JP4914341B2 - レーザ技術およびインキジェット法による吸収体の塗布によって3次元の対象物を製造するための方法および装置 - Google Patents
レーザ技術およびインキジェット法による吸収体の塗布によって3次元の対象物を製造するための方法および装置 Download PDFInfo
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- JP4914341B2 JP4914341B2 JP2007503318A JP2007503318A JP4914341B2 JP 4914341 B2 JP4914341 B2 JP 4914341B2 JP 2007503318 A JP2007503318 A JP 2007503318A JP 2007503318 A JP2007503318 A JP 2007503318A JP 4914341 B2 JP4914341 B2 JP 4914341B2
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- 239000001257 hydrogen Substances 0.000 description 1
- 229910052739 hydrogen Inorganic materials 0.000 description 1
- 230000002209 hydrophobic effect Effects 0.000 description 1
- UCNNJGDEJXIUCC-UHFFFAOYSA-L hydroxy(oxo)iron;iron Chemical compound [Fe].O[Fe]=O.O[Fe]=O UCNNJGDEJXIUCC-UHFFFAOYSA-L 0.000 description 1
- 229940097275 indigo Drugs 0.000 description 1
- COHYTHOBJLSHDF-UHFFFAOYSA-N indigo powder Natural products N1C2=CC=CC=C2C(=O)C1=C1C(=O)C2=CC=CC=C2N1 COHYTHOBJLSHDF-UHFFFAOYSA-N 0.000 description 1
- AMGQUBHHOARCQH-UHFFFAOYSA-N indium;oxotin Chemical compound [In].[Sn]=O AMGQUBHHOARCQH-UHFFFAOYSA-N 0.000 description 1
- 239000003112 inhibitor Substances 0.000 description 1
- 238000007641 inkjet printing Methods 0.000 description 1
- 230000002452 interceptive effect Effects 0.000 description 1
- DCYOBGZUOMKFPA-UHFFFAOYSA-N iron(2+);iron(3+);octadecacyanide Chemical compound [Fe+2].[Fe+2].[Fe+2].[Fe+3].[Fe+3].[Fe+3].[Fe+3].N#[C-].N#[C-].N#[C-].N#[C-].N#[C-].N#[C-].N#[C-].N#[C-].N#[C-].N#[C-].N#[C-].N#[C-].N#[C-].N#[C-].N#[C-].N#[C-].N#[C-].N#[C-] DCYOBGZUOMKFPA-UHFFFAOYSA-N 0.000 description 1
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- 230000003647 oxidation Effects 0.000 description 1
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- 125000002080 perylenyl group Chemical group C1(=CC=C2C=CC=C3C4=CC=CC5=CC=CC(C1=C23)=C45)* 0.000 description 1
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- IEQIEDJGQAUEQZ-UHFFFAOYSA-N phthalocyanine Chemical compound N1C(N=C2C3=CC=CC=C3C(N=C3C4=CC=CC=C4C(=N4)N3)=N2)=C(C=CC=C2)C2=C1N=C1C2=CC=CC=C2C4=N1 IEQIEDJGQAUEQZ-UHFFFAOYSA-N 0.000 description 1
- 238000006116 polymerization reaction Methods 0.000 description 1
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- 229920005989 resin Polymers 0.000 description 1
- 239000006254 rheological additive Substances 0.000 description 1
