Method and device for producing three-dimensional models

• US 10,220,567 B2
• Filed: 03/24/2017
• Issued: 03/05/2019
• Est. Priority Date: 03/06/2012
• Status: Active Grant

• Current Assignee: Voxeljet AG
• Original Assignee: Voxeljet AG
• Inventors: Gunther, Johannes, Gunther, Daniel, Hartmann, Andreas
• Primary Examiner(s): Daniels, Matthew J
• Assistant Examiner(s): Cummins, IV, Manley L
• Application Number:
  US15/468,918
• Publication Number:
  US 20170197367A1
• Time in Patent Office: 711 Days
• Field of Search: None
• CPC Class Codes: B22F 10/28 Powder bed fusion, e.g. selective laser melting [SLM] or electron beam melting [EBM]
• CPC Class Codes: B22F 10/70 Recycling
• CPC Class Codes: B22F 12/22 Driving means
• CPC Class Codes: B22F 12/224 for motion along a direction within the plane of a layer
• CPC Class Codes: B22F 12/30 Platforms or substrates
• CPC Class Codes: B22F 12/60 Planarisation devices; Compression devices
• 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 64/227 Driving means
• CPC Class Codes: B29C 64/245 Platforms or substrates support structures intended to be sacrificed after manufacture B29C64/40
• CPC Class Codes: B33Y 10/00 Processes of additive manufacturing
• CPC Class Codes: B33Y 30/00 Apparatus for additive manufacturing; Details thereof or accessories therefor
• CPC Class Codes: Y02P 10/25 Process efficiency

Abstract

The present invention relates to a method for producing three-dimensional objects based on computer data by repeated application in layers of a medium containing particulate material and selective solidification of the medium, whereby a feedstock made of medium in a build space is provided and a layer application of the medium takes place on a surface of the feedstock bordering the build space at an angle β and a solidification according to computer data occurs by use of a solidification unit, characterized in that the feedstock is not moved during build-up of the object.

Claims

1. A device for producing three-dimensional objects based on computer data by repeated application in layers of a medium containing a particulate material and selective solidification of the medium, wherein the layers include sequential layers,

wherein the device comprises:

a support surface for supporting a feedstock made of the medium during the production of a build object;

a build space over the support surface;

a coating unit for depositing the particulate material on a build surface of the feedstock; and

a solidification unit for solidifying the medium according to computer data;

wherein the build surface has a build angle, α

, relative to the support surface, wherein α

is greater than 0 degrees;

wherein the feedstock has bordering surfaces adjacent to the build surface, each bordering surface having an angle β

relative to a horizontal plane; and

wherein the coating unit and the solidification units move in a direction parallel to the support surface away from the feedstock between application of the sequential layers so that the feedstock is stationary during build-up of the build object until the build object is complete or until the build space is entirely built upon.

2. The device of claim 1, wherein the solidification unit has a droplet generator.

3. The device of claim 2, wherein the coating unit and the solidification unit move on a coordinate system placed at the angle α

relative to the support surface and parallel to the build surface of the feedstock.

4. The device of claim 3, wherein the angle α

is less than 90 degrees and the support surface is a horizontal surface.

5. The device of claim 4, wherein

i) the support surface is a work bay floor of a production facility,

ii) the support surface is a surface of a build platform,

iii) the support surface includes slidable floors,

iv) the support surface is a surface of an intermittent conveyor belt that moves along linear guides after the build object is complete or after the build space is entirely built upon,

v) or any combination of (i) through (iv);

and wherein the coating unit and solidification unit are horizontally moved on tracks.

6. The device of claim 4, wherein

the support surface has an intermittent conveyor belt that moves along linear guides after the build object is complete or after the build space is entirely built upon.

7. The device of claim 6, wherein the coating unit and solidification unit are horizontally moved on tracks.

8. The device of claim 7, wherein the device includes a carrier unit that moves with the solidification unit and the coating unit in a build direction.

9. The device of claim 8, wherein the device includes rail tracks for guiding the carrier unit.

10. The device of claim 8, wherein the device includes a drive system having a ball screw drive.

11. The device of claim 8, wherein an angle between the carrier unit and a horizontal plane is zero degrees.

12. The device of claim 11, wherein the device includes a conveyor belt extending over the build space and over an unpacking area.

13. The device of claim 8, wherein the tracks are horizontal.

14. The device of claim 1, wherein the solidification unit rests on walls that the solidification unit builds as the solidification unit proceeds.

15. The device of claim 1, wherein the coating unit and/or solidification unit are/is angled at the angle α

, wherein the angle α

is less than 90 degrees, relative to the support surface and are/is moved in relation to the feedstock.

16. The device of claim 15, wherein

i) the support surface is a work bay floor of a production facility,

ii) the support surface is a surface of a build platform,

iii) the support surface includes slidable floors,

iv) the support surface is a surface of an intermittent conveyor belt that moves along linear guides after the build object is complete or after the build space is entirely built upon,

v) or any combination of (i) through (iv);

and wherein the coating unit and solidification unit are horizontally moved on tracks.

17. The device of claim 1, wherein the solidification unit has a radiation source.

18. The device of claim 17, wherein the coating unit and the solidification unit move on a coordinate system placed at the angle α

relative to the support surface and parallel to the build surface of the feedstock.

19. The device of claim 1, wherein the device includes a material silo that moves on tracks.

20. The device of claim 1, wherein the solidification unit and the coating unit move in a circular direction.

21. The device of claim 1, wherein the support surface is a surface of a build platform, the build platform moves along a first set of tracks and the device includes a carrier unit that moves along a second set of tracks in the same direction, wherein the carrier unit supports the coating unit and the solidification unit.

22. The device of claim 1, wherein the device includes a conveyor belt that moves in a first direction and a linear drive for moving the solidification unit and the coating unit in a direction parallel to the first direction, wherein the movement of the solidification unit and the movement of the conveyor belt in the first direction are independently controlled.

23. The device of claim 1, wherein the angle β

is an acute angle.

24. The device of claim 23, wherein the angle β

is the angle of repose of the particulate material.