WO2016008876A1 - Procédé et ensemble de fabrication additive d'éléments - Google Patents

Procédé et ensemble de fabrication additive d'éléments Download PDF

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Publication number
WO2016008876A1
WO2016008876A1 PCT/EP2015/066047 EP2015066047W WO2016008876A1 WO 2016008876 A1 WO2016008876 A1 WO 2016008876A1 EP 2015066047 W EP2015066047 W EP 2015066047W WO 2016008876 A1 WO2016008876 A1 WO 2016008876A1
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WO
WIPO (PCT)
Prior art keywords
solid phase
component
building material
phase
liquid
Prior art date
Application number
PCT/EP2015/066047
Other languages
German (de)
English (en)
Inventor
Holger LEONARDS
Andreas Hoffmann
Arnold Gillner
Original Assignee
Fraunhofer-Gesellschaft zur Förderung der angewandten Forschung e. 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 Fraunhofer-Gesellschaft zur Förderung der angewandten Forschung e. V. filed Critical Fraunhofer-Gesellschaft zur Förderung der angewandten Forschung e. V.
Publication of WO2016008876A1 publication Critical patent/WO2016008876A1/fr

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Classifications

    • 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
    • B29C64/40—Structures for supporting 3D objects during manufacture and intended to be sacrificed after completion thereof
    • 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
    • B29C64/124—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

