WO2016003277A1 - Device and method for forming a coloured workpiece by means of 3d extrusion - Google Patents

Device and method for forming a coloured workpiece by means of 3d extrusion Download PDF

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Publication number
WO2016003277A1
WO2016003277A1 PCT/NL2015/050479 NL2015050479W WO2016003277A1 WO 2016003277 A1 WO2016003277 A1 WO 2016003277A1 NL 2015050479 W NL2015050479 W NL 2015050479W WO 2016003277 A1 WO2016003277 A1 WO 2016003277A1
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WO
WIPO (PCT)
Prior art keywords
layer
extrusion
ink
head
inkjet head
Prior art date
Application number
PCT/NL2015/050479
Other languages
French (fr)
Inventor
Martinus Petrus Otten
Petrus Johannes Marie Otten
Original Assignee
Leapfrog B.V.
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by Leapfrog B.V. filed Critical Leapfrog B.V.
Publication of WO2016003277A1 publication Critical patent/WO2016003277A1/en

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Classifications

    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B41—PRINTING; LINING MACHINES; TYPEWRITERS; STAMPS
    • B41J—TYPEWRITERS; SELECTIVE PRINTING MECHANISMS, i.e. MECHANISMS PRINTING OTHERWISE THAN FROM A FORME; CORRECTION OF TYPOGRAPHICAL ERRORS
    • B41J3/00—Typewriters or selective printing or marking mechanisms characterised by the purpose for which they are constructed
    • B41J3/407—Typewriters or selective printing or marking mechanisms characterised by the purpose for which they are constructed for marking on special material
    • B41J3/4073—Printing on three-dimensional objects not being in sheet or web form, e.g. spherical or cubic objects
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • 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
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • 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
    • B29C64/118—Processes of additive manufacturing using only liquids or viscous materials, e.g. depositing a continuous bead of viscous material using filamentary material being melted, e.g. fused deposition modelling [FDM]
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • 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
    • B29C64/20—Apparatus for additive manufacturing; Details thereof or accessories therefor
    • B29C64/205—Means for applying layers
    • B29C64/209—Heads; Nozzles
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • 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
    • B29C64/20—Apparatus for additive manufacturing; Details thereof or accessories therefor
    • B29C64/245—Platforms or substrates
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • 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
    • B29C64/30—Auxiliary operations or equipment
    • B29C64/307—Handling of material to be used in additive manufacturing
    • B29C64/321—Feeding