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- 238000007873 sieving Methods 0.000 description 1
- RMAQACBXLXPBSY-UHFFFAOYSA-N silicic acid Chemical compound O[Si](O)(O)O RMAQACBXLXPBSY-UHFFFAOYSA-N 0.000 description 1
- 235000012239 silicon dioxide Nutrition 0.000 description 1
- 239000000377 silicon dioxide Substances 0.000 description 1
- 229910052709 silver Inorganic materials 0.000 description 1
- 239000004332 silver Substances 0.000 description 1
- FPSFKBGHBCHTOE-UHFFFAOYSA-N sodium 3-hydroxy-4-[(3-methyl-5-oxo-1-phenyl-4H-pyrazol-4-yl)diazenyl]naphthalene-1-sulfonic acid Chemical compound [Na+].O=C1C(N=NC=2C3=CC=CC=C3C(=CC=2O)S(O)(=O)=O)C(C)=NN1C1=CC=CC=C1 FPSFKBGHBCHTOE-UHFFFAOYSA-N 0.000 description 1
- 239000011343 solid material Substances 0.000 description 1
- 239000010959 steel Substances 0.000 description 1
- NVKTUNLPFJHLCG-UHFFFAOYSA-N strontium chromate Chemical compound [Sr+2].[O-][Cr]([O-])(=O)=O NVKTUNLPFJHLCG-UHFFFAOYSA-N 0.000 description 1
- 229920001169 thermoplastic Polymers 0.000 description 1
- FRNOGLGSGLTDKL-UHFFFAOYSA-N thulium atom Chemical compound [Tm] FRNOGLGSGLTDKL-UHFFFAOYSA-N 0.000 description 1
- XOLBLPGZBRYERU-UHFFFAOYSA-N tin dioxide Chemical compound O=[Sn]=O XOLBLPGZBRYERU-UHFFFAOYSA-N 0.000 description 1
- 229910001887 tin oxide Inorganic materials 0.000 description 1
- 239000003440 toxic substance Substances 0.000 description 1
- 229910000391 tricalcium phosphate Inorganic materials 0.000 description 1
- 235000019731 tricalcium phosphate Nutrition 0.000 description 1
- 229940078499 tricalcium phosphate Drugs 0.000 description 1
- 238000007514 turning Methods 0.000 description 1
- 239000004034 viscosity adjusting agent Substances 0.000 description 1
- 239000010456 wollastonite Substances 0.000 description 1
- 229910052882 wollastonite Inorganic materials 0.000 description 1
- 238000010626 work up procedure Methods 0.000 description 1
- 229910052727 yttrium Inorganic materials 0.000 description 1
- VWQVUPCCIRVNHF-UHFFFAOYSA-N yttrium atom Chemical compound [Y] VWQVUPCCIRVNHF-UHFFFAOYSA-N 0.000 description 1
- 229910052725 zinc Inorganic materials 0.000 description 1
- 239000011701 zinc Substances 0.000 description 1
- NDKWCCLKSWNDBG-UHFFFAOYSA-N zinc;dioxido(dioxo)chromium Chemical compound [Zn+2].[O-][Cr]([O-])(=O)=O NDKWCCLKSWNDBG-UHFFFAOYSA-N 0.000 description 1
- 229910001928 zirconium oxide Inorganic materials 0.000 description 1
Images
