JP7254905B2 - 層状の材料被着により3次元の成形物を製造する方法 - Google Patents
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Description
a)ネガ型層を形成するために、流動性の第1の材料の部分材料を、幾何学形状データに基づいて、基底面および/または基底面上に位置する、3次元の成形物の硬化した材料層に、ネガ型層の基底面とは反対の側の表面に、製造しようとする成形物の材料層のネガ形状を有する少なくとも1つのキャビティが形成されるように被着させ、
b)ネガ型層を硬化させ、
c)キャビティに第2の材料を充填し、これによりネガ形状をポジ形状として成形物層に転移させることで成形物層を形成し、
d)キャビティに充填された第2の材料を硬化させ、
e)硬化したネガ型層および/または硬化した成形物層の、基底面に対して所定の間隔をあけて配置された平面を越えて突出した領域を、切削式の材料除去により除去し、
f)ステップa)~e)を少なくとも1回繰り返し、
g)ネガ型層を溶剤と接触させ、これにより、硬化した第1の材料を溶剤に溶かす。
Claims (14)
- 層状の材料被着により3次元の成形物(1)を製造する方法であって、該成形物(1)用の幾何学形状データ、前記3次元の成形物(1)を支持する基底面(3)を備えた支持体部材(2)、硬化可能な液状または流動性の第1の材料(4)、硬化可能な液状、流動性、ペースト状または粉末状の第2の材料(5)および溶剤を準備し、前記第2の材料(5)は、硬化状態では硬化した前記第1の材料(4)よりも高い強度を有しており、硬化した前記第1の材料(4)は、前記溶剤中で溶解可能であり、
a)ネガ型層(12)を形成するために、流動性の前記第1の材料(4)の部分材料を、前記幾何学形状データに基づいて、前記基底面(3)および/または該基底面(3)上に位置する前記3次元の成形物(1)の硬化した材料層に、前記ネガ型層(12)の前記基底面(3)とは反対の側の表面に、製造しようとする前記成形物(1)の材料層のネガ形状を有する少なくとも1つのキャビティ(13)が形成されるように被着させ、
b)前記ネガ型層(12)を硬化させ、
c)前記キャビティ(13)に前記第2の材料(5)を充填し、これにより前記ネガ形状をポジ形状として成形物層(16)に転移させることで該成形物層(16)を形成し、
d)前記キャビティ(13)に充填された前記第2の材料(5)を硬化させ、
e)硬化した前記ネガ型層(12)および/または硬化した前記成形物層(16)の、前記基底面(3)に対して所定の間隔をあけて配置された平面を越えて突出した領域を、切削式の材料除去により除去し、
f)ステップa)~e)を少なくとも1回繰り返し、
g)前記ネガ型層(12)を溶剤と接触させ、これにより、硬化した前記第1の材料(4)を溶剤に溶かす、
方法。 - 前記第1の材料(4)の部分材料が、インクジェット印刷法によりまたは電子写真により、前記基底面および/または該基底面上に位置する硬化した前記ネガ型層(12)および/または硬化した前記成形物層(16)に被着され、前記第1の材料(4)は、エネルギの作用に基づき硬化可能な材料であって、前記ネガ型層(12)を硬化させるために前記第1の材料(4)にエネルギを供給する、請求項1記載の方法。
- 前記第2の材料(5)の粘度は、硬化されていない状態では、硬化されていない状態の前記第1の材料(4)の粘度よりも高くかつ/または流動性の前記第1の材料および流動性、ペースト状または粉末状の前記第2の材料は、所定の固形物量を有しており、前記第2の材料(5)の固形物量は、前記第2の材料(5)が硬化されていない状態では、前記第1の材料(4)が硬化されていない状態における前記第1の材料(4)の固形物量より多い、請求項1または2記載の方法。
- 前記第1の材料(4)は、噴射に適した、1000mPa・s未満の粘度を有しており、少なくとも360dpiの解像度を有する液滴の形態で、前記基底面および/または該基底面上に位置する前記3次元の成形物(1)の硬化した材料層に被着される、請求項1から3までのいずれか1項記載の方法。