Definitions

  • a device is therefore known from the prior art for forming a workpiece by means of 3D extrusion, wherein the device is provided with a substantially horizontally extending work platform movable in vertical direction for supporting the workpiece, an extrusion head displaceable in a substantially horizontal direction above the work platform, feed means for feeding material for extrusion to the at least one extrusion head and a control member for controlling the vertical displacement of the work platform, the horizontal displacement of the extrusion head and the extrusion head.
  • Use is usually made for the manufacture of the workpieces of plastics such as PLA
  • a device of the above stated type which is provided with at least one inkjet head which is displaceable in substantially horizontal direction, connected to at least one ink reservoir, controllable by the control member and configured to direct the inkjet downward, and wherein the control member is configured to control the inkjet head and the displacement of the inkjet head.
  • the invention likewise relates to a method for manufacturing by means of 3D extrusion a workpiece at least partially coloured on its outer surface, comprising the steps of arranging at least a first layer of extrusion material on a work platform by means of an extrusion head, applying an ink layer to the arranged layer of extrusion material by means of an inkjet head, arranging a subsequent layer of extrusion material on the layer of extrusion material present by means of the extrusion head and applying an ink layer to the subsequent layer of extrusion material by means of the inkjet head, and repeating the latter two steps until the workpiece is complete.
  • the extrusion head is preferably configured to arrange a layer of extrudable material permeable to a type of ink, and the inkjet head is configured to apply the type of ink which can permeate the extruded material. This measure makes it possible to colour the material through and through so that the outer wall of the workpiece is coloured.
  • Permeation of the ink into the layer of extrusion material can take place when the extrusion material is suitable for the purpose, and particularly when it has a certain porosity.
  • Types of ink can in principle be used which can permeate the porous material. This is particularly the case for water-based inks and for solvent-based inks.
  • Tnks which cure in UV light can also be used provided they are thinly liquid enough to permeate into the extrusion material prior to curing by means of irradiation with UV light.
  • This embodiment also provides a method wherein following application of an ink layer to an extrusion layer the ink permeates at least partially into the material of the extrusion layer.
  • control member is configured to apply a layer of ink extending over only a part of the surface of the arranged layer of extrusion material.
  • control member is configured to apply a layer of ink which extends over a strip of the arranged layer of extrusion material adjacent to the outer contour of the arranged layer of extrusion material. Ink is after all then used only in the areas where it is visible from the outside.
  • This embodiment likewise provides a method wherein the ink layer is applied to a strip extending adjacently of the outer contour of the arranged layer of extrusion material.
  • control member is configured to apply an ink layer to at least that part of a layer of extrusion material which is present and which is not covered by a subsequent layer of extrusion material. After all, this part also forms a part of the visible side of the workpiece.
  • This embodiment likewise provides a method wherein the ink layer is applied to areas of the arranged layer of extrusion material which are not covered by a subsequent layer of extrusion material.
  • the invention particularly comprises the aspect that an ink layer is not applied to areas of the arranged layer of extrusion material which will be covered by a subsequent layer of extrusion material.
  • a further embodiment provides for this purpose the measure that the inkjet head is connected to at least two different ink reservoirs and that the control member is configured to apply an ink layer with locally differing colours.
  • This embodiment likewise provides a method wherein an ink layer with locally differing colours is applied.
  • the inkjet head When ink is used in combination with an extrusion material which the ink cannot permeate, it is attractive for the inkjet head to be configured to direct the ink jet exiting the head obliquely downward, for the inkjet head to be mounted on the carrier for rotation about a substantially vertical axis and for the control member to be configured to apply an ink layer to the outer wall of the arranged layer of extrusion material.
  • This embodiment further provides a method wherein, during application of an ink layer to the strip adjacent to the periphery of an arranged layer of extrusion material, an ink layer is applied to the outer wall of the arranged layer of extrusion material.
  • the rotatability of the inkjet head about a substantially vertical axis enables adequate irradiation of corner points in the outer contour of an arranged layer of extrusion material from the side, with a similar result on both sides of a corner point.
  • the inkjet head is even configured here to direct the inkjet not only obliquely downward but also substantially horizontally.
  • a preferred aspect of the method according to the invention is moreover that an ink layer is applied wholly or partially to the side walls of a layer of extrusion material.
  • extrusion head it is attractive for the extrusion head to be placed on a first carrier movable in a horizontal plane and for the inkjet head to be placed on a second carrier movable in a horizontal plane.
  • the extrusion head and the inkjet head can hereby be moved independently of each other so that the extrusion of extrusion material can take place simultaneously with application of ink. This configuration requires two different carriers and a control suitable for the purpose.
  • the construction of the device according to the invention is simplified when the extrusion head and the inkjet head are both placed on a carrier movable in a horizontal plane.
  • the control of the movements of the heads is then also simplified.