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- B22F3/003—Apparatus, e.g. furnaces
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
- B23K—SOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
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- B23K—SOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
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- B28B—SHAPING CLAY OR OTHER CERAMIC COMPOSITIONS; SHAPING SLAG; SHAPING MIXTURES CONTAINING CEMENTITIOUS MATERIAL, e.g. PLASTER
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- C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
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- B22F12/00—Apparatus or devices specially adapted for additive manufacturing; Auxiliary means for additive manufacturing; Combinations of additive manufacturing apparatus or devices with other processing apparatus or devices
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- B29C35/00—Heating, cooling or curing, e.g. crosslinking or vulcanising; Apparatus therefor
- B29C35/02—Heating or curing, e.g. crosslinking or vulcanizing during moulding, e.g. in a mould
- B29C35/08—Heating or curing, e.g. crosslinking or vulcanizing during moulding, e.g. in a mould by wave energy or particle radiation
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
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- B29C64/00—Additive manufacturing, i.e. manufacturing of three-dimensional [3D] objects by additive deposition, additive agglomeration or additive layering, e.g. by 3D printing, stereolithography or selective laser sintering
- B29C64/10—Processes of additive manufacturing
- B29C64/106—Processes of additive manufacturing using only liquids or viscous materials, e.g. depositing a continuous bead of viscous material
- B29C64/124—Processes of additive manufacturing using only liquids or viscous materials, e.g. depositing a continuous bead of viscous material using layers of liquid which are selectively solidified
- B29C64/129—Processes of additive manufacturing using only liquids or viscous materials, e.g. depositing a continuous bead of viscous material using layers of liquid which are selectively solidified characterised by the energy source therefor, e.g. by global irradiation combined with a mask
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- B29C64/00—Additive manufacturing, i.e. manufacturing of three-dimensional [3D] objects by additive deposition, additive agglomeration or additive layering, e.g. by 3D printing, stereolithography or selective laser sintering
