WO2011117137A2 - Procédé et dispositif de fabrication d'un produit par formage initial à partir d'un matériau sous forme de liquide, de coulis, de pâte, de poudre, de grains, de solide et/ou ses additifs de composition - Google Patents

Procédé et dispositif de fabrication d'un produit par formage initial à partir d'un matériau sous forme de liquide, de coulis, de pâte, de poudre, de grains, de solide et/ou ses additifs de composition Download PDF

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Publication number
WO2011117137A2
WO2011117137A2 PCT/EP2011/054045 EP2011054045W WO2011117137A2 WO 2011117137 A2 WO2011117137 A2 WO 2011117137A2 EP 2011054045 W EP2011054045 W EP 2011054045W WO 2011117137 A2 WO2011117137 A2 WO 2011117137A2
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WIPO (PCT)
Prior art keywords
energy
pulsed
sintering
pressure
products
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PCT/EP2011/054045
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German (de)
English (en)
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WO2011117137A3 (fr
Inventor
Roland Gschwinder
Nikita Hirsch
Boris Tarasov
Original Assignee
Roland Gschwinder
Nikita Hirsch
Boris Tarasov
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Application filed by Roland Gschwinder, Nikita Hirsch, Boris Tarasov filed Critical Roland Gschwinder
Priority to DE212011100068U priority Critical patent/DE212011100068U1/de
Publication of WO2011117137A2 publication Critical patent/WO2011117137A2/fr
Publication of WO2011117137A3 publication Critical patent/WO2011117137A3/fr

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    • BPERFORMING OPERATIONS; TRANSPORTING
    • B28WORKING CEMENT, CLAY, OR STONE
    • B28BSHAPING CLAY OR OTHER CERAMIC COMPOSITIONS; SHAPING SLAG; SHAPING MIXTURES CONTAINING CEMENTITIOUS MATERIAL, e.g. PLASTER
    • B28B3/00Producing shaped articles from the material by using presses; Presses specially adapted therefor
    • B28B3/02Producing shaped articles from the material by using presses; Presses specially adapted therefor wherein a ram exerts pressure on the material in a moulding space; Ram heads of special form
    • B28B3/022Producing shaped articles from the material by using presses; Presses specially adapted therefor wherein a ram exerts pressure on the material in a moulding space; Ram heads of special form combined with vibrating or jolting
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B28WORKING CEMENT, CLAY, OR STONE
    • B28BSHAPING CLAY OR OTHER CERAMIC COMPOSITIONS; SHAPING SLAG; SHAPING MIXTURES CONTAINING CEMENTITIOUS MATERIAL, e.g. PLASTER
    • B28B1/00Producing shaped prefabricated articles from the material
    • B28B1/08Producing shaped prefabricated articles from the material by vibrating or jolting
    • B28B1/087Producing shaped prefabricated articles from the material by vibrating or jolting by means acting on the mould ; Fixation thereof to the mould
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B29WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29CSHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C45/00Injection moulding, i.e. forcing the required volume of moulding material through a nozzle into a closed mould; Apparatus therefor
    • B29C45/17Component parts, details or accessories; Auxiliary operations
    • B29C45/46Means for plasticising or homogenising the moulding material or forcing it into the mould
    • B29C45/56Means for plasticising or homogenising the moulding material or forcing it into the mould using mould parts movable during or after injection, e.g. injection-compression moulding
    • B29C45/568Applying vibrations to the mould parts
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B30PRESSES
    • B30BPRESSES IN GENERAL
    • B30B11/00Presses specially adapted for forming shaped articles from material in particulate or plastic state, e.g. briquetting presses, tabletting presses
    • B30B11/02Presses specially adapted for forming shaped articles from material in particulate or plastic state, e.g. briquetting presses, tabletting presses using a ram exerting pressure on the material in a moulding space
    • B30B11/022Presses specially adapted for forming shaped articles from material in particulate or plastic state, e.g. briquetting presses, tabletting presses using a ram exerting pressure on the material in a moulding space whereby the material is subjected to vibrations
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B30PRESSES
    • B30BPRESSES IN GENERAL
    • B30B11/00Presses specially adapted for forming shaped articles from material in particulate or plastic state, e.g. briquetting presses, tabletting presses
    • B30B11/02Presses specially adapted for forming shaped articles from material in particulate or plastic state, e.g. briquetting presses, tabletting presses using a ram exerting pressure on the material in a moulding space
    • B30B11/027Particular press methods or systems
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B22CASTING; POWDER METALLURGY
    • B22FWORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
    • B22F2999/00Aspects linked to processes or compositions used in powder metallurgy

