JP7101887B2 - 形成体の層毎付加製造のための方法 - Google Patents
形成体の層毎付加製造のための方法 Download PDFInfo
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- JP7101887B2 JP7101887B2 JP2021525183A JP2021525183A JP7101887B2 JP 7101887 B2 JP7101887 B2 JP 7101887B2 JP 2021525183 A JP2021525183 A JP 2021525183A JP 2021525183 A JP2021525183 A JP 2021525183A JP 7101887 B2 JP7101887 B2 JP 7101887B2
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- B22F3/10—Sintering only
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Description
バット光重合(光造形SLA、デジタル光処理DLP、連続デジタル光処理CDLP)、
材料押出(熱溶解積層法FDM)、
材料噴射(材料噴射MJ、ナノ粒子噴射NPJ、ドロップオンデマンドDOD)、
結合剤噴射(BJ)、
粉体床融合(マルチ噴射融合MJF、選択的レーザ焼結SLS、直接金属レーザ焼結/選択的レーザ融解DMLS/SLM、電子ビーム融解EBM)、
指向性エネルギー堆積(レーザエンジニアリングネットシェイプLENS、電子ビーム付加製造EBAM)、および
シート積層(積層物体製造LOM)。
(a)微粒子充填剤材料として、セラミックおよび/またはガラスセラミック粒子と、
(b)少なくとも1つの結合剤と、
(c)少なくとも1つのエネルギー転換成分と、
(d)少なくとも1つの分散媒質と、
を含む、スラリが、使用される。
本願明細書は、例えば、以下の項目も提供する。
(項目1)
処理された層のスライスから構成される形成体の層毎付加製造のための方法であって、前記方法は、
スラリの層を生成するステップであって、前記スラリは、結合剤と、分散媒質と、微粒子充填剤材料とを含む、ステップと、
前記スラリ層を固化させるステップと、
固化された層を脱バインダおよび/または焼結によって処理するために、電磁放射を前記固化された層に指向するステップと、
上述のステップを繰り返し、前記形成体を連続的に蓄積するステップと
を含み、
前記スラリ層を生成するステップが、レーザ誘起前方転写(LIFT)プロセスによって実施されることであって、前記LIFTプロセスは、レーザ(8)を利用し、レーザビーム(1)パルスをキャリア(2)上のスラリのコーティング(4)に作用するように指向し、スラリの液滴を受容体表面に転写することにより、前記スラリ層(11)を生成し、前記スラリ層(11)は、次いで、上記の固化させるステップおよび脱バインダステップおよび/または焼結ステップによってさらに処理される、こと
を特徴とする、方法。
(項目2)
前記スラリ層(11)を固化させるステップが、温かいガスフローからの熱を前記スラリ層に作用するように印加することによって実施されることを特徴とする、項目1に記載の方法。
(項目3)
前記スラリ層(11)を固化させるステップが、電磁放射を前記スラリ層に作用するように指向することによって実施されることを特徴とする、項目1に記載の方法。
(項目4)
前記電磁放射を指向するステップが、レーザ(8)を制御し、レーザビームを層材料に作用するように指向することによって実施されることを特徴とする、前記項目のいずれかに記載の方法。
(項目5)
前記レーザビームを前記スラリ層に作用するように指向することによって前記固化させるステップが、前記スラリ層(11)を加熱し、前記スラリの蒸発可能成分を蒸発させることによって実施されることを特徴とする、項目3および4に記載の方法。
(項目6)
前記スラリ層の固化を引き起こす前記レーザビーム(1)、および脱バインダおよび/または焼結をもたらす前記レーザビーム(1)が、同一のレーザ(8)によって発生されることを特徴とする、項目3および4または5に記載の方法。
(項目7)
