Device for pattern building in layers

• US 20060108090A1
• Filed: 12/28/2005
• Published: 05/25/2006
• Est. Priority Date: 09/26/2000
• Status: Active Grant

• Current Assignee: Exone GMBH (Desktop Metal, Inc.)
• Original Assignee: Alexander Kudernatsch, Bernhard Graf, Ingo Ederer, Rainer Hochsmann
• Inventors: Ederer, Ingo, Hochsmann, Rainer, Graf, Bernhard, Kudernatsch, Alexander
• Granted Patent: US 7,137,431 B2
• Time in Patent Office: Days
• US Class Current: 164/155.100
• CPC Class Codes: B22C 7/00 Patterns; Manufacture thereof so far as not provided for in other classes
• CPC Class Codes: B22F 12/10 Auxiliary heating means
• CPC Class Codes: B29C 31/006 Handling moulds, e.g. between a mould store and a moulding machine movable moulds B29C33/34; for injection moulding B29C45/1756
• CPC Class Codes: B29C 31/044 with moving heads for distributing liquid or viscous material into the moulds
• CPC Class Codes: B29C 41/34 Component parts, details or accessories; Auxiliary operations
• CPC Class Codes: B29C 64/135 the energy source being concentrated, e.g. scanning lasers or focused light sources
• CPC Class Codes: B29C 64/153 using layers of powder being selectively joined, e.g. by selective laser sintering or melting
• 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 40/00 Auxiliary operations or equipment, e.g. for material handling
• CPC Class Codes: Y02P 10/25 Process efficiency

Abstract

Described herein is a device for pattern building in layers, which has a frame (1), a vertically movable and interchangeable workpiece platform (17), and a material feeder with a spreader (4), whereby the spreader (4) serves to feed material from a storage bin situated in the workspace above the workpiece platform (17), and the workpiece platform (17) is fixed at least when building a pattern. The workpiece platform (17) is accordingly loaded into the device from one side and unloaded from the other side of the device.

Claims

1-16. -16. (canceled)

17. A method for pattern building in layers, comprising the steps of:

a) feeding material including a molding sand to a work piece platform that is positioned within a frame of a pattern building device, the workpiece platform being height adjustable, the workpiece platform being essentially rectangular in plan view, and the workpiece platform having a pair of longer edges and a pair of shorter edges when viewed from the top;

b) spreading the material including the molding sand by translating a spreader along at least one of the shorter edges of the rectangular cross-section of the workpiece platform;

c) selectively contacting the material including the molding sand with a casting resin and curing agent;

d) curing the casting resin in contact with the molding sand for forming a cured layer;

e) adjusting the height of the workpiece platform;

f) successively repeating at least steps (a)-(d) until a metal casting mold pattern is completed.

18. The method of claim 17, wherein the selectively contacting step (c) includes a step of depositing a curing agent onto a mixture that includes the molding sand and the casting resin using a drop-on-demand system.

19. The method of claim 18, wherein the depositing step includes dispensing the curing agent from a drop-on-demand system that includes an ink-jet dispenser.

20. The method of claim 17, further comprising steps of loading and unloading the workpiece platform.

21. The method of claim 20, wherein the step of loading the workpiece platform on a first side of the device and the step of unloading the workpiece platform occurs on a second side of the device.

22. The method of claim 19, further comprising steps of loading the workpiece platform on a first side of the device and unloading the workpiece platform from a second side of the device.

34. A metal casting pattern made according to the method of claim 17.

23. A method for pattern building in layers, comprising the steps of:

a) loading a workpiece platform within a frame of a pattern building device from a first side of the pattern building device, the workpiece platform being essentially rectangular in plan view, and the workpiece platform having a pair of longer edges and a pair of shorter edges when viewed from the top;

b) feeding material to the workpiece platform that is positioned within a frame of a pattern building device, the workpiece platform being height adjustable within the frame;

c) spreading the material by translating a spreader along at least one of the shorter edges of the rectangular cross-section of the workpiece platform;

d) balancing out sag of the spreader along its length;

e) curing the material for forming a cured layer;

f) adjusting the height of the workpiece platform; and

g) successively repeating at least steps (a)-(e) until a pattern is completed; and

h) unloading the workpiece platform from a second side of the device.

24. The method of claim 23, wherein the feeding of the material includes vibratingly advancing the material from a storage bin located above the work piece platform.

25. The method of claim 23 wherein the curing step includes a step of contracting a curing agent with a resin.

26. The method of claims 25, wherein the contacting step includes depositing a curing agent from an ink-jet dispenser.

27. The method of claim 24 wherein the curing step includes a step of contracting a curing agent with a resin.

28. The method of claims 27, wherein the contacting step includes depositing a curing agent from an ink-jet dispenser.

35. A metal casting pattern made according to the method of claim 23.

29. A method for pattern building in layers, comprising the steps of:

a) feeding material including a molding sand admixed with a resin to a work piece platform that is positioned within a frame of a pattern building device, the workpiece platform being height adjustable, the workpiece platform being essentially rectangular in plan view, and the workpiece platform having a pair of longer edges and a pair of shorter edges when viewed from the top;

b) spreading the material including the admixture of molding sand and resin by translating a spreader along at least one of the shorter edges of the rectangular cross-section of the workpiece platform;

c) balancing out sag of the spreader along its length;

d) selectively contacting the material the admixture of molding sand and resin with a curing agent via an ink-jet deposition head;

e) curing the casting resin in contact with the molding sand for forming a cured layer;

f) adjusting the height of the workpiece platform;

g) successively repeating at least steps (a)-(e) until a metal casting mold pattern is completed.

30. The method of claim 29, wherein the feeding of the material includes vibratingly advancing the material from a storage bin located above the work piece platform.

31. The method of claim 29, further comprising steps of loading the workpiece platform on a first side of the device and unloading the workpiece platform from a second side of the device.

32. The method of claim 30, further comprising steps of loading the workpiece platform on a first side of the device and unloading the workpiece platform from a second side of the device.

33. The method of claim 29, wherein the workpiece platform is mounted in a job box.

36. A metal casting pattern made according to the method of claim 29.