  • Application of the ink must then however take place after the layers of extrusion material have been arranged, which requires more time.
  • the workpiece has a form which is provided with parts extending outside those parts of the workpiece resting on the work platform.
  • a specific embodiment provides for this purpose the measure that an additional extrusion head is arranged on the first carrier for the purpose of arranging removable material, that the device is provided with additional feed means for feeding removable material to the additional extrusion head and that the control member is configured to control the additional extrusion head.
  • the removable material here forms a removable base for the respective parts of the workpiece.
  • the ink usual in inkjets generally has a considerable drying time.
  • the device is preferably provided with a UV light source configured to irradiate the ink applied to the workpiece by the inkjet head.
  • the use of ink which dries in UV light also provides the option of applying more durable types of ink.
  • Use can be made here of a single UV light source which can irradiate the whole workpiece or the whole surface of the work platform, or of a UV light source which is placed on a carrier movable in a horizontal plane.
  • Figure 1 is a schematic cross-sectional view of a first embodiment of a device according to the invention
  • Figure 2 is a schematic cross-sectional view of a workpiece by way of elucidating the invention
  • Figure 3 is a view corresponding to figure 2 of another workpiece
  • Figure 4 is a detail view of the workpiece shown in figure 3 ;
  • FIG. 5 is a detail view corresponding to figure 4 of another workpiece; and Figure 6 is a detail view corresponding to figures 4 and 5 of yet another workpiece.
  • the device shown schematically in figure 1 and designated as a whole with 1 comprises a base 2 on which a schematically represented frame 3 is placed.
  • the device further comprises a horizontally extending work platform 4 which is displaceable by means of an adjusting mechanism operative in vertical direction and having a number of spindles 6, each drivable by a motor 5 and extending through nuts 7 connected to the work platform.
  • a carrier 8 is connected by means of a horizontal moving member 9 to frame 3. Carrier 8 is displaceable in the longitudinal direction of moving member 9.
  • Moving member 9 is connected at both ends to a rail 10 extending in the transverse direction of moving member 9, and moving member 9 is displaceable along rail 10.
  • An extrusion head 11 and an inkjet head 12 are placed on carrier 8.
  • Extrusion head 11 is connected by means of a feed hose (not shown) to a supply of extrusion material (not shown).
  • a control member in the form of a digital computer 14 is placed in a compartment 13.
  • Computer 14 is configured to control adjusting mechanism 5, 6, 7 for work platform 4, moving members 8, 9, extrusion head 11 and inkjet head 12.
  • a workpiece is formed on work platform 4 in per se known manner by extruding extrusion material layer by layer through extrusion head 11 onto work platform 4 under the control of control member 14.
  • an ink layer is applied according to the invention in order to give the workpiece a colour.
  • inkjet head 13 which is likewise controlled by control member 14.
  • control member 14 In the embodiment shown in this figure use is made of a single carrier 8 on which extrusion head 11 and inkjet head 12 are placed, so that the process of applying the ink must take place after a layer of extrusion material has been arranged. It is otherwise also possible to arrange the two heads on carriers movable independently of each other.
  • Figure 2 subsequently shows a schematic cross-sectional view of a workpiece 20.
  • the workpiece comprises a first layer of arranged extrusion material 21a.
  • An ink layer 22a in the desired colour is applied to strips of the upper surface of layer 21a adjacent to the edges of layer 21a.
  • a second layer of extrusion material 21b is then arranged on the thus formed assembly and an ink layer 22b in the desired colour is applied to strips of the upper surface of layer 21b adjacent to the edges of layer 21b.
  • upper layer 21e is provided with a wider layer of ink 22e; this is because the layer 22f placed thereon extends to lesser extent and the parts not covered by this upper layer 22f form an outer surface of the completed workpiece, so that these parts have to be covered in their entirety by the layer of ink 22f .
  • the upper layer of extrusion material 21h also forms the upper surface of the workpiece, and this upper layer is therefore wholly covered with a layer of ink 22h.
  • This embodiment is based on the situation that the ink forms a separate layer and does not permeate into the layer of extrusion material.
  • This behaviour of the ink does of course depend on the nature of the ink and the extrusion material. Colouring of the side surfaces of the layers of extrusion material not covered by the ink takes place in that the extrusion material is transparent to some extent. It is however also possible to make use of extrusion material which is permeable to the ink so that the ink diffuses inside the extrusion material and the ink also colours the outer surface of the extrusion material.
  • Each ink layer 22 disappears here into the underlying part 23 of the layer of extrusion material. This is also the case for each of the underlying parts 23a-23h.
  • area 23e into which the ink has diffused is wider than the areas 23a-23d.
  • Area 23h likewise covers the whole layer 22h of the extrusion material. It is thus not only the upper surface of the layers of extrusion material which are coloured, but also the side surfaces of these layers.
  • Figure 4 shows two layers 21a and 21b, in which areas 23a and 23 are formed by means of applying a respective ink layer 22a, 22b from above by means of the inkjet head and distributing the ink over the area lying under the ink layer by the combination of type of ink and the nature of the extrusion material.
  • a gradient also occurs in the transverse direction as a result of the distribution process.
  • the latter described embodiments relate to the distribution of the ink in the extrusion material.
  • the inventors have found that almost all types of ink which can be used by an inkjet are suitable for this process. It has further been found that the following extrusion materials are readily suitable for this purpose.