- 前記第2の材料(5)は、選択的なコーティング法により、前記幾何学形状データに基づいて前記ネガ型層(12)に被着され、これにより、流動性、ペースト状または粉末状の前記第2の材料の少なくとも1つの部分材料が少なくとも1つのキャビティ(13)内に供給されることになり、該キャビティの外側に位置する前記ネガ型層の少なくとも1つの箇所に、前記第2の材料(5)が接触することはない、請求項1から4までのいずれか1項記載の方法。
- 前記第2の材料(5)は、流体と少なくとも1つの添加剤とを含む複合材料であり、前記流体は室温において少なくとも50mPa・sの粘度を有しており、前記添加剤は、前記流体中に配置された固形物粒子を有している、請求項1から5までのいずれか1項記載の方法。
- 前記第2の材料(5)は、前記第1の材料(4)よりも高い粘度および/または多い固形物量を有しており、前記第1および前記第2の材料(4,5)は両方共インクジェット印刷法により、前記基底面(3)および/または該基底面(3)上に位置する硬化した前記ネガ型層(12)および/または前記成形物層(16)に被着され、前記インクジェット印刷法では、前記第1の材料(4)は少なくとも1つの第1のノズルから吐出されかつ前記第2の材料(5)は少なくとも1つの第2のノズルから吐出され、該第2のノズルの流出開口は、前記第1のノズルの流出開口よりも大きな横断面を有しておりかつ/または高い作業圧力を加えられ、前記第2のノズルの前記流出開口の直径は、前記第1のノズルの前記流出開口の直径よりも大きくなっている、請求項5または6記載の方法。
- 前記第2の材料(5)に気体圧力を供給し、このようにして加圧された前記第2の材料(5)を、少なくとも1つの弁(30)を介して少なくとも1つのノズル(27)に案内し、該ノズルの流出開口は、前記基底面(3)に沿って前記支持体部材(2)に対して位置決めされており、前記弁(30)は、製造しようとする前記成形物(1)用に準備された前記幾何学形状データに基づいてかつ前記ノズル(27)と前記支持体部材(2)との間の相対位置に応じて制御され、これにより、前記流出開口が前記キャビティ(13)のところに位置決めされると材料流が解放され、前記流出開口が前記キャビティ(13)のところに位置決めされていないと前記材料流は遮断される、請求項2から7までのいずれか1項記載の方法。
- 前記ノズル(27)の前記流出開口は、前記キャビティ(13)内に延びる連続的な線に沿って、前記支持体部材(2)に対して相対的に移動させられ、液状、流動性またはペースト状の前記第2の材料(5)は、前記流出開口から前記線に沿って前記キャビティ(13)内に連続的に供給される、請求項7または8記載の方法。
- 支持体シートが準備され、該支持体シート上に前記第2の材料(5)が配置されており、該第2の材料(5)は、前記第1の材料よりも高い粘度を有しておりかつ/または前記第1の材料(4)よりも多い固形物量を含んでおり、前記支持体シートは、前記第2の材料(5)を前記キャビティ(13)に充填するために、前記支持体シート上に位置する前記第2の材料(5)が前記キャビティ(13)に向かい合うように前記キャビティ(13)に位置決めされ、前記支持体シートを透過するエネルギビームが前記支持体シートに向けられ、これにより、前記支持体シートの、前記キャビティ(13)に面した側における前記第2の材料が、加熱により液化されて前記キャビティ(13)内に供給される、請求項5または6記載の方法。
- 前記第2の材料(5)は、フレキソ印刷法、グラビア印刷法、オフセット印刷法、スクリーン印刷法、レーザ転写法、微量調量法によりかつ/またはドクタ(24)またはチャンバドクタを介して前記キャビティ(13)内に充填される、請求項1から6までのいずれか1項記載の方法。
- 前記第2の材料(5)は、加熱により液化されてから前記キャビティ(13)内に充填され、その後冷却により硬化させられる熱可塑性樹脂である、請求項1から11までのいずれか1項記載の方法。
- 硬化した最も上の前記ネガ型層(12)および/または硬化した最も上の前記成形物層(16)から、前記切削式の材料除去時に生じる切りくずが除去される、請求項1から12までのいずれか1項記載の方法。
- 前記基底面(3)を有する前記支持体部材(2)は、材料被着中に回転軸線(11)を中心として回転させられる、請求項1から13までのいずれか1項記載の方法。
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