Definitions

  • the invention relates to a method and apparatus for the production of products of arbitrarily complex shapes by primary molding (injection molding, pressing) of liquid, pasty, pasty, powdery, granular and / or solid material and / or its compositional states, according to the preamble of Claim 1 or that of claim 31.
  • binders are often used various waxes, polyolefins, polyalcohols, polycaprolactones, polyvinyl alcohols and other polymer solutions and liquid polymers, algae water mixtures, cellulose water mixtures, thermoplastics and others.
  • feedstocks are prepared in the above-mentioned manner, in order to then be urformed in special tools, extruded or injected. This results in the shaping and a first compression at ambient temperature. After the primary molding, extrusion and / or injection molding process, the products are removed from the mold in the form of so-called "green parts".
  • the next technological step involves the debinding (removal) of the binder.
  • Debinding is carried out by thermal, catalytic and / or extraction debinding (solvent removal).
  • thermal debinding the preliminary products (green parts) are placed in an oven for several hours in order to ensure debindering that is as damage-free and as slow as possible.
  • the sintering involves a special physical process; this is done by the thermal treatment in a special oven or by laser sintering or by plasma sintering or by self-sustained chemical sintering or by microwave sintering.
  • the sintering temperatures and sintering times depend on the materials and sometimes reach up to 2700 ° C or higher and can last up to several hours or days.
  • the quasi-finished product is pressed again under high pressure in a mold.
  • a high dimensional stability or e.g. Compliance with technical tolerances (form and position tolerance) possible.
  • Binderstoff solutions usually do not have sufficient for the compaction necessary viscosities, which is why all known feedstocks do not have sufficient flow properties.
  • binder residues e.g., carbon
  • the known primary molding or injection molding is often the cause of defects that are only visible on the sintered product, such as cracks, voids, stresses in the product, mechanical distortion or deformation, alloy changes or C content.
  • WO2007066969 A describes sintering under vacuum in order to remove residues of binding agents.
  • Such special thermal treatments are very expensive and need a lot of energy and time; For example, the proposed heating of 700 ° C to 1250 ° C at a heating rate of 5 ° C per hour gives a 110 hour treatment time.
  • US7012036A describes a process which provides for compaction of a precursor in a rubber tube having an isostatic pressure of 1400 bar and then sintering at a temperature of about 1700 ° C.
  • US20040265161A describes the compaction of powders by application of pressure waves generated by gas explosions. This is a very costly and dangerous process, which requires very complex molding machines with special explosion protection equipment.
  • Decisive properties for shaping or molding of products from powder-based material mixtures or "feedstocks” is the flow behavior and the packing behavior of the mixtures of powder particles and binder. These properties are determined by bulk forces (mass) and surface forces (attraction and repulsion between the powder particles). The smaller the powder particles, the more the powder properties are marked by the surface forces.
  • Stable suspensions are understood to mean well-dispersed powder slurries in which the particles do not accumulate. High stability is achieved when the mutual approach of particles by Brownian motion (thermal kinetic energy) does not lead to the Van der Waals attraction.
  • van der Waals attraction can be reduced or compensated for by charging the particles (electrostatic repulsion) and / or by coating the particles with polymers, which hinders mutual contact of the Patrtikelober inhabit (steric hindrance).
  • the interactions between the particles are essentially determined by the different ranges of attraction, repulsion and hindrance forces.
  • the sintering in addition to the shaping or prototyping is the core of a powder technology manufacturing of products. In this process step formed from molded powder product with its essential properties.
  • Sintering is the densification of green bodies under certain physical applications, such as heat treatment by the diffusion transport of atoms.
  • the grains grow together, the porosity decreases, and almost always grain growth (coarsening of the grains) takes place.
  • the driving force is the reduction of surface and interfacial energy.
  • atomic transport during sintering takes place exclusively in the solid phase, while in some cases a liquid phase occurs during sintering.
  • Characteristic of the sintering process is that not all components melt and thus the outer shape is retained. The compaction may only lead to a uniform and reproducible shrinkage. In the course of this process, a homogeneous and crack-free material with the finest possible fine-grained microstructure and certain (in many cases as small as possible) porosity is to be created.
  • Solid phase sintering occurs at temperatures below the melting point of the lowest melting component.
  • liquid phase sintering at least one component must form a low melting percentage.
  • Another possibility is sintering by viscous flow, in which case there is a high melting percentage.
  • Reaction sintering is characterized by the emergence of a new phase (from the transitional melt that first formed).
