Device for the generative manufacturing of three-dimensional components

• US 10,548,695 B2
• Filed: 09/23/2016
• Issued: 02/04/2020
• Est. Priority Date: 03/02/2011
• Status: Active Grant

• Current Assignee: Bego Medical GmbH
• Original Assignee: Bego Medical GmbH
• Inventors: Uckelmann, Ingo, Hoges, Simon
• Primary Examiner(s): Kennedy, Timothy
• Application Number:
  US15/274,834
• Publication Number:
  US 20170071707A1
• Time in Patent Office: 1,229 Days
• CPC Class Codes: A61C 13/0019 using three dimensional printing
• CPC Class Codes: A61C 13/20 Methods or devices for soldering, casting, moulding or melting A61C13/04, A61C13/081 take 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 64/176 Sequentially
• CPC Class Codes: B29C 64/188 involving additional operations performed on the added layers, e.g. smoothing, grinding or thickness control surface shaping B29C59/00; after-treatment of articles without altering their shape B29C71/00
• CPC Class Codes: B29C 64/205 Means for applying layers
• CPC Class Codes: B29C 64/236 for motion in a direction within the plane of a layer
• CPC Class Codes: B29C 64/245 Platforms or substrates support structures intended to be sacrificed after manufacture B29C64/40
• CPC Class Codes: B29C 64/393 for controlling or regulating additive manufacturing processes
• CPC Class Codes: B29C 67/0007 Manufacturing coloured articles not otherwise provided for, e.g. by colour change
• CPC Class Codes: B29L 2031/7536 Artificial teeth
• 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: B33Y 50/02 for controlling or regulating additive manufacturing processes
• CPC Class Codes: B33Y 80/00 Products made by additive manufacturing

Abstract

The invention relates to a device for producing products having individual geometries, comprising a substrate carrier device, a material application device for applying material, preferably above the substrate carrier device, which material application device can be moved relative to the substrate carrier device, and a control device which is coupled to the material application device for signaling. According to the invention, the material application device is coupled to an input interface for signaling and for selection of a first or a second application mode, the control device and the application device being designed such as to produce, in the first application mode, a three-dimensional product on the surface of a substrate plate by way of an additive production method, said substrate plate being connected to the substrate carrier device. According to the additive production method, a curable material is applied in consecutive layers, one or more predetermined regions are selectively cured after or during each application of a layer, the predetermined regions being bonded to one or more regions of the underlying layer. The predetermined region(s) is/are predetermined by a cross-section geometry of the product in the respective layer and is/are stored in the control device, and the curable material is applied in a plurality of consecutive layers to produce the three-dimensional product. The control device and the application device are further designed such that in the second mode of application one or more colors are applied to predetermined regions of a print substrate material connected to the substrate carrier device to produce a monochrome or polychrome print.

Claims

1. A device for manufacturing multi-layered products with individual geometry, the device comprising:

a substrate plate;

a material application device movable relative to the substrate plate for application of material above the substrate plate, wherein the material application device comprises a printing head for applying the material in a three-dimensional printing process, a contour crafting process, a fused deposition modeling process, a laminated object modeling process, a polyamide casting process or a multi jet modeling process; and

a control device for transmitting signals to the material application device and/or a conveyor device for conveying the substrate plate, wherein the control device is adapted to control the material application device such that it dispenses the material selectively on predetermined regions corresponding to the cross-section of the product in the respective layer;

wherein the material application device is adapted to apply the material in a plane, the plane aligned at an oblique angle relative to the surface of the substrate plate on which the material is applied.

2. The device according to claim 1, wherein the substrate plate is divided into a plurality of substrate plate segments;

the material application device is adapted to simultaneously apply a material layer onto a number of the plurality of substrate plate segments; and

the substrate plate segments are connectably-detachable with each other or with a base carrier.

4. The device according to claim 1, wherein the substrate plate is adapted to be moved in a horizontal direction after a layer of material is applied to the product.

7. The device of claim 1, wherein the material application device is adapted to apply the material at an angle smaller or equal to a dumping angle of the material on a surface of the substrate on which the material is applied.

3. A device for manufacturing multi-layered products with individual geometry, the device comprising:

a substrate plate;

a material application device movable relative to the substrate plate for application of material above the substrate plate; and

a control device for transmitting signals to the material application device and/or a conveyor device for conveying the substrate plate, wherein the control device is adapted to control the material application device such that it dispenses the material selectively on predetermined regions corresponding to the cross-section of the product in the respective layer;

wherein the material application device is adapted to apply the material in a plane, the plane aligned at an oblique angle to a surface of the substrate plate on which the material is applied;

wherein the substrate plate comprises a plurality of substrate plate segments which are arranged on an endless conveyor belt running partially or completely in a processing chamber, the chamber at least partially sealed in a controlled atmosphere during use, wherein the control device is adapted to produce a relative movement between the substrate plate segments and the material application device in a direction substantially parallel to the surface of the substrate plate segments after a layer of the material was applied.

9. The device according to claim 3, wherein the substrate plate is moved relative to the material application device.

10. The device according to claim 3, wherein the material application device is moved relative to the substrate plate.

5. A device for manufacturing products with individual geometry and multiple layers, the device comprising:

a substrate plate coupled to a substrate carrier;

a material application device, wherein at least one of the material application device and the substrate plate is movable relative to the other, the material application device configured to apply material above the substrate plate, wherein the material application device comprises a printing head for applying the material in a three-dimensional printing process, a contour crafting process, a fused deposition modeling process, a laminated object modeling process, a polyamide casting process or a multi jet modeling process; and

a control device coupled with the material application device, the control device capable of transmitting signals;

wherein the control device is adapted to control the material application device such that the material application device dispenses material selectively onto predetermined regions, the regions corresponding to a cross-section of the product in the respective layer;

wherein the substrate plate is divided into a plurality of substrate plate segments, the segments connectably-detachable with each other or with the substrate carrier, wherein the control device is further adapted to manufacture several products distributed over several substrate plate segments and to adjust the heights of the substrate segments in relation to each other such that the products can be produced in different stages of manufacturing on different substrate plate segments,

wherein the substrate carrier forms an endless conveyor device and that the material application device is adapted to dispense the material directly onto the substrate carrier and/or that a separation device is arranged at the substrate carrier to detach manufactured products after their completion from the substrate carrier or from the substrate plate arranged thereon.

6. The device according to claim 5, wherein the control device is adapted to control the material application device and/or the endless conveyor device in such a way that a layer with a thickness between about 5 μ

m and 200 μ

m is applied during use.

11. The device according to claim 5, wherein the endless conveyor device is turned around at a deflecting device and deformed so as to cause the products to detach from the endless conveyor device.

8. A device for manufacturing multi-layered products with individual geometry, the device comprising:

a substrate plate;

a material application device movable relative to the substrate plate for application of material above the substrate plate; and

a control device for transmitting signals to the material application device and/or a conveyor device for conveying the substrate plate, wherein the control device is adapted to control the material application device such that it dispenses the material selectively on predetermined regions corresponding to the cross-section of the product in the respective layer,

wherein the control device and the application device are adapted to manufacture a three-dimensional product by means of an additive manufacturing method excluding the LENS process,

wherein the material application device is adapted to apply the material in a plane, the plane aligned at an oblique angle relative to a surface of the substrate plate on which the material is applied,

wherein the control device is adapted to produce a relative movement between the substrate plate and the material application device in a direction parallel to the surface of the substrate plate after a layer of the material was applied.