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Description
ドイツ連邦共和国特許第19918981号明細書には、100〜3000nmの波長を有するレーザによる電磁的なエネルギの導入によって、吸収体を含有する粉末層の範囲を選択的に溶融させることにより3次元の対象物を製造するための方法が開示されている。請求項1に記載の本発明による方法はこの公知の方法とは、懸濁液の形の吸収体または液状の吸収体をインキジェット法により、焼結させたい範囲へ選択的に塗布する点で異なっている。
a)粉末状の基材の層を準備し、
b)構成空間を調温し、
c)吸収体を懸濁液または液状の吸収体の形でインキジェット法により、焼結させたい範囲へ選択的に塗布し、
d)規定の特性を有する別の特殊な液体または懸濁液を塗布し、
e)100〜3000nmの波長、有利には800〜1070nmの波長を有するレーザ、特に有利にはYAGレーザまたはダイオードレーザによって電磁的なエネルギを導入することにより粉末層の範囲を選択的に溶融させ、
f)溶融された範囲と溶融されていない範囲とを、成形部分の破壊なしの取出しを可能にする温度にまで冷却し、
g)成形部分を取り出す、
のステップにより成ることを特徴とする、3次元の対象物を製造するための方法ならびに該方法により製造された成形体である。ステップa)〜e)は、層毎に所望の成形部分が加工成形されるまで繰り返される。ステップb)は材料に依存しており、したがってオプショナルである。ステップd)もやはりオプショナルである。塗布された層の厚さは、たとえば0.05〜2mm、有利には0.08〜0.2mmである。
意想外にも、100〜3000nmの波長を有するレーザを用いて、粉末状の基材から成る3次元の対象物を製造することが比較的簡単に可能となることが判った。この場合、上で挙げたレーザのエネルギを吸収しないか、または極めて劣悪にしか吸収しない粉末状の基材から成る層の結合したい範囲へ、吸収体を有する材料が塗布され、この吸収体はレーザエネルギを吸収することができるので、吸収されたエネルギは熱の形で、この吸収体を取り囲む基材へ引き渡される。これにより、前記層の基材もしくは場合によってはその下またはその上に位置する層の基材が前記範囲において溶融または焼結によって結合される。吸収体および場合よっては使用される別の付加剤の被着は、1つまたは複数のノズルを備えた印刷ヘッド、たとえばインキジェットプリンタの印刷ヘッドに類似して圧電効果またはバブルジェット原理により作動する印刷ヘッドを用いて行うことができる。レーザのエネルギの導入は集束されて行われるか、あるいは集束されずに行われ得る。このことは方法の迅速性の利点を意味する。
−当該装置が、粉末状の基材を作業プラットホームまたは場合によっては既に作業プラットホーム上に存在する、処理済みまたは未処理の粉末状の基材(2)の層へ層状に塗布するための可動の装置を有しており、
−当該装置が、吸収体を有する材料(4)と、場合によっては使用される別の付加剤とを、粉末状の基材から成る層の選択された範囲へ塗布するための、x、y平面で運動可能な装置(3)を有しており、
−当該装置が、100〜3000nmの波長、有利には800〜1070nmの波長または1900〜2100nmの波長を有するレーザを有しており、エネルギ導入が、集束されているか、または集束されていなくてよく、有利には集束されていない
ことを特徴とする、3次元の対象物を層状に製造するための装置である。
a)粉末状の基材の層を準備し、
b)構成空間を調温し、
c)吸収体を懸濁液または液状の吸収体の形でインキジェット法により、焼結させたい範囲へ選択的に塗布し、
d)規定の特性を有する別の特殊な液体または懸濁液を塗布し、
e)100〜3000nmの波長、有利には800〜1070nmまたは1900〜2100nmの波長を有するレーザ、特に有利にはYAGレーザまたはダイオードレーザによって電磁的なエネルギを導入することにより粉末層の範囲を選択的に溶融させ、
f)溶融された範囲と溶融されていない範囲とを、成形部分の破壊なしの取出しを可能にする温度にまで冷却し、
g)成形部分を取り出す、
のステップにより成ることによりすぐれている。さらに本発明の対象は、該方法により製造された成形体である。ステップa)〜e)は、層毎に所望の成形部分が加工成形されるまで繰り返される。ステップb)は材料に依存しており、したがってオプショナルである。ステップd)もやはりオプショナルである。塗布された層の厚さは、たとえば0.05〜2mm、有利には0.08〜0.2mmである。
粉末状の層の準備は、たとえば基材としての粉末材料をボトムプレートへ被着させるか、もしくは既に存在している場合には、ステップb)〜e)により処理された既存の層へ被着させることにより行われ得る。被着はドクタ塗布、ローラ塗布、堆積塗布および続いて行われる引取りまたは類似の方法により行われ得る。層の準備が満たさなければならない唯一つの前提条件は、層が均一な高さを有していることである。有利には、ステップa)で準備された層は3mmよりも小さな高さ、有利には20〜2000μm、特に有利には80〜200μmの高さを有している。層の高さはこの場合、解像度を決定し、ひいては製造された3次元の対象物の外側の構造の滑らかさを決定する。ボトムプレートあるいは層を準備するための機器は、高さ方向で可動に形成されていてよいので、ステップd)またはステップe)の実施後に、得られた層を、次に被着させたい層の高さ分だけ降下させるか、または機器を次の層の高さ分だけ、先行した層に対して持ち上げることができる。
