粉末(54)の支持体(18)とは逆の表面を介し、及び/又は硬化されていない第2の原材料粉末(54)の支持体(18)側の表面を介して、熱エネルギを供給する、請求項1から5のいずれか1項に記載の方法。
- 加熱装置(40)が第1の加熱部材(42)を有し、前記第1の加熱部材が支持体(18)を収容するプロセスチャンバ(14)内で支持体(18)の上方に配置されており、及び/又はその場合に加熱装置(40)が第2の加熱部材(44)を有し、前記第2の加熱部材が、支持体(18)内に統合されており、あるいは支持体(18)を収容するプロセスチャンバ(14)の外部で支持体(18)の下方に配置されている、請求項6に記載の方法。
- ステップ(iii)内で支持体(18)から除去された、硬化されていない第1の原材料粉末(50)が、三次元のワークピース(12)を製造するために再使用される、請求項1から7のいずれか1項に記載の方法。
- 焼結層セクション(58)が、三次元のワークピース(12)を製造する形成プロセスの終了後に、分離プロセスによって、完成した三次元のワークピース(12)から分離され、その場合に分離プロセスが、好ましくは、個別化プロセス、特に焼結層セクション(58)を個々の粉末粒に個別化するための送風プロセスを有している、請求項1から8のいずれか1項に記載の方法。
- 個別化プロセス内で発生した、焼結層セクション(58)の個々の粉末粒が、三次元のワークピース(12)を製造するために再使用される、請求項9に記載の方法。
- 三次元のワークピース(12)を製造する装置であって、前記装置が:
-粉末塗布装置(22)を有し、前記粉末塗布装置が、第1と第2の原材料粉末(50、54)を支持体(18)上に塗布するように、構成されており、
-照射装置(16)を有し、前記照射装置が、支持体(18)上に塗布された原材料粉末層を、電磁放射又は粒子砲者によって選択的に照射するように、構成されており、
-除去装置(24)を有し、前記除去装置が、硬化されていない第1の原材料粉末(50)を支持体(18)から除去するように、構成されており、
-加熱装置(40)を有し、前記加熱装置が、支持体(18)上に塗布された原材料粉末層を加熱するように、構成されており、かつ
-制御装置(46)を有し、前記制御装置が、前記装置(10)の駆動を次のように制御するように構成されている:
(i)第1の原材料粉末(50)からなる原材料粉末層を形成するために、粉末塗布装置(22)を用いて第1の原材料粉末(50)が支持体(18)上に塗布され、
(ii)第1の原材料粉末(50)からなる硬化された第1のワークピース層セクション(52)を形成するために、照射装置(16)を用いて第1の原材料粉末(50)からなる原材料粉末層が選択的に電磁放射又は粒子放射によって照射され、
(iii)除去装置(24)を用いて、硬化されていない第1の原材料粉末(50)が支持体(18)から除去され、
(iv)第1のワークピース層セクション(52)に隣接して、第2の原材料粉末(54)からなる原材料粉末層セクションを形成するために、粉末塗布装置(22)を用いて第2の原材料粉末(54)が支持体(18)上に塗布され、
(v)第1のワークピース層セクション(52)に隣接して、第2の原材料粉末(54)からなる硬化された第2のワークピース層セクション(56)を形成するために、照射装置(16)を用いて原材料粉末層セクションが電磁放射又は粒子放射によって照射され、かつ
(vi)第1のワークピース層セクション(52)と第2のワークピース層セクション(56)に隣接して、第2の原材料粉末(54)からなるつながりあった多孔の焼結層セクション(58)を形成するために、加熱装置(40)を用いて硬化されていない第2の原材料粉末(54)が加熱される、
三次元のワークピースを製造する装置。 - 制御装置(46)が、さらに、装置(10)の駆動を制御して、ステップ(iv)の実施前にステップ(i)から(iii)が多数回実施され、前記ステップ(i)から(iii)の各繰り返しにおいて、特に異なる第1の原材料粉末(50)が使用されるように、構成されており、及び/又は
制御装置(46)が、さらに、前記装置(10)の駆動を制御して、前記ステップ(vi)の実施前に、前記ステップ(iv)から(v)が複数回実施されるように、構成されており、前記ステップ(vi)において複数の互いに重なり合って配置された原材料粉末層セクションからなるつながりあった多孔の焼結層セクション(58)が形成され、及び/又は
制御装置(46)が、さらに、前記装置(10)を制御して、第1のワークピース層セクション(52)及び第2のワークピース層セクション(56)に隣接して、第2の原材料粉末(54)からなるつながりあった多孔の焼結層セクション(58)を形成するために、ステップ(iv)において硬化されていない第2の原材料粉末(54)の一部のみが加熱されるように、構成されている、
請求項11に記載の装置。 - 制御装置(46)が、さらに、加熱装置(40)を制御して、
硬化されていない第2の原材料粉末(54)が、焼結層セクション(58)を形成するために、第2の原材料粉末(54)の材料の溶融温度を下回る温度に加熱され、及び/又は
硬化されていない第2の原材料粉末(54)が、焼結層セクション(58)を形成するために、所望の期間加熱され、及び/又は
硬化されていない第2の原材料粉末(54)が、焼結層セクション(58)を形成するために、第2の原材料粉末(54)の材料の溶融温度への加熱をもたらす溶融エネルギ投入よりも小さいエネルギ投入によって加熱される、
ように、整えられている、請求項11又は12に記載の装置。 - 加熱装置(40)が、硬化されていない第2の原材料粉末(54)に、前記硬化されていない第2の原材料粉末(54)の表面であって支持体(18)とは逆の表面及び/又は前記硬化されていない第2の原材料粉末(54)の表面であって前記支持体(18)側の表面を介して熱エネルギを供給するように、整えられている、請求項11から13のいずれか1項に記載の装置。
- 加熱装置(40)が第1の加熱部材(42)を有し、前記第1の加熱部材が、支持体(18)を収容するプロセスチャンバ(14)内で支持体(18)の上方に配置されており、及び/又は、加熱装置(40)が第2の加熱部材(44)を有し、前記第2の加熱部材が支持体(18)内に統合されており、あるいは前記支持体(18)を収容する前記プロセスチャンバ(14)の外部で前記支持体(18)の下方に配置されている、請求項14に記載の装置。
- さらに分離装置(48)を有し、三次元のワークピース(12)を製造するための製造プロセスの終了後に、前記分離装置が、焼結層セクション(58)を完成した三次元のワークピース(12)から分離するように構成されており、前記分離装置(48)は、特に、焼結層セクション(58)を個々の粉末粒に分離するように、構成されている、請求項11から15のいずれか1項に記載の装置。
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