Method and device for producing three-dimensional models

• US 10,179,365 B2
• Filed: 02/07/2018
• Issued: 01/15/2019
• Est. Priority Date: 04/17/2010
• Status: Active Grant

• Current Assignee: Voxeljet AG
• Original Assignee: Voxeljet AG
• Inventors: Ederer, Ingo, Gunther, Daniel, Hartmann, Andreas Dominik
• Primary Examiner(s): Grun, Robert J
• Application Number:
  US15/890,592
• Publication Number:
  US 20180169758A1
• Time in Patent Office: 342 Days
• CPC Class Codes: B22F 10/14 by jetting of binder onto a bed of metal powder
• CPC Class Codes: B22F 10/28 Powder bed fusion, e.g. selective laser melting [SLM] or electron beam melting [EBM]
• CPC Class Codes: B22F 10/43 characterised by material
• CPC Class Codes: B22F 12/55 Two or more means for feeding material
• CPC Class Codes: B22F 12/86 Serial processing with multiple devices grouped
• CPC Class Codes: B22F 12/88 Handling of additively manufactured products, e.g. by robots
• CPC Class Codes: B22F 3/105 by using electric current other than for infrared radiant energy, laser radiation or plasma B22F3/11 takes precedence; by ultrasonic bonding B22F3/115 takes precedence
• CPC Class Codes: B29C 64/153 using layers of powder being selectively joined, e.g. by selective laser sintering or melting
• CPC Class Codes: B29C 64/165 using a combination of solid and fluid materials, e.g. a powder selectively bound by a liquid binder, catalyst, inhibitor or energy absorber
• CPC Class Codes: B29C 64/176 Sequentially
• CPC Class Codes: B33Y 10/00 Processes of additive manufacturing
• CPC Class Codes: Y02P 10/25 Process efficiency

Abstract

The present invention relates to a method for producing three-dimensional objects based on computer-provided data, whereby a material is deposited in layers in a process chamber and the material is selectively solidified and/or bonded using a bonding apparatus and/or a solidifying apparatus in the process chamber, these steps being repeated. A conveyance of the material proceeds during the build process and proceeds continuously, sequentially and evenly up to an unpacking position.

Claims

1. A system for producing objects from a build material including a first material, the system comprising:

i) at least one device for depositing the first material in layers;

ii) at least one solidifying apparatus for selectively solidifying the first material; and

iii) at least one means to convey the build material throughout a build-up process;

wherein the means to convey includes a continuous solid surface for supporting the deposited layers.

2. The system of claim 1, wherein the device for depositing the first material or the solidifying apparatus are moved on a coordinate system arranged at an angle to a reception plane of the continuous solid surface.

3. The system of claim 1, wherein the first material is deposited on a reception plane angled relative to a horizontal plane, with an acute angle, a, wherein the acute angle is less than an angle of repose of the first material.

4. The system of claim 3, wherein the device for depositing the first material is a spreader, the first material is a particulate material, and the spreader moves back and forth in a moving direction that is an x-direction or a y-direction of the reception plane, wherein the x-direction is parallel to the horizontal plane and the y-direction is angled relative to the horizontal plane.

5. The system of claim 4, wherein the spreader deposits the particulate material while moving backward in the moving direction and while moving forward in the moving direction.

6. The system of claim 5, wherein the system moves the means to convey a distance controlled by a measured height of the deposited layer.

7. The system of claim 6, wherein the reception plane is angled relative to the continuous solid surface.

8. The system of claim 7, wherein the means to convey moves in a horizontal direction, and the angle between the layer plane and the reception plane is less than the angle of repose of the particulate material.

9. The system of claim 3, wherein the solidifying apparatus moves back and forth in a moving direction that is an x-direction or a y-direction of the reception plane, wherein the x-direction is parallel to the horizontal plane and the y-direction is angled relative to the horizontal plane.

10. The system of claim 9, wherein the solidifying apparatus includes one or more printheads, a radiation source of a combination thereof.

11. The system of claim 10, where the system includes two different solidifying apparatus.

12. The system of claim 1, wherein the means to convey moves in a conveying direction that forms an acute angle, σ

, to a horizontal plane.

13. The system of claim 12, wherein the first material is a particulate material having an angle of repose, wherein the acute angle, σ

, is less than or equal to the angle of repose.

14. The system of claim 1, wherein the conveying direction is parallel to a horizontal plane.

15. The system of claim 1, wherein the means to convey includes one or more conveyor belts.

16. The system of claim 15, wherein the convey belt is a link conveyor belt.

17. The system of claim 15, wherein the means to convey includes openings near an unpacking end of the conveyor belt or the system includes a gap between two sequential conveyor belts for removing loose particulate material.

18. The systems of claim 15, wherein the system includes bordering surfaces on each side of the reception plane to stabilize the first material while the build material is conveyed.

19. The system of claim 18, wherein each of the bordering surfaces includes an upright conveyor belt that is angled relative to the conveyor belt that conveys the build material, wherein the upright conveyor belts preferably moves synchronously with the conveyor belt moving the build material.

20. The system of claim 15, wherein the conveyor belt has a surface on the edge to the deposited material which is parallel to the reception plane of the deposited material.