  • the geometrical and microscopic change of the green body during sintering can be divided into three stages:
  • the individual powder particles form so-called sintering necks at the points of contact with their neighbors.
  • the necks on the contact points grow, more contacts are formed over time, the pores between the particles are completely interconnected via channels.
  • the pore volume remains approximately constant.
  • the kinetics at this stage is dominated by different radii of curvature.
  • the initial stage is usually regarded as finished when a density of about 60-70% of the theoretical density (theoretical maximum achievable density, all pores disappeared) is reached.
  • the driving force for sintering, neck growth, pore shape change, shrinkage and grain growth is the reduction in surface and interfacial energy, as part of free Gibbs energy G.
  • gs, gb are the specific surface energy and grain boundary energy and As and Ab, respectively, are the entire surface or grain boundary surface of the sintered body.
  • Atomic transport takes place with differences in the chemical potential of atoms or vacancies.
  • the different chemical potential ⁇ in the sintered body is associated with locally different curvatures of the grains. Mathematically, this can be formulated as
  • ⁇ K is the difference in surface curvature between two sites in the sintered body and ⁇ is the volume of the atomic species.
  • the curvature scales with 1 / grain size.
  • the ratio of chemical potential to volume ⁇ is the sintering potential ⁇ (unit MPa)
  • Typical activation energies for the diffusion in oxides are in the range of 200-600 kJ / mol.
  • the object of the present invention is to provide a method and a device of the type mentioned that avoids the disadvantages of the above-described method / device.
  • the compaction and formation of the metal powder or ceramic powder structures or their compositions is carried out by Van der Waals forces or on a nano basis by Casimir forces.
  • the necessary energy influence is achieved by the application of the pulsed controllable energy input unit, such as one or more ultrasound beam elements and / or one or more megasonic radiating elements and / or one or more gigasound beam elements and / or one or more microwave radiating elements and / or one or more laser beam elements and / or one or more magnetic field generating elements and / or one or more electrostatic field generating elements and / or one or more pressure generating elements and / or any combinations thereof.
  • the pulsed controllable energy input unit such as one or more ultrasound beam elements and / or one or more megasonic radiating elements and / or one or more gigasound beam elements and / or one or more microwave radiating elements and / or one or more laser beam elements and / or one or more magnetic field generating elements and / or one or more electrostatic field generating elements and / or one or more pressure generating elements and / or any combinations thereof.
  • the pressure-generating elements that serve to generate pulsed pressures can be designed in various ways, for example as a pneumatic, hydraulic, gas-dynamic pulsed pressure generator, ultrasound or megasonic pulsed pressure generator, pulsed laser pressure generator, pulsed magnetostrictive pressure generator, pulsed plasma pressure generator, pulsed thermostrictive pressure generator, pulsed chemical Pressure generator, pressure generator, by means of microscopic explosions, electric discharge pressure generator.
  • the application of the pulsed energy influences produces an almost ideal homogenous distribution during primary molding for sintering certain constituents in whole primary volumes, generates a significantly higher compaction and thereby reduces the pressures required for the compaction, initiates first presintering by facilitating the chemical bonds, significantly accelerates the debindering process. and sintering processes, thereby ensuring the ideal density of the products and significantly reduces the sintering temperature.
  • the application of the periodic energy influences by the application of the controllable energy influences also initiates some chemical reactions with binder materials and thereby produces debindering already during prototyping.
  • the complete debinding and substantial sintering takes place during prototyping. This significantly reduces the sintering temperature.
  • Sintering is understood to mean thermal sintering, including self-heating sintering (Self Heating Sintering or Self-Propagating High-Temperature Synthesis), explosion sintering and hydrathermic sintering, microwave sintering, as well as ultrasonic sintering and laser sintering.
  • the method according to the invention has further advantages in comparison with the known methods.
  • a further advantage is that the possibility arises by the new method according to the invention of reducing the height of the applied pressure by at least 10 to 500 bar.
  • Another advantage is that the sintering temperature can be significantly reduced by up to 900 ° C by the inventive method.
  • a further advantage is that the process according to the invention overcomes the disadvantages of insufficient viscosities of the material mixtures, the so-called "feedstock” (material constituent states and different materials which are best mixed homogeneously together with different binder agents), and / or the composites This is the first time that it has been possible to achieve ideal densities in the entire volume of the sintered product.