本発明による方法では、100〜3000nmの波長を有するレーザの電磁放射線により加熱されるあらゆる吸収体を使用することができる。
このような本発明による方法では、さらに多くの吸収体/基材組合せが考えられる。この場合、当該方法のためには、当該方法の終了時に、溶融された(つまり吸収体によって処理された)基材と、溶融されていない基材との間に明確な境界を達成するマトリックスが得られるようにするために、100〜3000nmの波長を有するレーザの放射線により励起される能力の点で、吸収体と基材との間に十分に大きな差異が存在することが重要となる。このようにしてのみ、製造された3次元の対象物が十分に平滑な輪郭を有し、かつ結合されていない基材から簡単に剥離され得るようになることが確保されている。当該方法の精度は、たとえばレーザ焼結の方法よりもすぐれている。なぜならば、レーザ焼結法の場合よりもエネルギをはるかに的確に導入することができるからである。
−当該装置が、粉末状の基材を作業プラットホームまたは場合によっては既に作業プラットホーム上に存在する、処理済みまたは未処理の粉末状の基材(2)の層へ層状に塗布するための可動の装置を有しており、
−当該装置が、吸収体を有する材料(4)と、場合によっては使用される別の付加剤とを、粉末状の基材から成る層の選択された範囲へ塗布するための、x、y平面で運動可能な装置(3)を有しており、
−当該装置が、100〜3000nmの波長、有利には800〜1070nmの波長または1900〜2100nmの波長を有するレーザを有しており、エネルギ導入が、集束されているか、または集束されていなくてよく、有利には集束されていない
ことにより特徴付けられている。
図1につき説明した装置において、コポリアミド粉末(VESTAMELT 170、 デグサ社;Degussa-AG, Marl)から成る寸法3*20*1mm3を有するプレートのモデルを製造する。吸収体としては、蒸留水40質量%、KHP40質量%およびイソプロパノール20質量%を有する、KHP(デグサ社のVestodur FP-LAS)を主体とした懸濁液を使用する。当該装置は約40℃の作動温度を有している。1.5×3.5mmのビームスポットの寸法を有するダイオードレーザの波長は940nmである。層厚さは0.15mmである。層1つ当たり、200ワットの出力を有するダイオードレーザを、700mm/秒の速度で行毎に構成プラットホームにわたって運動させる。粉末のD50値は60μmである。
既に説明した装置において、ポリアミド12粉末(EOSINT P PA 2200, EOS GmbH Electro Optical Systems, Krailling, ドイツ連邦共和国)から成る、3*20*1mm3の寸法を有する別のプレートを製造する。吸収体としては、イリオジン(Iriodin)LS825を使用する。インキジェット法により分配された液体は、その30重量%がイリオジンから成り、59%がイソプロパノールから成り、そして1%がプリル(Henkel)から成っていた。当該装置は約160℃の作動温度を有している。面状のダイオードレーザの波長は940nmであり、ビームスポットは1.5×3.5mmである。粉末層が塗布された高さは0.15mmであった。層1つ当たり、ダイオードレーザは構成平面を行毎に200ワットの出力および500mm/秒の速度で走査する。使用された粉末は55μmのD50値を有していた。
例3:Nd:YAGレーザを用いたポリアミド12から成るプレートの製造
10×10cmの上側の開いたボックスに底部を装備した。この底部はスピンドルを介して移動可能である。この底部を上側の縁部へ1/2センチメートルのところにまで運動させ、残った空間を粉末で充填し、そして金属プレートによって均した。装置を、Nd:YAGレーザ スターマーク(Star Mark)65(製造者 Carl Basel Lasertechnik)の構成空間内へ設置した。ボックスの開口を半分だけカバーし、そして噴霧器(市販、香水用)を用いて、吸収体を有する液体を塗布した。このときに、均一な濡らしならびに滴下の回避に配慮しなければならない。その後にカバーを取り除き、面全体をレーザエネルギで走査した。
Claims (24)
- 粉末状の基材の層を準備しかつレーザを使用することにより3次元の対象物を製造するための方法において、100〜3000nmの範囲のレーザ放射線を完全にまたは大部分吸収することのできる付加剤を含む、懸濁液の形の吸収体または液状の吸収体をインキジェット法により、焼結させたい範囲へ選択的に塗布し、粉末層の範囲の選択的な溶融を、100〜3000nmの波長を有するレーザによる電磁的なエネルギの導入によって行うことを特徴とする、3次元の対象物を製造するための方法。
- 当該方法が、以下のステップ;
a)粉末状の基材の層を準備し、
b)構成空間を調温し、
c)100〜3000nmの範囲のレーザ放射線を完全にまたは大部分吸収することのできる付加剤を含む、懸濁液の形の吸収体または液状の吸収体をインキジェット法により、焼結させたい範囲へ選択的に塗布し、
d)規定された特性を有する別の特殊な液体または懸濁液を塗布し、