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  • Engineering & Computer Science (AREA)
  • Chemical & Material Sciences (AREA)
  • Materials Engineering (AREA)
  • Manufacturing & Machinery (AREA)
  • Physics & Mathematics (AREA)
  • Mechanical Engineering (AREA)
  • Optics & Photonics (AREA)

Abstract

The invention relates to a device (1) for forming a workpiece-by means of 3D extrusion, comprising a horizontally extending work platform (4) movable in vertical direction for the workpiece, an extrusion head (11) displaceable relative to the work platform in a horizontal direction above the work platform (4), feed means for feeding material for extrusion to the extrusion head, and a control member for controlling the displacement of the work platform, the displacement of the extrusion head (11) and the extrusion head, wherein the device comprises an inkjet head (12) which is displaceable in horizontal direction, connected to an ink reservoir and controllable by the control member for directing the ink jet downward, and the control member is configured to control the inkjet head (12), the displacement of the inkjet head and, after a layer of extrusion material has been arranged, the application of at least one layer of ink thereto. The invention also relates to such a method.

Description

Device and method for forming a coloured workpiece by means of 3D extrusion
The use of 3D extrusion for manufacturing workpieces has increased greatly in recent years. This relates not only to the manufacture of prototypes and models but also, as a result of the falling prices of this technique, to production of small series.
A device is therefore known from the prior art for forming a workpiece by means of 3D extrusion, wherein the device is provided with a substantially horizontally extending work platform movable in vertical direction for supporting the workpiece, an extrusion head displaceable in a substantially horizontal direction above the work platform, feed means for feeding material for extrusion to the at least one extrusion head and a control member for controlling the vertical displacement of the work platform, the horizontal displacement of the extrusion head and the extrusion head. Use is usually made for the manufacture of the workpieces of plastics such as PLA
(polylactic acid) or ABS (acrylonitrile butadiene styrene) with a neutral colour such as white, grey or beige. Use is otherwise also made of other thermoplastic materials. Once the workpiece has been completed it is painted or sprayed in the desired colour. It is likewise known to make use of material in the desired colour in order to obtain a workpiece in this colour. It is usually desired to provide a workpiece with more than a single colour. According to the prior art, use then has to be made of a device with more than one extrusion head, i.e. one extrusion head for each colour. If the workpiece has to have many colours, such as in the manufacture of scale models, this becomes difficult. It also occurs that a workpiece or a part of a workpiece has to be given a colour which is not available as basic material. There is therefore a need for a device suitable for manufacturing a workpiece coloured as desired, and the invention seeks to provide such a device.
This object is achieved by means of a device of the above stated type which is provided with at least one inkjet head which is displaceable in substantially horizontal direction, connected to at least one ink reservoir, controllable by the control member and configured to direct the inkjet downward, and wherein the control member is configured to control the inkjet head and the displacement of the inkjet head.
Using these measures it is possible to give the workpieces a random colour. Use is made here of the fact that in the 3D technique the workpiece is built up of thin layers The ink can be sprayed between the layers here, wherein the transparency of the layers initially gives the workpiece the respective colour. The invention likewise relates to a method for manufacturing by means of 3D extrusion a workpiece at least partially coloured on its outer surface, comprising the steps of arranging at least a first layer of extrusion material on a work platform by means of an extrusion head, applying an ink layer to the arranged layer of extrusion material by means of an inkjet head, arranging a subsequent layer of extrusion material on the layer of extrusion material present by means of the extrusion head and applying an ink layer to the subsequent layer of extrusion material by means of the inkjet head, and repeating the latter two steps until the workpiece is complete.
The extrusion head is preferably configured to arrange a layer of extrudable material permeable to a type of ink, and the inkjet head is configured to apply the type of ink which can permeate the extruded material. This measure makes it possible to colour the material through and through so that the outer wall of the workpiece is coloured.
Permeation of the ink into the layer of extrusion material can take place when the extrusion material is suitable for the purpose, and particularly when it has a certain porosity. Types of ink can in principle be used which can permeate the porous material. This is particularly the case for water-based inks and for solvent-based inks. Tnks which cure in UV light can also be used provided they are thinly liquid enough to permeate into the extrusion material prior to curing by means of irradiation with UV light. This embodiment also provides a method wherein following application of an ink layer to an extrusion layer the ink permeates at least partially into the material of the extrusion layer.
In order to save ink and time it is recommended that the control member is configured to apply a layer of ink extending over only a part of the surface of the arranged layer of extrusion material.