脱バインダおよび/または焼結をもたらすための前記レーザビーム(1)、および、新しいスラリ層(11)を生成するためのLIFTプロセスのために使用される前記レーザビームが、同一のレーザ(8)によって発生されることを特徴とする、項目2または3および4に記載の方法。
(項目8)
固化をもたらすために前記レーザビーム(1)を発生させる前記レーザ(8)、および、新しいスラリ層を生成するための前記LIFTプロセスのために使用される前記レーザビームが、同一のレーザによって発生されることを特徴とする、項目3および4に記載の方法。
(項目9)
固化をもたらすため、かつ、脱バインダおよび/または焼結をもたらすために前記レーザビーム(1)を発生させる前記レーザ(8)が、新しいスラリ層(11)を生成するための前記LIFTプロセスのために使用される同一のレーザ(8)によって発生されることを特徴とする、項目6に記載の方法。
(項目10)
前記スラリがさらに、前記電磁放射のエネルギーを熱エネルギーに変換することが可能なエネルギー伝達成分を含むことを特徴とする、前記項目のいずれかに記載の方法。
(項目11)
前記キャリア(11)が、相互の隣に配列される複数の別個のコーティング区域(4、4’、4’’)を担持することであって、各コーティング区域(4、4’、4’’)は、複数のスラリ組成物のうちの関連付けられる1つを含有する、ことと、
制御ユニットが、生成されているスラリの層毎に、堆積される層内の前記複数のスラリ組成物から選択されるスラリ組成物の選択される空間分布が、コーティング区域(4、4’、4’’)を前記LIFTプロセスにおいて効果的であるように選択的に位置付け、生成される層内にスラリ組成物の所望の空間パターンを達成することによって形成されるように、前記レーザ(8)および前記受容体表面に対して前記キャリア(2)を位置付けるための位置付けデバイスを制御するように配列されることと
を特徴とする、前記項目のいずれかに記載の方法。
(項目12)
前記位置付けデバイスが、前記レーザのレーザビームが、前記キャリアによって影響を及ぼされることなく、前記スラリ層上に指向され得るように、前記レーザ(8)に対して前記キャリア(2)を位置付けることが可能であることを特徴とする、項目11に記載の方法。
(項目13)
前記スラリ層を生成し、これを固化させるステップが、前記スラリ層(11)から形成されるべき前記スライスの領域より大きい面積内で実施されることと、
前記固化された層の脱バインダおよび/または焼結が、脱バインダおよび/または焼結が、蓄積されるべき前記スライスの輪郭内でのみ生じるように、空間的に選択される様式において、電磁放射を前記固化された層に作用するように指向することによって実施されることと
を特徴とする、前記項目のいずれかに記載の方法。
(項目14)
前記スラリ層(11)を生成するステップが、前記スラリ層が、蓄積されるべき前記スライスの輪郭と合致するように、空間的に選択される様式において前記LIFTプロセスによって実施されることと、
支持材料(21)が、形成されるべき前記形成体が、少なくとも部分的に、支持材料(21)内に埋め込まれるように、蓄積されるべき前記スライスの領域を囲繞するように適用されることと
を特徴とする、項目1-12のいずれかに記載の方法。
(項目15)
前記スラリの微粒子充填剤材料が、ガラス粉末、ガラスセラミック粉末、セラミック粉末、または金属粉末であることを特徴とする、前記項目のいずれかに記載の方法。
Claims (7)
- 処理された層のスライスから構成される形成体の層毎付加製造のための方法であって、前記方法は、
スラリの層を生成するステップであって、前記スラリは、結合剤と分散媒質と微粒子充填剤材料とを含み、前記微粒子充填剤材料は、セラミックまたはガラスセラミック粉末である、ステップと、
前記スラリの層を固化させるステップと、
前記固化されたスラリの層を脱バインダおよび/または焼結によって処理するために、電磁放射を前記固化されたスラリの層に指向するステップと、
上述のステップを繰り返すことにより、前記形成体を連続的に蓄積するステップと
を含み、