  • a further advantage is that the targeted control of the pore development is achieved by the method according to the invention. This allows accurate determination of the pore size (from 0.1 nm to 800 ⁇ m) or complete elimination of pores.
  • porous products for example porous bone implants and others
  • porous products can be produced in one technological step. This was possible in the known methods only by additional applications with a simultaneous significant increase in costs.
  • Another advantage is that it is possible by the method according to the invention to produce the products without wall thickness limitation.
  • the wall thickness of the producible products is limited by the binder removal process, usually up to 10 mm, otherwise the binder can not be completely removed.
  • a further advantage is that the method according to the invention makes it possible to produce the products from a plurality of different materials having different properties (for example particle size) and combinations thereof without additional primary shaping steps.
  • Another advantage is that the process according to the invention makes it possible for the first time to carry out the debindering at least in part already during the forming process.
  • a further advantage lies in the fact that defined geometry structures can also be impressed into the surface by the novel method according to the invention. Such structures are particularly in the micro range and can serve, for example, for improved frictional properties of the product.
  • Another advantage is that the new process according to the invention offers the possibility of producing the superplastic products in a technological step.
  • a further advantage is that structural composition material structures which are difficult to produce by the method according to the invention, or structural porous composition material structures, for example in the case of turbine or gas turbine blade production, which have a porous core with metallic or ceramic walls, or porous bone implants are produced in a primary molding process can be.
  • the different parts of a product can have different hardness and strength properties, such as that an inner part has a higher hardness and strength compared to the outer part by the application of a specially aligned pressure pulse train and a having matching binder mixture.
  • a further advantage is that the method according to the invention ensures a gradual introduction of energy, a leveling of the temperature increase and an increase in the particle composite forces up to the presintering temperature and pre-sintering force so that the compacting and pre-sintering are uniformly generated and distributed throughout the mold space.
  • Another advantage is better handling of semi-finished products due to higher strength.
  • a further advantage lies in the fact that the binder removal is generated and accelerated in an even distribution throughout the molding space by the process according to the invention.
  • Another advantage is that the process of the invention and the use of supercritical fluids, the complete debindering and complete binder agent trace elimination is achieved.
  • Another advantage is that the compacting, pre-sintering and binder removal in the entire mold cavity is uniformly generated, distributed and accelerated by the application of one or more ultrasonic pulses with preferably different power and / or pulse duration, by a gradual energy input ensure a leveling of the temperature increase and the increase of the particle composite forces up to the presinter temperature and Vorsinterverbundkraft.
  • the invention relates to the method and / or products produced with the device according to one or more of claims 48 to 50.
  • Figures 1 and 2 show in schematic side view respectively an apparatus for producing a product by primary molding (injection molding, pressing) of a material which is present in a liquid, pasty, pasty, powdery, granular and / or solid state and / or a mixed state , According to two embodiments of the present invention.
  • the device 10 shown in Figure 1 for producing a product by injection molding of a material certain initial state has a press screw 11 in a housing 21 which is provided with a funnel 22, through which in the interior 23 of the housing 21 in which the press screw 11th is rotatably mounted, a mixture 12 of the material used (material) and a binder agent is introduced.
  • the binder may be of a customary in injection molding and tailored to the material to be processed substance.
  • the material (material) used in the injection molding can be in liquid, pasty, pasty, powdery, granular and / or solid state and / or its compositional states and mixed with the binder means are introduced. It is understood that instead of a rotationally driven pressing device may be provided which is driven linearly.
  • the material-binder mixture 12 is brought in the axial direction of the housing 21 to one or more spray nozzles 13, during which process the mixture 12 is compacted under pressure applied by the press screw 11.
  • the equipped with the one or more nozzles 13 end of the housing 21 is connected to the stationary part 14 of an injection mold 25, between which stationary part 14 and in the direction of the double arrow A for opening and closing the injection mold 25 movable part 16, an injection chamber 26 and Molded space is arranged, in which the molded product 15 is produced.