This is the case particularly when the control member is configured to apply a layer of ink which extends over a strip of the arranged layer of extrusion material adjacent to the outer contour of the arranged layer of extrusion material. Ink is after all then used only in the areas where it is visible from the outside.
This embodiment likewise provides a method wherein the ink layer is applied to a strip extending adjacently of the outer contour of the arranged layer of extrusion material.
It is further recommended that the control member is configured to apply an ink layer to at least that part of a layer of extrusion material which is present and which is not covered by a subsequent layer of extrusion material. After all, this part also forms a part of the visible side of the workpiece.
This embodiment likewise provides a method wherein the ink layer is applied to areas of the arranged layer of extrusion material which are not covered by a subsequent layer of extrusion material. In this embodiment the invention particularly comprises the aspect that an ink layer is not applied to areas of the arranged layer of extrusion material which will be covered by a subsequent layer of extrusion material.
It is usually desired for the workpiece to have different colours. A further embodiment provides for this purpose the measure that the inkjet head is connected to at least two different ink reservoirs and that the control member is configured to apply an ink layer with locally differing colours.
This embodiment likewise provides a method wherein an ink layer with locally differing colours is applied.
When ink is used in combination with an extrusion material which the ink cannot permeate, it is attractive for the inkjet head to be configured to direct the ink jet exiting the head obliquely downward, for the inkjet head to be mounted on the carrier for rotation about a substantially vertical axis and for the control member to be configured to apply an ink layer to the outer wall of the arranged layer of extrusion material.
This embodiment further provides a method wherein, during application of an ink layer to the strip adjacent to the periphery of an arranged layer of extrusion material, an ink layer is applied to the outer wall of the arranged layer of extrusion material. The rotatability of the inkjet head about a substantially vertical axis enables adequate irradiation of corner points in the outer contour of an arranged layer of extrusion material from the side, with a similar result on both sides of a corner point. If desired, the inkjet head is even configured here to direct the inkjet not only obliquely downward but also substantially horizontally.
A preferred aspect of the method according to the invention is moreover that an ink layer is applied wholly or partially to the side walls of a layer of extrusion material.
It is attractive for the extrusion head to be placed on a first carrier movable in a horizontal plane and for the inkjet head to be placed on a second carrier movable in a horizontal plane. The extrusion head and the inkjet head can hereby be moved independently of each other so that the extrusion of extrusion material can take place simultaneously with application of ink. This configuration requires two different carriers and a control suitable for the purpose.
The construction of the device according to the invention is simplified when the extrusion head and the inkjet head are both placed on a carrier movable in a horizontal plane. The control of the movements of the heads is then also simplified. Application of the ink must then however take place after the layers of extrusion material have been arranged, which requires more time.
In many cases the workpiece has a form which is provided with parts extending outside those parts of the workpiece resting on the work platform. A specific embodiment provides for this purpose the measure that an additional extrusion head is arranged on the first carrier for the purpose of arranging removable material, that the device is provided with additional feed means for feeding removable material to the additional extrusion head and that the control member is configured to control the additional extrusion head. The removable material here forms a removable base for the respective parts of the workpiece.
The ink usual in inkjets generally has a considerable drying time. For use of types of ink which cure in UV light the device is preferably provided with a UV light source configured to irradiate the ink applied to the workpiece by the inkjet head. The use of ink which dries in UV light also provides the option of applying more durable types of ink. Use can be made here of a single UV light source which can irradiate the whole workpiece or the whole surface of the work platform, or of a UV light source which is placed on a carrier movable in a horizontal plane.
The invention will now be elucidated with reference to the following non-limitative drawings, in which:
Figure 1 is a schematic cross-sectional view of a first embodiment of a device according to the invention;
Figure 2 is a schematic cross-sectional view of a workpiece by way of elucidating the invention;
Figure 3 is a view corresponding to figure 2 of another workpiece;
Figure 4 is a detail view of the workpiece shown in figure 3 ;
