WO2021110253A1 - Continuous three-dimensional printing technology - Google Patents

Continuous three-dimensional printing technology Download PDF

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Publication number
WO2021110253A1
WO2021110253A1 PCT/EP2019/083631 EP2019083631W WO2021110253A1 WO 2021110253 A1 WO2021110253 A1 WO 2021110253A1 EP 2019083631 W EP2019083631 W EP 2019083631W WO 2021110253 A1 WO2021110253 A1 WO 2021110253A1
Authority
WO
WIPO (PCT)
Prior art keywords
real
structural element
sheet
virtual
target structural
Prior art date
Application number
PCT/EP2019/083631
Other languages
French (fr)
Inventor
Nicola Maria CERIANI
Original Assignee
Siemens Aktiengesellschaft
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 Siemens Aktiengesellschaft filed Critical Siemens Aktiengesellschaft
Priority to PCT/EP2019/083631 priority Critical patent/WO2021110253A1/en
Publication of WO2021110253A1 publication Critical patent/WO2021110253A1/en

Links

Classifications

    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B33—ADDITIVE MANUFACTURING TECHNOLOGY
    • B33Y—ADDITIVE MANUFACTURING, i.e. MANUFACTURING OF THREE-DIMENSIONAL [3-D] OBJECTS BY ADDITIVE DEPOSITION, ADDITIVE AGGLOMERATION OR ADDITIVE LAYERING, e.g. BY 3-D PRINTING, STEREOLITHOGRAPHY OR SELECTIVE LASER SINTERING
    • B33Y50/00—Data acquisition or data processing for additive manufacturing
    • 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
    • B29C53/00—Shaping by bending, folding, twisting, straightening or flattening; Apparatus therefor
    • B29C53/56—Winding and joining, e.g. winding spirally
    • B29C53/562—Winding and joining, e.g. winding spirally spirally
    • 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
    • B29C53/00—Shaping by bending, folding, twisting, straightening or flattening; Apparatus therefor
    • B29C53/56—Winding and joining, e.g. winding spirally
    • B29C53/564—Winding and joining, e.g. winding spirally for making non-tubular articles
    • 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
    • B29C64/20—Apparatus for additive manufacturing; Details thereof or accessories therefor
    • B29C64/205—Means for applying layers
    • B29C64/223—Foils or films, e.g. for transferring layers of building material from one working station to another
    • 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
    • B29C64/227—Driving means
    • B29C64/241—Driving means for rotary motion
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B33—ADDITIVE MANUFACTURING TECHNOLOGY
    • B33Y—ADDITIVE MANUFACTURING, i.e. MANUFACTURING OF THREE-DIMENSIONAL [3-D] OBJECTS BY ADDITIVE DEPOSITION, ADDITIVE AGGLOMERATION OR ADDITIVE LAYERING, e.g. BY 3-D PRINTING, STEREOLITHOGRAPHY OR SELECTIVE LASER SINTERING
    • B33Y10/00—Processes of additive manufacturing
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B33—ADDITIVE MANUFACTURING TECHNOLOGY
    • B33Y—ADDITIVE MANUFACTURING, i.e. MANUFACTURING OF THREE-DIMENSIONAL [3-D] OBJECTS BY ADDITIVE DEPOSITION, ADDITIVE AGGLOMERATION OR ADDITIVE LAYERING, e.g. BY 3-D PRINTING, STEREOLITHOGRAPHY OR SELECTIVE LASER SINTERING
    • B33Y30/00—Apparatus for additive manufacturing; Details thereof or accessories therefor

Definitions

  • a three-dimensional printing system comprising a sheet printer device as described above and a rolling device, the rolling device being adapted to roll a real planar sheet, extruded by the material extruder and transported by the conveyor belt, to form a real target structural element.
  • the rolling device can be formed by motorized rollers and can comprise guiding elements which guide, bend and press the real planar sheet to form a cylindri cal shape.
  • a three-dimensional printing system comprising a sheet printer device as described above, a rolling device and a computer, the rolling device being adapted to roll a real planar sheet, extruded by the material extruder and transported by the conveyor belt, to form a real target structural element, and the computer being adapted to run a software program to transform a virtual target structural element into the virtual planar sheet.
  • the rolling device can be formed by motorized rollers and can comprise guiding elements which guide, bend and press the real planar sheet to form a cylindrical shape.
  • Computation starts from an inner end 7 of the spiral and moves along the unrolled virtual planar sheet 6 to wards an outer end 8.
  • the virtual planar sheet 6 is divided in lines 9 per pendicular to a direction D along which the algorithm moves, which is also the printing direction D. Each line corresponds to a three-dimensional printing step.
  • FIG 8 shows the cylinder 19 of the rolled planar sheet
  • planar sheet 13 can be rolled around a cylinder of another material to create hybrid parts .