Definitions

  • the present invention relates to a method for the additive production of components, in which the components are constructed by layerwise solidification of a construction ⁇ material, which is characterized by a
  • the invention also relates to an arrangement designed for carrying out the method.
  • CAD Computer-Aided Design
  • CAM Computer-Aided Manufacturing
  • FDM Fusion Modeling
  • SLM / SLS Selective Laser Melting / Sintering
  • thermoplastic With the SLM / SLS, thermoplastics or other materials are selectively melted with a laser beam.
  • Starting material is in the form of a powder.
  • the part of the layer is in each case
  • the solidification of the three-dimensional component is achieved by a chemical reaction (chemical curing, polymerization, crosslinking).
  • the individual layers of the component are generated by site-selective ⁇ , photo-induced curing of the photo-sensitive ⁇ building material, for example a photo-resin.
  • the best known photochemical methods are the stereolithography (SLA), in which the SLA is the stereolithography (SLA).
  • Resolution are printed, which are then cured by a flat irradiation with a UV lamp.
  • heated printheads can also liquefy meltable materials and then selectively dose them. These then harden through the
  • phase transition liquid-solid by cooling Phase transition liquid-solid by cooling.
  • support structures or supports
  • polyj et process polyj et process
  • support structures are additionally required in order to avoid thermal distortion of the components during production.
  • support structures are then either mechanically (in SLM, SLA or DLP) or using a
  • Construction for example, from WO 89/10254 AI so-called support generators known as software solutions that support the construction of component-specific support structures. These are adapted to the component on the computer and then printed with the component during the later manufacturing process. After the printing or production process, these must Support structures, however, also consuming again be removed from the component.
  • Component geometries also can not be planned completely automated.
  • US 2005/0186508 Al a method for the additive manufacturing of components is known, in which the components are strengthened by site-selective irradiation of a building material by means of photopolymerization ⁇ layer.
  • the building material here has except the solidification determined photo-curable material component of another material ⁇ component that makes it possible to transform the building material thermally into a gel state.
  • a sol-gel transition is a phase separation of a dissolved solid component in a second liquid component. If the temperature falls below a critical temperature, segregation of the components leads to a gel phase, which in this process is used to support the already established component areas.
  • Method is additionally a support structure for
  • Support structure are each materials with
  • the object of the present invention is to specify a method for the additive production of components, which does not require elaborate support structures, regardless of the complexity of the component to be produced. Furthermore, one for the
  • the task is with the method and the
  • Photochemical reaction can be converted from a liquid to a first solid phase.
  • the building material has for this purpose a determining the solidification
  • the building material may consist solely of this material ⁇ component or other additives contain.
  • the layer-by-layer solidification takes place with formation of the first solid phase in each case by locally selective, local irradiation of a layer of the liquid phase of the building material in accordance with the component geometry. By this irradiation in the irradiated region by chemical or photochemical reaction, in particular a crosslinking or Polymeri ⁇ sationsre force triggered.
  • the building material in particular the above determining the solidification material component of the building material, is chosen so that the construction ⁇ material or determining the solidification
  • Material component during the generative production still controllable by external action further phase transition between the liquid phase and the liquid state of matter and a further solid state of matter as a second solid phase
  • the already solidified component regions are already embedded in solid build-up material during or immediately after solidification, or even after a time that can be set by selecting the external conditions, which material has been converted into the second solid phase or in this phase is present.
  • this solid building material the already solidified component areas are supported, so that no support structures or additional support materials according to the prior art are required.
  • the finished component can then in a simple
  • phase is used in the present patent application in the sense of a classical state of aggregation (solid, liquid, gaseous) in order to distinguish liquid and solid states of the building material.
  • a sol-gel transition does not constitute a phase transition in the sense of the proposed method
  • radiation or irradiation include in the present patent application both electromagnetic radiation such as UV or visual light or microwave radiation and Particle radiation such as electron radiation.
  • Beam guiding and beam focusing devices denote an arrangement of optics for electromagnetic radiation and an arrangement of electric or magnetic fields for particle radiation.
  • the building material or the solidification-determining material component contained therein is selected such that the further phase transition can be produced by heating and / or cooling. It may thus be the purely physical process of melting and solidification. Thus, this phase transition, depending on the ambient temperature in the generative production and melting or solidification point of
  • Construction material either by increasing the temperature of the second solid phase in the liquid phase or by cooling from the liquid to the second solid phase.
  • the respective opposite transition can be made automatically depending on the ambient temperature, as soon as no longer cooled or no longer heated.