e)100〜3000nmの波長を有するレーザによる電磁的なエネルギの導入によって粉末層の範囲を選択的に溶融させ、
f)溶融された範囲および溶融されていない範囲を、成形部分の破壊なしの取出しを可能にする温度にまで冷却し、
g)成形部分を取り出す、
より成る、請求項1記載の3次元の対象物を製造するための方法。 - 初期に、一度ステップa)〜d)を実施し、引き続きステップb)を実施し、その後にもう一度ステップa)を実施した後に、一度ステップe)を実施し、引き続き別のステップを順序c)、d)、a)、b)およびe)で実施する、請求項2記載の方法。
- 使用される粉末状の基材が、10〜150μmの平均粒度を有している、請求項1から3までのいずれか1項記載の方法。
- 800〜1070nmの波長を有するレーザを使用する、請求項1から4までのいずれか1項記載の方法。
- 1900〜2100nmの波長を有するレーザを使用する、請求項1から5までのいずれか1項記載の方法。
- Nd:YAGレーザを使用する、請求項1から6までのいずれか1項記載の方法。
- ダイオードレーザを使用する、請求項1から7までのいずれか1項記載の方法。
- 集束されていないビーム、細長いビームまたは面状のビームを有するレーザを使用する、請求項1から8までのいずれか1項記載の方法。
- 吸収体が着色剤を有している、請求項1から9までのいずれか1項記載の方法。
- 吸収体が顔料を有している、請求項10記載の方法。
- 吸収体が染料を有している、請求項10記載の方法。
- 吸収体がカーボンブラック、KHP、骨炭、黒鉛、炭素繊維、白亜または干渉顔料を有している、請求項1から9までのいずれか1項記載の方法。
- 吸収体がカーボンブラック、KHP、骨炭、黒鉛、炭素繊維、白亜または干渉顔料と共に別の成分を有している、請求項1から9までのいずれか1項記載の方法。
- 吸収体が、リンまたはメラミンシアヌレートを主体とした難燃剤を有している、請求項1から9までのいずれか1項記載の方法。
- 吸収体が付加的に蒸留水またはアルコールまたは溶剤を有している、請求項10から15までのいずれか1項記載の方法。
- 吸収体が付加的に界面活性剤および/または湿潤剤および/または殺生剤および/または保湿剤を含有している、請求項10から15までのいずれか1項記載の方法。
- 粉末状の基材としてポリマを使用する、請求項1から17までのいずれか1項記載の方法。
- 粉末状の基材として、ポリマ材料によって被覆されている砂、金属粒子またはセラミック粒子を使用する、請求項1から17までのいずれか1項記載の方法。
- ポリマとして、有利にはポリエステル、ポリ塩化ビニル、ポリアセタール、ポリプロピレン、ポリエチレン、ポリスチロール、ポリカーボネート、ポリブチレンテレフタレート、ポリエチレンテレフタレート、ポリスルホン、ポリアリーレンエーテル、ポリウレタン、熱可塑性のエラストマ、ポリラクチド、ポリオキシアルキレン、ポリ−(N−メチルメタクリルイミド)(PMMI)、ポリメチルメタクリレート(PMMA)、イオノマ、ポリアミド、コポリエステル、コポリアミド、シリコーンポリマ、ターポリマ、アクリルニトリル・ブタジエン・スチロール・コポリマ(ABS)またはこれらの混合物から選択されたポリマまたはコポリマを使用する、請求項18または19記載の方法。
- 流動助剤0.05〜5重量%を有する粉末状の基材を使用する、請求項18から20までのいずれか1項記載の方法。
- 無機充填体を有する粉末状の基材を使用する、請求項18から21までのいずれか1項記載の方法。
- 充填体としてガラス球を使用する、請求項22記載の方法。
- 無機顔料または有機顔料を有する粉末状の基材を使用する、請求項18から23までのいずれか1項記載の方法。
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EP1737646B1 (de) | 2007-05-23 |
CA2560181A1 (en) | 2005-09-29 |
JP2007529340A (ja) | 2007-10-25 |
AU2005223365A1 (en) | 2005-09-29 |
US20070183918A1 (en) | 2007-08-09 |
EP1737646A1 (de) | 2007-01-03 |
US20150251247A1 (en) | 2015-09-10 |
CN1950192A (zh) | 2007-04-18 |
US10118222B2 (en) | 2018-11-06 |
KR20060123637A (ko) | 2006-12-01 |
ATE362836T1 (de) | 2007-06-15 |
US9114567B2 (en) | 2015-08-25 |
NO20064551L (no) | 2006-10-06 |
WO2005090055A1 (de) | 2005-09-29 |
KR100785584B1 (ko) | 2007-12-13 |
DE102004012682A1 (de) | 2005-10-06 |
PL1737646T3 (pl) | 2007-10-31 |
CN100564007C (zh) | 2009-12-02 |
ES2287901T3 (es) | 2007-12-16 |
DE502005000753D1 (de) | 2007-07-05 |
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