Abstract

What is proposed is a method of printing a real structural element (31) three-dimensionally, comprising : a) Determining a virtual target structural element (1) to be printed three-dimensionally by means of a specialized computer software program; b) Sectioning of the virtual target structural element (1) into spiral slices (5), thereby generating a virtual geometry equivalent to a rolled sheet; c) Transforming the virtual geometry into a virtual planar sheet (6); d) Starting a manufacturing of the real target structural element (31), the real target structural element (31) being equivalent to the virtual target structural element (1), by means of a sheet printer device (12), wherein material (2, 3, 11) is extruded out of at least one material extruder (15, 16, 17), being part of the sheet printer device (12), to build a real planar sheet (13); e) Rolling of the real planar sheet (13) to form the real target structural element (31).

Description

Description
Continuous three-dimensional printing technology
The present disclosure is directed to a method of print ing a structural element three-dimensionally according to claim 1. Furthermore, the present disclosure is di rected to a sheet printer device according to claim 5. Still further, the present disclosure is directed to a three-dimensional printing system according to claim 7. Still further, the present disclosure is directed to a three-dimensional printing system according to claim 8.
One of the most common technologies used in additive manufacturing (AM) is fused deposition modeling (FDM). Fused deposition modeling is a form of material extru sion (ME) of thermoplastic materials using a print head that is moved by numerically controlled kinematics with three or more independent axes.
State of the art three-dimensional printing technologies work by creating parts layer-wise. This means they produce the parts by depositing one layer of material at a time until the part is completed as the sum of the layers. The parts there fore grow vertically while the layers composing them are de posited horizontally.
Such manufacturing technique have some downsides: Since the process is inherently discontinuous, discontinuities appear in the printed material, constituting weak points of the pro duced parts. Furthermore, the start/stop phases of the manu facturing process can lead to problems, e.g. in the material extrusion technology polymer dripping uncontrolled from its extruder during the layer transition phase. Moreover, the transition between layers during the production process im plies dead times that diminish the productivity of the pro- cess. An objective of the present invention is to increase a rigidity of parts printed by a three-dimensional printer and to increase a throughput of the according three- dimensional printing process.
The problem is solved by a method of printing a struc tural element three-dimensionally according to claim 1. Furthermore, the problem is solved by a sheet printer device according to claim 5. Still further, the problem is solved by a three-dimensional printing system accord ing to claim 7. Still further, the problem is solved by a three-dimensional printing system according to claim 8. Advantageous aspects of the invention are the subject of the dependent claims.
According to the invention, the method of printing a re al structural element three-dimensionally comprises the following steps: a) Determining a virtual target structural element to be printed three-dimensionally by means of a spe cialized computer software program; b) Sectioning of the virtual target structural element into spiral slices, thereby generating a virtual ge ometry equivalent to a rolled sheet; c) Transforming the virtual geometry into a virtual planar sheet; d) Starting a manufacturing of the real target struc tural element, the real target structural element being equivalent to the virtual target structural element, by means of a sheet printer device, wherein material is extruded out of at least one material extruder, being part of the sheet printer device, to build a real planar sheet; e) Rolling of the real planar sheet to form the real target structural element. The structural element can be of any shape being printa ble three-dimensionally .
The method according to the invention works by creating a continuous sheet of material which is then rolled. As com pared to classical three-dimensional printing techniques, the structural element to be printed is not made by a sum of lay ers but instead by a single continuous layer (planar sheet) which is rolled after having been deposited by a material ex truder.
First steps of the method according to the invention are the computations of the specialized computer software program to produce the planar sheet that will be rolled to create the target structural element. In state of the art, three- dimensional printing methods the (virtual) structural ele ments to be printed three-dimensionally are sliced using par allel planes. The obtained layers are then used to compute the manufacturing program of the (virtual) structural element as the sum of the manufacturing programs of each layer. The method according to the invention proposes instead to section the (virtual) target structural element into spiral slices, which generates a virtual geometry equivalent to a rolled sheet. This virtual geometry is transformed into a (virtual) planar sheet.