Figure 5 is a detail view corresponding to figure 4 of another workpiece; and Figure 6 is a detail view corresponding to figures 4 and 5 of yet another workpiece. The device shown schematically in figure 1 and designated as a whole with 1 comprises a base 2 on which a schematically represented frame 3 is placed. The device further comprises a horizontally extending work platform 4 which is displaceable by means of an adjusting mechanism operative in vertical direction and having a number of spindles 6, each drivable by a motor 5 and extending through nuts 7 connected to the work platform. A carrier 8 is connected by means of a horizontal moving member 9 to frame 3. Carrier 8 is displaceable in the longitudinal direction of moving member 9. Moving member 9 is connected at both ends to a rail 10 extending in the transverse direction of moving member 9, and moving member 9 is displaceable along rail 10. An extrusion head 11 and an inkjet head 12 are placed on carrier 8. Extrusion head 11 is connected by means of a feed hose (not shown) to a supply of extrusion material (not shown). A control member in the form of a digital computer 14 is placed in a compartment 13. Computer 14 is configured to control adjusting mechanism 5, 6, 7 for work platform 4, moving members 8, 9, extrusion head 11 and inkjet head 12. A workpiece is formed on work platform 4 in per se known manner by extruding extrusion material layer by layer through extrusion head 11 onto work platform 4 under the control of control member 14. After a layer of extrusion material has been arranged, an ink layer is applied according to the invention in order to give the workpiece a colour. Use is made here of inkjet head 13 which is likewise controlled by control member 14. In the embodiment shown in this figure use is made of a single carrier 8 on which extrusion head 11 and inkjet head 12 are placed, so that the process of applying the ink must take place after a layer of extrusion material has been arranged. It is otherwise also possible to arrange the two heads on carriers movable independently of each other.
Figure 2 subsequently shows a schematic cross-sectional view of a workpiece 20. The workpiece comprises a first layer of arranged extrusion material 21a. An ink layer 22a in the desired colour is applied to strips of the upper surface of layer 21a adjacent to the edges of layer 21a. A second layer of extrusion material 21b is then arranged on the thus formed assembly and an ink layer 22b in the desired colour is applied to strips of the upper surface of layer 21b adjacent to the edges of layer 21b.
The following five layers of the workpiece are formed in similar manner, with the understanding that upper layer 21e is provided with a wider layer of ink 22e; this is because the layer 22f placed thereon extends to lesser extent and the parts not covered by this upper layer 22f form an outer surface of the completed workpiece, so that these parts have to be covered in their entirety by the layer of ink 22f . The upper layer of extrusion material 21h also forms the upper surface of the workpiece, and this upper layer is therefore wholly covered with a layer of ink 22h.
This embodiment is based on the situation that the ink forms a separate layer and does not permeate into the layer of extrusion material. This behaviour of the ink does of course depend on the nature of the ink and the extrusion material. Colouring of the side surfaces of the layers of extrusion material not covered by the ink takes place in that the extrusion material is transparent to some extent. It is however also possible to make use of extrusion material which is permeable to the ink so that the ink diffuses inside the extrusion material and the ink also colours the outer surface of the extrusion material. Such a situation is shown in figure 3. Each ink layer 22 disappears here into the underlying part 23 of the layer of extrusion material. This is also the case for each of the underlying parts 23a-23h. It is noted that the area 23e into which the ink has diffused is wider than the areas 23a-23d. Area 23h likewise covers the whole layer 22h of the extrusion material. It is thus not only the upper surface of the layers of extrusion material which are coloured, but also the side surfaces of these layers.
It is assumed that the ink is not distributed uniformly over the area but that the distribution has a gradient, since the process whereby the ink is distributed over the underlying area resembles diffusion to some extent. This results in a distribution as shown in figure 4. Figure 4 shows two layers 21a and 21b, in which areas 23a and 23 are formed by means of applying a respective ink layer 22a, 22b from above by means of the inkjet head and distributing the ink over the area lying under the ink layer by the combination of type of ink and the nature of the extrusion material. A gradient also occurs in the transverse direction as a result of the distribution process.
Application of the ink to the side surface of the arranged layer of extrusion material is not otherwise precluded, as shown in figure 5. This requires an inkjet head configured to generate an inkjet with a horizontal directional component or a mounting of the inkjet head on the carrier which enables a tilting of the inkjet head so that the inkjet head can dispense an ink jet directed at these side surfaces. In the latter case the inkjet head must al o be rotatable about a vertical axi . Figure 5 shows the applied vertical ink layers 24a and 24b.
It is also possible in this latter situation to make use of a combination of a type of ink and a nature of extrusion material wherein the ink is distributed at least partially into the extrusion material, although this is not essential per se for the required effect. The situation which then results is shown in figure 6. Ink layers 24a and 24b are applied here to the side surfaces of the layers of extrusion material 21 a and 21b. The ink has then been distributed into the parts 25a, 25b of the layers of extrusion material 21a, 21b adjacent to ink layers 24a, 24b.
The latter described embodiments relate to the distribution of the ink in the extrusion material. The inventors have found that almost all types of ink which can be used by an inkjet are suitable for this process. It has further been found that the following extrusion materials are readily suitable for this purpose.