  • the building material for each layer can be applied liquid in already heated form and then cools due to a lower
  • Ambient temperature to form the second solid phase automatically.
  • the cooling can of course also be accelerated by explicit cooling.
  • a photo-crosslinkable construction ⁇ material is selected, for example, one of several
  • a building material whose phase transition is e.g. can be triggered by pressure change or other external influences.
  • a material which is solid in the ground state and undergoes a phase transition from solid to liquid by suitable irradiation e.g. Crosslinking temporarily resolved or induced photo-induced rearrangement reactions.
  • suitable irradiation e.g. Crosslinking temporarily resolved or induced photo-induced rearrangement reactions.
  • the non-polymerized raw material of the starting material from the liquid phase returns to the solid phase and thereby forms the support ⁇ material.
  • building material into which ferromagnetic nanoparticles are introduced and which is locally selectively liquefied by induction by means of high-frequency magnetic fields can be used, for example, for the proposed method. Others too
  • Materials such as polar or polarizable materials which can be converted to a different phase state by electromagnetic radiation, for example by microwave radiation, can be used for the proposed method.
  • Other classes of materials for the building material or the solidification determining material ⁇ component are polymers, prepolymers or monomers having one or more functional groups, such as epoxides (glycidyl ether), acrylates, methacrylates, vinyl ethers, allyl ethers, thiols, norbornenes, proteins as well as other particular biological Substances which chemically crosslink or polymerize upon irradiation with UV light directly and / or in combination with a photo-initiator.
  • the building materials used can also absorbers, inhibitors, initiators, reactive diluents, plasticizers, solvents and others
  • Additives such as nanoparticles included are included.
  • Additives such as nanoparticles included are included.
  • the building material for each layer is first applied in liquid form as a continuous layer, then irradiated in the liquid form site-selective and after formation of the solidified component areas of the layer (first solid phase) in the
  • This transfer can be achieved by targeted active cooling of the respective layer or due to the
  • Construction material must lie.
  • the building material is also first be ⁇ wear for each layer in liquid form as a continuous layer and then the entire surface, that is transferred over the entire layer, the second solid phase. The entire newly applied layer is then in solid form in the second solid phase. This can in turn be done by active cooling or due to a space temperature below the
  • Freezing point of the liquid phase is.
  • the building material can also be applied in the form of a film to the previous layer. Subsequently, the areas of the layer, which must be transferred for the production of the component in the first solid phase, selectively melted location and then irradiated in the liquid form for transfer into the first solid phase accordingly. This can be done for example by multiple beam sources or even with only one beam source, the more
  • Wavelengths (> 2) for example one
  • Microchip laser with Nd YAG fundamental (1064nm) and frequency multiplied radiation (e.g., 355nm). Furthermore, the melting can be done by others
  • Energy sources such as induction or microwave radiation or by infrared radiation.
  • the amounts ⁇ formed for carrying out the process device comprises a machining head which has an application device for the surface application of the building material onto a building platform, or it already-established areas of the component and is connected via a working plane movable, guiding a jet and / or focusing means for the Projection or focusing of the radiation in the
  • the beam guiding and / or focusing ⁇ siers is designed so that it is a location-selective irradiation of the processing plane
  • the arrangement is characterized in that it has a cooling and / or a heating device, with which the applied building material can be cooled or heated in a location-selective manner.
  • the cooling and / or heating device can also be attached to the machining head or integrated into the machining head. This also applies to the beam guiding and / or focusing device.
  • the method and the associated arrangement can be used for all fields of application in which three-dimensional objects are to be produced by additive manufacturing. This concerns, for example, the generative production of plastic components as
  • Prototype as a small series product, as a lost form or other plastic parts.
  • Figure 1 shows a first example of the implementation of the proposed method with reference to a schematic representation
  • Figure 2 is a comparison of the production of several 3D components between a conven tional ⁇ method and the proposed method.
  • FIG. 11 shows another example of the structure of a machining head in
  • the photoresin used as a building material has a melting point T M , which is between the
  • T 2 eg room temperature
  • the temperature ⁇ is set, at which the photoresin is fixed ( ⁇ ⁇ T M ).
  • a thin layer of the photoresin at the temperature T 2 at which the photoresin is liquid, flat on the
  • corresponding resin reservoir with liquid photoresin comprises.
  • Layer regions which belong to the layer of the component or object to be produced are selectively irradiated with a light source immediately after application and before physical solidification. So that the irradiation takes place in a liquid phase of the layer, the applied
  • Heating source e.g. with a scanning diode laser or other scanning or planar radiation source, selectively heated and thereby kept liquid or re-liquefied.
  • the irradiation for curing or polymerization i. for the production of the first solid phase, can be carried out with methods, as they are also used in the SLA or the DLP.
  • Irradiation can also be done with a modulated, linear
  • Light source for example, a modulated laser with a polygon scanner, behind (with respect to the feed direction of the surface coater) or parallel to the surface coater or done with any other type of local irradiation.
  • the resin solidifies by a photochemically induced