As compared to state-of-the-art methods, the method as de scribed above can eliminate the discontinuities in the three- dimensional printing process. As a consequence, firstly the productivity is improved because dead times between the pro duction of successive layers are eliminated and secondly the problems and defects caused by the discontinuities in the production process are eliminated, thus improving the final product quality and making the production process easier to control. Finally, the structural elements to be printed three-dimensionally have better mechanical properties thanks to the continuity of the material which leads also to a bet ter isotropy.
Advantageously, there is used at least one first material and at least one support material to build the real pla nar sheet, wherein the at least one support material is removed after having rolled the real planar sheet to form the real target structural element. With the help of the support material, complex three-dimensional structural elements can be printed more easily.
Preferably, at least one thermoplastic material is used to form the real planar sheet. Such a thermoplastic ma terial can be easily deformed and fused together, more simplifying the method as described above. The thermo plastic material can also be filled with metal powders to be later used in a sintering process. Preferably, the thermo plastic material is a thermoplastic polymer.
Regarding the optional support material, water soluble poly mers can be used. Such polymers allow to easily remove the support material after the printing process is completed by simply immerging the printed structural element in a water bath.
The problem as described above is also solved by a sheet printer device, comprising at least one material extrud er and one conveyor belt, the material extruder being adapted to extrude molten material and deposit the mol ten material on a part of the conveyor belt, and the conveyor belt being adapted to transport the deposited molten material in a specific direction. Preferably, the conveyor belt is adapted to be heated to keep the molted material at a temperature where it shows a plastic be havior . The problem as described above is also solved by a three-dimensional printing system, comprising a sheet printer device as described above and a rolling device, the rolling device being adapted to roll a real planar sheet, extruded by the material extruder and transported by the conveyor belt, to form a real target structural element. The rolling device can be formed by motorized rollers and can comprise guiding elements which guide, bend and press the real planar sheet to form a cylindri cal shape.
The problem as described above is also solved by a three-dimensional printing system, comprising a sheet printer device as described above, a rolling device and a computer, the rolling device being adapted to roll a real planar sheet, extruded by the material extruder and transported by the conveyor belt, to form a real target structural element, and the computer being adapted to run a software program to transform a virtual target structural element into the virtual planar sheet. As mentioned before, the rolling device can be formed by motorized rollers and can comprise guiding elements which guide, bend and press the real planar sheet to form a cylindrical shape.
The invention as described above is not limited to be used only to strengthen a three-dimensional printed structural el ement mechanically. It can also be used to add conductive rods as defined electrical conductors into the printed struc tural element to enable mechatronic functionalities.
Features of examples of the present disclosure will be come apparent by reference to the following detailed de scription of the drawings. For the sake of brevity, ref erence numerals or features having a previously de scribed function may or may not be described in connec tion with other drawings in which they appear. FIG 1 is a perspective view of a structural element to be printed by means of a three-dimensional printer according to the state of the art;
FIG 2 is a perspective view of a structural element to be printed by means of a three-dimensional printer according to the invention;
FIG 3 is a perspective view of the structural element transformed into a planar sheet;
FIG 4 shows a sheet printer device in a perspective view;
FIG 5 shows a rolling device in a perspective view;
FIG 6 shows the rolling device according to FIG 5 in a cut view;
FIG 7 is a perspective view of a three-dimensional printing system with a rolling device and a sheet printer device; and
FIG 8 is a perspective view of the structural element according to FIG 1 having been printed three- dimens ional1y .
In FIG 1 there is depicted a perspective view of a (vir tual) structural element 1. The expression "virtual" means that the structural element 1 is not a real physi cal element but a digital representation of such a real physical element implemented in a specialized computer software program, e.g. a CAD (computer aided design) program . The (virtual) target structural element 1 consists of a first material 2 and a second material 3. It shall be printed by means of a three-dimensional printer. As a first step, in state-of-the-art printing methods, the ele ments to be printed three-dimensionally are sliced using par allel planes 4. The obtained layers are then used to compute the according manufacturing program of the structural element 1 as the sum of the manufacturing programs of each layer.