Claims

Claims
1. Device for forming a workpiece by means of 3D extrusion, wherein the device comprises:
- a substantially horizontally extending work platform movable in vertical direction for supporting the workpiece;
- an extrusion head displaceable relative to the work platform in a substantially horizontal direction above the work platform;
- feed means for feeding material for extrusion to the at least one extrusion head; and - a control member for controlling the vertical displacement of the work platform, the horizontal displacement of the extrusion head and the extrusion head,
characterized in that
- the device is provided with at least one inkjet head which is displaceable in substantially horizontal direction, connected to at least one ink reservoir, controllable by the control member and configured to direct the inkjet downward in vertical direction, and
- the control member is configured to control the inkjet head, to control the
displacement of the inkjet head and, after a layer of extrusion material has been arranged, to apply at least one layer of ink to the arranged layer of extrusion material.
2. Device as claimed in claim 1 , characterized in that the extrusion head is configured to arrange a layer of material permeable to a type of ink, and that the inkjet head is configured to apply the type of ink which can permeate the extruded material.
3. Device as claimed in claim 1 or 2, characterized in that the control member is configured to apply a layer of ink extending over only a part of the surface of the arranged layer of extrusion material.
4. Device as claimed in claim 3, characterized in that the control member is configured to apply a layer of ink which extends over a strip of the arranged layer of extrusion material adjacent to the outer contour of the arranged extrusion layer.
5. Device as claimed in claim 3, characterized in that the control member is configured to apply a layer of ink to areas of the arranged extrusion layer which are not covered by a subsequent extrusion layer.
6. Device as claimed in any of the foregoing claims, characterized in that the inkjet head is connected to at least two different ink reservoirs and that the control member is configured to apply an ink layer with locally differing colours.
7. Device as claimed in any of the foregoing claims, characterized in that the inkjet head is configured to direct the ink jet exiting the head obliquely downward, that the inkjet head is mounted on the carrier for rotation about a substantially vertical axis and that the control member is configured to apply a layer of ink to the outer wall of the arranged layer of extrusion material.
8. Device as claimed in any of the foregoing claims, characterized in that the extrusion head is placed on a first carrier movable in a horizontal plane and that the inkjet head is placed on a second carrier movable in a horizontal plane.
9. Device as claimed in any of the claims 1-7, characterized in that the extrusion head and the inkjet head are both placed on the same carrier movable in a horizontal plane.
10. Device as claimed in any of the foregoing claims, characterized in that the device is provided with a UV radiation source.
11. Method for manufacturing by means of 3D extrusion a workpiece at least partially coloured on its outer surface, comprising the following steps of:
- arranging at least a first layer of extrusion material on a work platform by means of an extrusion head;
- applying at least one ink layer to the at least first layer of extrusion material by means of an inkjet head;
- arranging a subsequent layer of extrusion material on the layer of extrusion material present by means of the extrusion head;
- applying an ink layer to the subsequent layer of extrusion material by means of the inkjet head; and
- repeating the latter two steps until the workpiece is complete.
12. Method as claimed in claim 11, characterized in that following application of an ink layer to an extrusion layer the ink permeates at least partially into the material of the extrusion layer.
13. Method as claimed in claim 11 or 12, characterized in that the ink layer is applied to a strip extending adjacently of the outer contour of the arranged extrusion layer.
14. Method as claimed in claim 11, 12 or 13, characterized in that the ink layer is applied to areas of the arranged extrusion layer which are not covered by a subsequent extrusion layer, and preferably moreover that an ink layer is not applied to areas of the arranged layer of extrusion material which will be covered by a subsequent layer of extrusion material.
15. Method as claimed in any of the claims 11-14, characterized in that an ink layer with locally differing colours is applied.
16. Method as claimed in claim 13, characterized in that during application of an ink layer to the strip adjacent to the periphery of an arranged layer of extrusion material an ink layer is also applied to the outer wall of the arranged layer of extrusion material.
17. Method as claimed in any of the claims 11-16, wherein an ink layer is applied wholly or partially to the side surfaces of a layer of extrusion material.
PCT/NL2015/050479 2014-06-30 2015-06-30 Device and method for forming a coloured workpiece by means of 3d extrusion WO2016003277A1 (en)

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