  • pressure line In the region of the spray nozzle 13 or the injection chamber 26 opens radially not shown in detail pressure line whose other end is connected to a generator 17 of pulsed pressures. These pressure pulses are superimposed on the mixture 12 in the injection nozzle 13 or the injection mold due to the pressure screw 11 existing pressure.
  • a sealer 18 On the spray nozzle (s) 13 also acts a sealer 18, which may be formed for example as a check valve for materials of very high viscosity and pressure in the injection chamber 26.
  • the device 110 shown in FIG. 2 for producing a product, for example a dental blank 115, by pressing from a material of a given initial state has a vertically or axially movable tool top 116 with a die 127 and a stationary tool base 114 with a die recess 128, which is hydraulically driven, for example is.
  • a mixture 112 of the material used (material) and a binder means is introduced in the Matrizenaus strictlyung 128, which represents the mold space.
  • the binding agent may be of a customary in pressing and tailored to the material to be processed substance.
  • the material (material) used in the injection molding can be in liquid, pasty, pasty, powdery, granular and / or solid state and / or its compositional states and mixed with the binder means are introduced.
  • the material-binder mixture 112 is compressed in the axial direction by the application of the die 127 by the applied pressure.
  • two radially extending pressure lines 129, 130 whose other end is connected to a respective generator 117, 118 of pulsed pressures, open. These pressure pulses are superimposed on the mixture 112 in the filled die recess 128 due to the die 127 pressure.
  • the pressure generators 17 and 117 and 118 which serve to generate periodic pressures may be formed in various ways, for example as a pneumatic, hydraulic, gas-dynamic, pulsed pressure generator, as a pulsed ultrasonic pressure generator, pulsed magnetostrictive pressure generator, pulsed thermostrictive pressure generator, pulsed plasma pressure generator, pulsed Laser pressure generator, pulsed chemical pressure generator and / or by discharges and / or laser initiated discharges and / or pulsed microscopic explosions.
  • the pressure generators 17 and 117, 118 may be designed so that the number of pressure pulses and / or their force or energy and / or their pulse duration and / or their time can be controlled.
  • the shape of the pressure pulses may ideally be approximately rectangular or approximately sawtooth.
  • the number of pressure pulses is > 1, for example in the range of 1 to 1000 pressure pulses, preferably in the range of 1 to 500, but most preferably in the range of 1 to 100 pressure pulses.
  • the pulse duration may be between 1 ns and 30 minutes, preferably between 2 ⁇ s to 10 minutes, but most preferably between 100 ms and 5 minutes.
  • the pulse interval ranges between 1 ns and 30 minutes, preferably between 1 ⁇ s and 10 minutes, preferably between 100 ms and 5 minutes.
  • the generated pulsed pressure is transferred to the material mixture feedstock, which is located in the injection mold 25.
  • the pulsed pressures are applied together with the injection molding or pressing pressure.
  • the pulsed pressures generated by the application of special membranes which are according to Figure 1, for example, in the injection mold 25 or in the injection molding nozzles 13, transferred to the injection molding chamber 26.
  • the inventive method was further tested using the example of a hot gas turbine blade with different material mixtures, such as:
  • Nickel-hafnium-tungsten-titanium-molybdenum-chromium-zirconium-yttrium oxides
  • the turbine blades were also made with a ceramic top layer.
  • the process according to the invention was also tested on the example of ceramic composition parts, such as, for example, aluminum oxides with BN fiber.
  • the method according to the invention also offers the possibility of producing toothed wheels with different material properties, such as lightweight on the inside and hard on the outside.
  • porous products has been shown by the example of parts which are similar to metallic foams. As a result, structures such as closed and / or open metallic foams were produced.
  • the pulsed pressurization of the mixture 12, 112 in the relevant mold space in addition to the injection molding or pressing pressure or this superimposed can be effected by other pulsed controllable energy influences.
  • specific consequences of the pulsed controllable energy effects include electromagnetic energy and / or sound energy, such as ultrasonic energy or megasonic energy or giga-sound energy.
  • the specific consequences of the pulsed controllable energy influences include the electromagnetic energy, any compositions of ultrasound energy and / or megasonic energy and / or gigasound energy and / or microwave energy and / or electrostatic energy and / or laser energy of photon emitters and / or phonon radiating lasers and / or their Combination and / or pulsed magnetic field energy and / or energy of rotating magnetic fields.
  • the particular consequences of the pulsed controllable energy effects may include any combination of electromagnetic and mechanical energy.
  • the activation and / or mobilization and / or control of quantum mechanical and / or quantum chemical effects and forces and / or their arbitrary combinations results in better compaction, primary shaping and pre-sintering of the precursor product as well as predentraction and significant reduction of sintering temperatures and sintering times Even Urform tray achieved, the compaction and pre-sintering is generated evenly distributed and accelerated throughout the cavity.