Such a manufacturing technique has disadvantages. On the one hand, discontinuities appear in the printed material due to the inherently discontinuous printing process, constituting weak points of the produced elements. Moreover, the start/stop phases of the manufacturing process can lead to problems, e.g. in the material extrusion technology polymer dripping uncontrolled from its extruder during the layer transition phase. Furthermore, the transition between layers during the production process implies dead times that dimin ish the productivity of the process.
In contrast, FIG 2 illustrates the first step of a method of printing a real structural element three-dimensionally according to the invention. The (virtual) structural el ement 1 is sectioned with a spiral 5 which generates a geometry equivalent to a rolled sheet.
In a next step, the geometry obtained in the first step is transformed into a (virtual) planar sheet by un rolling the spiral section of the (virtual) structural element 1 as shown in FIG 3. The manufacturing program for a three-dimensional printer is then computed accord ing to the following algorithm:
1. Computation starts from an inner end 7 of the spiral and moves along the unrolled virtual planar sheet 6 to wards an outer end 8. 2. The virtual planar sheet 6 is divided in lines 9 per pendicular to a direction D along which the algorithm moves, which is also the printing direction D. Each line corresponds to a three-dimensional printing step.
3. Each line 9 is divided into a finite number of points 10, each corresponding to an elementary element of de posited material extruded by extrusion nozzles of the three-dimensional printer.
4. The three-dimensional printing program contains in structions for each point 10 of each line 9. When a cer tain material is present in a certain point 10 of a line 9, an instruction to print the corresponding material (here: first material 2 or second material 3) in that point 10 is generated.
5. When no material is present in a point 10, an in struction to print support material 11 in that point 10 is generated.
FIG 4 shows a sheet printer device 12, being part of a three- dimensional printer. The sheet printer device 12 uses the manufacturing instructions generated by the specialized com puter software program as described above to produce a (real) continuous planar sheet 13.
The sheet printer device 12 comprises a heated conveyor belt 14 and three material extruders 15, 16, 17. One material ex truder 15 lays the first material 2 on according positions on the conveyor belt 14. Another material extruder 16 does the same with the second material 3 and the third material ex truder 17 lays support material 11 on the conveyor belt 14.
Of course, the invention is not limited with respect to the amount of different materials 2, 3, 11 that can be used for the production process. If necessary, additional material ex- truders can be used to deposit additional materials on the conveyor belt 14.
In this embodiment, thermoplastic polymers are used to print the planar sheet 13. The conveyor belt 14 is heated in order to keep the printed planar sheet 13 at a temperature where it shows a plastic behavior. The material extruders 15, 16, 17 move along linear axes Al, A2, A3 (perpendicular to the mov ing direction D of the conveyor belt 14) depositing the mate rials 2, 3, 11 according to the manufacturing program.
FIG 5 and FIG 6 show a rolling device 18, which rolls the printed planar sheet 13 (cf. FIG 4) to form a cylin der 19. The rolling device 18 comprises three motors 20, 21, 22 which drive rollers 23, 24, 25. The motorized rollers 23, 24, 25 work together with guiding elements
26 to guide, bend and press the planar sheet 13 making it form the cylinder 19. Both the rollers 23, 24, 25 and the guiding elements 26 move radially along linear axes 27, 28, 29 in order to adjust their position to the growing diameter of the cylinder 19.
Since materials 2, 3, 11 are used that can be deformed and fused together, the rollers 23, 24, 25 of the roll ing device 18 are heated to keep the materials 2, 3, 11 at a temperature necessary to maintain a plastic behav ior.
In FIG 7 there is depicted a complete three-dimensional printing system 30 which comprises a sheet printer device
12 and a rolling device 18.
FIG 8 shows the cylinder 19 of the rolled planar sheet
13 with the real structural element 31 (comprising the first material 2 and the second material 3) whereas the real structural element 31 is inside a volume of support material 11. When the complete roll has been produced, the support material 11 is dissolved and the obtained parts (i.e. the target structural element 31) freed from such material undergo the finishing steps. In case a polymer with metal powder filling has been used to pro- duce a sintered part, the bounding agent is removed from the green part and then the sintering process can be ex ecuted.
In another example, the planar sheet 13 can be rolled around a cylinder of another material to create hybrid parts .
While several examples have been described in detail, it is to be understood that the disclosed examples may be modified. Therefore, the foregoing description is to be considered non-limiting.

