Method for producing a part using a deposition technique

• US 10,213,938 B2
• Filed: 08/01/2016
• Issued: 02/26/2019
• Est. Priority Date: 09/25/2000
• Status: Expired due to Fees

• Current Assignee: Voxeljet AG
• Original Assignee: Voxeljet AG
• Inventors: Ederer, Ingo, Hochsmann, Rainer
• Primary Examiner(s): Tentoni, Leo B
• Application Number:
  US15/225,381
• Publication Number:
  US 20170136524A1
• Time in Patent Office: 939 Days
• Field of Search: 264113
• CPC Class Codes: B22C 1/162 use of a gaseous treating agent for hardening the binder
• CPC Class Codes: B22C 23/00 Tools; Devices not mentioned before for moulding
• CPC Class Codes: B22C 9/00 Moulds or cores uniquely adapted to particular casting processes B22D; Moulding processes
• CPC Class Codes: B22C 9/02 Sand moulds or like moulds for shaped castings
• CPC Class Codes: B22C 9/10 Cores; Manufacture or installation of cores breaker cores B22C9/084
• CPC Class Codes: B22F 10/14 by jetting of binder onto a bed of metal powder
• CPC Class Codes: B22F 10/60 Treatment of workpieces or articles after build-up
• CPC Class Codes: B22F 10/73 of powder
• CPC Class Codes: B22F 12/224 for motion along a direction within the plane of a layer
• CPC Class Codes: B22F 12/67 Blades
• CPC Class Codes: B28B 1/16 for producing layered articles coating B28B11/04
• 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 71/009 using gases without chemical reaction C08J7/12 takes precedence; in combination with blow-moulding B29C49/46; surface treatment using plasma B29C59/14, ionised gas B29C59/16
• CPC Class Codes: B33Y 10/00 Processes of additive manufacturing
• CPC Class Codes: B33Y 80/00 Products made by additive manufacturing
• CPC Class Codes: Y02P 10/25 Process efficiency
• CPC Class Codes: Y10T 428/24893 including particulate material

Abstract

The invention relates to a method for producing a part using a deposition technique. A layered composite is built up in layers, the individual layers each containing particulate material and binding material as well as optionally, a treatment agent. The layers maintain a predetermined porosity. The layer composite is built up in the absence of hardening agent. Once construction is complete, the layer composite is hardened.

Claims

1. A method for producing a part using a deposition technique in layers by building a layered composite containing the part from particulate matter comprised of particles of a prescribed particle size, the method comprising steps of:

depositing the particulate matter layer-by-layer to form successive layers of a porous bulk in a build location, and

selectively apportioning a treatment agent in a predefined subarea of the layer prior to deposition of a subsequent layer, wherein the treatment agent is apportioned in a free-flowing state for setting up a bonding process, in which the particles in the predefined subarea bond firmly to one another, through a binder contained either in the particulate matter or deposited thereon, in the presence of an initiator,

moving the layered composite to a different location; and

bonding the particulate matter in the different location;

whereby the building of the layered composite is done in the absence of an initiator, and the bonding process is executed only after completion of the layered composite, through addition of such initiator.

2. The method of claim 1, wherein the layered composite is in a same container during the building of the layered composite and during the bonding of the particulate matter.

3. The method of claim 1, wherein the predefined subarea of the layer is different from a predefined subarea of the subsequent layer.

4. The method of claim 1, wherein bonding of the particulate matter is in a single step at the different location.

5. The method of claim 1, wherein the binder is in the particulate material.

6. The method of claim 1, wherein the binder is in the treatment agent.

7. The method of claim 1, wherein the initiator is added in the different location.

8. The method of claim 1, wherein during the bonding of the layered composite, an additional layered composite is built in the build location.

9. The method of claim 1, wherein the particulate material is deposited with a deposition device having a coating blade.

10. The method of claim 9, wherein each layer of particulate material is deposited in a single pass of the deposition device over a building platform.

11. The method of claim 1, wherein the treatment agent is dispensed using an inkjet printer.

12. The method of claim 1, wherein loose particulate material is removed after the step of bonding.

13. The method of claim 1, wherein the subareas of adjacent layers at least partially overlap and the layers are firmly bound to each other in the regions of overlap.

14. The method of claim 13, wherein the layered composite is in a same container during the building of the layered composite and during the bonding of the particulate matter.

15. The method of claim 1, wherein

bonding of the particulate matter is in a single step at the different location;

the initiator is added in the different location;

the particulate material is deposited with a deposition device having a coating blade;

each layer of particulate material is deposited in a single pass of the deposition device over a building platform;

the treatment agent is dispensed using an inkjet printer;

loose particulate material is removed after the step of bonding; and

the subareas of adjacent layers at least partially overlap and the layers are firmly bound to each other in the regions of overlap.

16. The method of claim 15, wherein the layered composite is in a same container during the building of the layered composite and during the bonding of the particulate matter.

17. The method of claim 16, wherein the predefined subarea of the layer is different from a predefined subarea of the subsequent layer.

18. The method of claim 17, wherein during the bonding of the layered composite, an additional layered composite is built in the build location.

19. The method of claim 18, wherein the binder is in the particulate material.

20. The method of claim 19, wherein the binder is in the treatment agent.