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  • Engineering & Computer Science (AREA)
  • Mechanical Engineering (AREA)
  • Manufacturing & Machinery (AREA)
  • Chemical & Material Sciences (AREA)
  • Ceramic Engineering (AREA)
  • Powder Metallurgy (AREA)
  • Producing Shaped Articles From Materials (AREA)

Abstract

L'invention concerne un procédé de fabrication d'un produit par formage initial (moulage par injection, pressage) à partir d'un matériau sous forme de liquide, de coulis, de pâte, de poudre, de grains et/ou de solide et/ou de ses additifs de composition au moyen d'un moule. Le procédé est caractérisé en ce qu'on obtient par l'activation et/ou la mobilisation et/ou la commande d'effets et forces de mécanique quantique et/ou de chimie quantique et/ou leur combinaison arbitraire un meilleur compactage, formage initial et préfrittage du produit ainsi qu'un retrait préliminaire et la nette réduction des températures de frittage ainsi que des temps de frittage ainsi que des pressions de formage initial, et en ce que le compactage et le préfrittage sont produits et accélérés de manière uniformément répartie dans tout l'espace du moule.
PCT/EP2011/054045 2010-03-26 2011-03-17 Procédé et dispositif de fabrication d'un produit par formage initial à partir d'un matériau sous forme de liquide, de coulis, de pâte, de poudre, de grains, de solide et/ou ses additifs de composition WO2011117137A2 (fr)

Priority Applications (1)

Application Number Priority Date Filing Date Title
DE212011100068U DE212011100068U1 (de) 2010-03-26 2011-03-17 Vorrichtung zur Herstellung eines Erzeugnisses durch Urformen aus flüssigem, breiigem, pastenförmigem, pulverigem, körnigem, festen Material und/oder dessen Kompositionszuständen

Applications Claiming Priority (2)

Application Number Priority Date Filing Date Title
DE201010013544 DE102010013544A1 (de) 2010-03-26 2010-03-26 Verfahren und Vorrichtung zur Herstellung eines Erzeugnisses durch Urformen aus flüssigem, breiigem, pastenförmigem, pulverigem, körnigem, festem Material und/oder dessen Kompositionszuständen
DE102010013544.5 2010-03-26

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WO2011117137A2 true WO2011117137A2 (fr) 2011-09-29
WO2011117137A3 WO2011117137A3 (fr) 2011-11-17

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BR112021000297A2 (pt) * 2018-07-24 2021-04-06 Straumann Holding Ag Processo para a preparação de um artigo por moldagem por injeção de pó

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