Claims

Patent claims
1. Method of printing a real structural element (31) three-dimensionally, comprising: a) Determining a virtual target structural element (1) to be printed three-dimensionally by means of a spe cialized computer software program; b) Sectioning of the virtual target structural element (1) into spiral slices (5), thereby generating a virtual geometry equivalent to a rolled sheet; c) Transforming the virtual geometry into a virtual planar sheet (6); d) Starting a manufacturing of the real target struc tural element (31), the real target structural ele ment (31) being equivalent to the virtual target structural element (1), by means of a sheet printer device (12), wherein material (2, 3, 11) is extruded out of at least one material extruder (15, 16, 17), being part of the sheet printer device (12), to build a real planar sheet (13); e) Rolling of the real planar sheet (13) to form the real target structural element (31).
2. Method according to claim 1, wherein there is used at least one first material (2) and at least one support material (11) to build the real planar sheet (13), wherein the at least one support material (11) is re moved after having rolled the real planar sheet (13) to form the real target structural element (31).
3. Method according to claim 1 or 2, wherein at least one thermoplastic material is used to form the real pla nar sheet (13).
4. Method according to claim 3, wherein the at least one thermoplastic material is a thermoplastic polymer.
5. Sheet printer device (12), comprising at least one material extruder (15, 16 ,17) and one conveyor belt
(14) , the material extruder (15, 16, 17) being adapted to ex trude molten material (2, 3, 11) and deposit the molten material (2, 3, 11) on a part of the conveyor belt (14), and the conveyor belt (14) being adapted to transport the deposited molten material (2, 3, 11) in a specific direction (D) .
6. Sheet printer device (12) according to claim 5, wherein the conveyor belt (14) is adapted to be heated to keep the molted material (2, 3, 11) at a temperature where it shows a plastic behavior.
7. Three-dimensional printing system (30), comprising a sheet printer device (12) according to claim 5 or 6, and a rolling device (18), the rolling device (18) being adapted to roll a real planar sheet (13), extruded by the material extruder (15, 16, 17) and transported by the conveyor belt (14), to form a real target structural element (31).
8. Three-dimensional printing system (30), comprising a sheet printer device (12) according to claim 5 or 6, a rolling device (18) and a computer, the rolling device (18) being adapted to roll a real planar sheet (13), extruded by the material extruder (15, 16, 17) and transported by the conveyor belt (14), to form a real target structural element (31), and the computer being adapted to run a software program to transform a virtual target structural element (1) in to the virtual planar sheet (6).
PCT/EP2019/083631 2019-12-04 2019-12-04 Continuous three-dimensional printing technology WO2021110253A1 (en)

Priority Applications (1)

Application Number Priority Date Filing Date Title
PCT/EP2019/083631 WO2021110253A1 (en) 2019-12-04 2019-12-04 Continuous three-dimensional printing technology

Applications Claiming Priority (1)

Application Number Priority Date Filing Date Title
PCT/EP2019/083631 WO2021110253A1 (en) 2019-12-04 2019-12-04 Continuous three-dimensional printing technology

Publications (1)

Publication Number Publication Date
WO2021110253A1 true WO2021110253A1 (en) 2021-06-10

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Citations (3)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US20130073073A1 (en) * 2010-08-18 2013-03-21 Nathaniel B. Pettis Automated 3d build processes
US20130196060A1 (en) * 2012-01-31 2013-08-01 Xavier Bruch Pla Forming three dimensional objects
WO2017216654A1 (en) * 2016-05-05 2017-12-21 Clevertek S.N.C. Di Turchi Maximilian E Brugnoli Satu-Susanna System and method of automatization of a printing unit for tridimensional objects

Patent Citations (3)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US20130073073A1 (en) * 2010-08-18 2013-03-21 Nathaniel B. Pettis Automated 3d build processes
US20130196060A1 (en) * 2012-01-31 2013-08-01 Xavier Bruch Pla Forming three dimensional objects
WO2017216654A1 (en) * 2016-05-05 2017-12-21 Clevertek S.N.C. Di Turchi Maximilian E Brugnoli Satu-Susanna System and method of automatization of a printing unit for tridimensional objects

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