  • the method can also be carried out so that the respectively applied liquid layer is frozen or solidified by means of a flat cooling element, for example with a Peltier cooler, directly after application.
  • a flat cooling element for example with a Peltier cooler
  • Layer thickness distributions can be realized. Directly behind the cooling (with respect to the feed direction of the surface coater), the solidified in the second solid phase layer is re-liquefied by means of a local Schu ⁇ source and transferred directly at the same time or selectively by appropriate irradiation in the first solid phase, ie polymerized. In the case of incomplete polymerization, in particular the respectively underlying layer may again become slightly local again at its surface
  • a setting of liquefaction ⁇ deep and Polymertechnische can be effected by adjusting the heating or irradiation power or irradiation energy and the absorption characteristics of the construction or support material.
  • Method consists in the simple separation of support and component material, since the unexposed parts of the resin become liquid when heated above T M and then drip from the object or component. Ideally, these parts of the resin can be collected and reused for the next process.
  • the proposed method offers the possibility of being free in the
  • FIG. 2 shows a comparison between the production of solidified components 24 in generative production with the known ones
  • FIG. 3 schematically shows an example of the structure of a component during the irradiation of the respectively applied layer from above.
  • the figure shows three already applied layers in which the solidified to the first solid phase regions 5 of
  • Component be supported by the surrounding present in the second solid phase 4 building material.
  • On the uppermost layer is thereby liquefied building material with the surface coater 2 or
  • Photoresistor 3 each newly applied and then solidified by the irradiation 8 in the desired areas to form the component.
  • the then still liquid areas of the building material are transferred to the second solid phase 4, since they are among the
  • the feed direction 14 of the surface coater 2 is indicated in the figure as well as the feed 9 for the photoresin used as a construction ⁇ material.
  • This photoresin is used as monomer / prepolymer, for example in the form of a
  • the arrangement has a movable building platform 10 and in the lower region of the installation space corresponding feeds 9 for the monomer / prepolymer.
  • the irradiation 8 takes place here by a corresponding optically transparent disc of the installation space from below.
  • the building material is in each case introduced below in liquid form and correspondingly by irradiation to the desired
  • FIG. 5 shows an example of the structure of the surface coater 2, which is moved in the feed direction 14 during the coating.
  • This coater has in this example, on the application device for the liquid resin after the optional ⁇ a heating element 13 and - also optional - a cooling element may be arranged 12th
  • the irradiation takes place via the light source 11 integrated in this surface coater in this example.
  • the surface coater 2 applies the liquid resin with the temperature T2 to the substrate via the application device, while the surface coater in FIG.
  • Feed direction 14 is moved.
  • the optional heating element 13 can be ensured that the applied layer in each case immediately before the irradiation by the light source 11 in liquid
  • Figure 6 shows a general example of the irradiation of the desired areas with a
  • Beam source 16 The beam is guided by a beam guiding and beam focusing device 17 onto the liquid resin 3, which is applied to the solid resin 4 or 5 via a surface coater 2 which moves in the feed direction 14.
  • FIG. 7 shows an example of the irradiation of the desired regions for forming the component with a laser 18, a scanner 19 and a telecentric F-theta lens 20.
  • the surface coater 2 can be seen, which is moved over the respective uppermost solidified layer for applying a new liquid photo resin layer in the feed direction 14. Irradiation can also take place by means of projection, as is indicated schematically in FIG. In this case, a projector 21 is used, which exposes directly or via a mirror 22, the respective top applied by the surface coater 2 liquid layer of the photoresin in the desired, predetermined by the component areas.
  • the irradiation device was shown separately from the surface coater 2. It is also possible to attach the irradiation device directly to the surface coater 2 or to integrate in this. This is indicated schematically in FIG. 9.
  • the irradiation device 23 can in this case For example, an ID scanner or a polygon scanner and a modulated laser or a
  • Beam source is in this case a beam source too
  • a scanner is phased in a ray trap, such as a sheet, so that the corresponding beam at
  • Hide does not hit the resin layer.
  • the laser itself can also be outside the
  • FIG. 10 shows two examples in which a rotatable construction platform 6 is used whose
  • Rotation direction 25 is also indicated.
  • the left-hand illustration here shows the static surface coater 2 in this case, which comprises the corresponding application device with the light sources 11.
  • the light sources 11 are arranged in this example so that they rotate with respect to the rotation of the building platform 6 in each case behind the
  • Construction platform 6 extends. Due to the rotation in this case, the entire surface of the
  • FIG. 11 shows another example of a machining head for the proposed one
  • a heating element is arranged, which is realized by an IR light source 24. Both the beam of the IR light source 24 and the beam of the UV light source 11 used for the irradiation are superposed on a beam splitter and on the same beam path with a scanner 19 to the corresponding to be exposed for the formation of the component areas applied layer.
  • the surface coater 2 comprises the application device and an optional cooling element 12. In this embodiment, there is thus a location-selective heating of the construction material for
  • the proposed method and the associated arrangement enable a lateral resolution in the generative production, that of the known