前記スラリの層を生成することが、レーザ誘起前方転写(LIFT)プロセスによって実施されることであって、前記LIFTプロセスが、レーザを利用することにより、レーザビームパルスをキャリア上のスラリのコーティングに作用するように指向し、スラリの液滴を受容体表面に転写することにより、前記スラリの層を生成し、前記スラリの層が、次いで、前記固化させるステップおよび前記脱バインダおよび/または焼結によってさらに処理される、ことと、
前記スラリの層を固化させることが、前記スラリの層に作用するように電磁放射を指向することによって実施されることと、
前記スラリの層に作用するように電磁放射を指向することが、前記スラリの層に作用するようにレーザビームを指向するようにレーザを制御することによって実施されることと、
前記スラリの層の固化を引き起こす前記レーザビームおよび脱バインダおよび/または焼結をもたらす前記電磁放射が、同一のレーザによって生成されることと、
前記スラリの層の固化を引き起こす前記レーザビームおよび脱バインダおよび/または焼結をもたらす前記電磁放射を生成するレーザが、前記LIFTプロセスが前記スラリの層を生成するために使用されるレーザと同一のレーザであることと
を特徴とする、方法。 - 前記スラリの層に作用するように前記レーザビームを指向することによって、前記スラリの層を固化させることが、前記スラリの層を加熱することにより、前記スラリの蒸発可能成分を蒸発させることによって実施されることを特徴とする、請求項1に記載の方法。
- 前記スラリが、前記電磁放射のエネルギーを熱エネルギーに変換することが可能なエネルギー伝達成分をさらに含むことを特徴とする、請求項1~2のいずれか一項に記載の方法。
- 前記キャリアが、相互の隣に配列される複数の別個のコーティング区域を担持することであって、各コーティング区域が、複数のスラリ組成物のうちの関連付けられる1つを含有する、ことと、
制御ユニットが、生成されているスラリの層毎に、堆積される層内の前記複数のスラリ組成物から選択されるスラリ組成物の選択される空間分布が、コーティング区域を前記LIFTプロセスにおいて効果的であるように選択的に位置付け、生成される層内にスラリ組成物の所望の空間パターンを達成することによって形成されるように、前記レーザおよび前記受容体表面に対して前記キャリアを位置付けるための位置付けデバイスを制御するように配列されることと
を特徴とする、請求項1~3のいずれか一項に記載の方法。 - 前記レーザのレーザビームが、前記キャリアによって影響を及ぼされることなく、前記スラリの層上に指向されることが可能であるように、前記位置付けデバイスが、前記レーザに対して前記キャリアを位置付けることが可能であることを特徴とする、請求項4に記載の方法。
- 前記スラリの層を生成すること、および、前記スラリの層を固化させることが、前記スラリの層から形成されるべき前記スライスの領域より大きい面積内で実施されることと、
脱バインダおよび/または焼結が、蓄積されるべき前記スライスの輪郭内でのみ生じるように、空間的に選択される様式で、前記固化されたスラリの層に作用するように電磁放射を指向することによって、前記固化されたスラリの層の脱バインダおよび/または焼結が実施されることと
を特徴とする、請求項1~5のいずれか一項に記載の方法。 - 前記スラリの層が、蓄積されるべき前記スライスの輪郭と合致するように、空間的に選択される様式で、前記スラリの層を生成することが前記LIFTプロセスによって実施されることと、
形成されるべき前記形成体が、支持材料内に少なくとも部分的に埋め込まれるように、前記支持材料が、蓄積されるべき前記スライスの領域を囲繞するように適用されることと
を特徴とする、請求項1~5のいずれか一項に記載の方法。
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JP2022507042A (ja) | 2022-01-18 |
WO2020108821A1 (en) | 2020-06-04 |
CN113226599A (zh) | 2021-08-06 |
US20220016707A1 (en) | 2022-01-20 |
CN113226599B (zh) | 2022-07-08 |
EP3659728B1 (en) | 2021-01-27 |
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