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

Abstract

L'invention concerne un procédé ainsi qu'un ensemble de fabrication additive d'éléments, les éléments (26) étant conçus par solidification couche par couche d'un matériau constitutif qui peut être solidifié à la suite d'une réaction chimique. La solidification couche par couche est réalisée respectivement par rayonnement (8) localement sélectif d'une couche de la phase liquide (3) du matériau constitutif en fonction de la géométrie de l'élément. On utilise comme matériau constitutif un matériau qui, pendant la fabrication additive, peut passer par une transition de phase supplémentaire entre la phase liquide (3) et une autre phase solide (4). Cette transition de phase supplémentaire est commandée pendant la constitution des éléments (26), de sorte que les zones d'élément consolidées par la formation des éléments sont soutenues par le matériau constitutif environnant dans la phase solide (4) supplémentaire. Il n'est donc pas nécessaire d'avoir recours à des structures d'appui additionnelles, si bien que le procédé peut être mis en œuvre de façon moins complexe et moins onéreuse.
PCT/EP2015/066047 2014-07-14 2015-07-14 Procédé et ensemble de fabrication additive d'éléments WO2016008876A1 (fr)

Applications Claiming Priority (2)

Application Number Priority Date Filing Date Title
DE102014010412.5A DE102014010412B4 (de) 2014-07-14 2014-07-14 Verfahren und Anordnung zur generativen Fertigung von Bauteilen
DE102014010412.5 2014-07-14

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WO2016008876A1 true WO2016008876A1 (fr) 2016-01-21

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WO (1) WO2016008876A1 (fr)

Cited By (4)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
WO2019192700A1 (fr) 2018-04-05 2019-10-10 Fraunhofer-Gesellschaft zur Förderung der angewandten Forschung e. V. Procédé et dispositif pour la fabrication additive continue ou quasi continue de pièces
TWI765889B (zh) * 2016-06-13 2022-06-01 瑞典商數位金屬公司 積層製造設備及製造方法
US11498268B2 (en) * 2019-03-04 2022-11-15 Photocentric Limited Method of making 3D printed objects by dispensing sequential layers of material
CN117087160A (zh) * 2016-02-26 2023-11-21 惠普发展公司，有限责任合伙企业 三维(3d)打印

Families Citing this family (1)

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Publication number Priority date Publication date Assignee Title
DE102016226150A1 (de) * 2016-12-23 2018-06-28 Robert Bosch Gmbh Vorrichtung zum generativen Herstellen von Werkstücken

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WO2003028985A1 (fr) * 2001-10-03 2003-04-10 3D Systems, Inc. Modelisation par depot selectif avec des materiaux a changement de phase durcissables
US20100208006A1 (en) * 2009-02-18 2010-08-19 Sony Corporation Printing bio-reactive materials
WO2012140658A2 (fr) * 2011-04-10 2012-10-18 Objet Ltd. Système et procédé pour l'impression couche par couche d'un objet avec soutien

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US4575330A (en) 1984-08-08 1986-03-11 Uvp, Inc. Apparatus for production of three-dimensional objects by stereolithography
KR100257135B1 (ko) 1988-04-18 2000-06-01 윌리엄 헐 찰스 서포트를 포함하는 스테레오리스그래피를 이용한 3차원 물체 형성방법 및 장치
JP2004123840A (ja) 2002-09-30 2004-04-22 Fuji Photo Film Co Ltd 光造形用樹脂組成物及びそれを用いた光造形方法

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WO2003028985A1 (fr) * 2001-10-03 2003-04-10 3D Systems, Inc. Modelisation par depot selectif avec des materiaux a changement de phase durcissables
US20100208006A1 (en) * 2009-02-18 2010-08-19 Sony Corporation Printing bio-reactive materials
WO2012140658A2 (fr) * 2011-04-10 2012-10-18 Objet Ltd. Système et procédé pour l'impression couche par couche d'un objet avec soutien

Cited By (5)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
CN117087160A (zh) * 2016-02-26 2023-11-21 惠普发展公司，有限责任合伙企业 三维(3d)打印
TWI765889B (zh) * 2016-06-13 2022-06-01 瑞典商數位金屬公司 積層製造設備及製造方法
US11426934B2 (en) 2016-06-13 2022-08-30 Digital Metal Ab Slot die additive manufacturing apparatus and manufacturing method
WO2019192700A1 (fr) 2018-04-05 2019-10-10 Fraunhofer-Gesellschaft zur Förderung der angewandten Forschung e. V. Procédé et dispositif pour la fabrication additive continue ou quasi continue de pièces
US11498268B2 (en) * 2019-03-04 2022-11-15 Photocentric Limited Method of making 3D printed objects by dispensing sequential layers of material

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DE102014010412B4 (de) 2021-08-12

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