Method and Device for Production of Three-Dimensional Objects by Means of Electromagnetic Radiation of Electromagnetic Radiation and Application of an Absorber by Means of an Ink-Jet Method

• US 20070238056A1
• Filed: 03/03/2005
• Published: 10/11/2007
• Est. Priority Date: 04/27/2004
• Status: Active Grant

• Current Assignee: Evonik Operations GmbH (Rag-Stiftung)
• Original Assignee: Degussa AG (Rag-Stiftung)
• Inventors: Baumann, Franz-Erich, Monsheimer, Sylvia, Grebe, Maik
• Granted Patent: US 9,643,359 B2
• Time in Patent Office: Days
• US Class Current: 430/325
• CPC Class Codes: B22F 10/10 Formation of a green body
• CPC Class Codes: B22F 10/36 of energy beam parameters
• CPC Class Codes: B22F 12/33 translatory in the deposition plane
• CPC Class Codes: B22F 12/41 characterised by the type, e.g. laser or electron beam
• CPC Class Codes: B22F 12/47 parallel to the deposition plane
• CPC Class Codes: B29C 35/08 by wave energy or particle radiation B29C64/00, B29C71/04 take precedence
• 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: B33Y 10/00 Processes of additive manufacturing
• CPC Class Codes: Y02P 10/25 Process efficiency

Abstract

The present invention relates to a process for the bonding of material for the production of three-dimensional objects by means of selective heating via electromagnetic energy which is either non-coherent and/or non-monochromatic and/or non-oriented, with a wavelength of from 100 nm to 1 mm. This radiation may be emitted in spot or linear form, or else in spread form. It is also possible to combine two or more sources of radiation in order to increase the speed of the process. The selectivity of the melting process is achieved via the application of an absorber to certain subregions of a layer composed of a pulverulent substrate, and then heating of the absorber by means of electromagnetic energy of wavelength from 100 nm to 1 mm. The heated absorber transfers the energy present therein to its surrounding pulverulent substrate, which is melted thereby and, after cooling, has firm cohesive bonding. The process is markedly more flexible, less expensive, and faster than conventional laser sintering.

Claims

1-26. -26. (canceled)

27. A process for producing a three-dimensional object, which comprises

the steps of.

a) providing a layer of a pulverulent substrate

b) controlling the temperature of the manufacturing chamber

c) selective application of an absorber in a suspension or of a liquid absorber via an inkjet to the e regions to be sintered

d) if appropriate adjusting one or more functionalized layers, e.g. conductive properties by application of appropriate substances

e) selective melting of regions of the powder layer by means of introduction of electromagnetic energy via laser of wavelength from 100 nm to 1 mm, by means of radiative heaters in the IR-A, and/or IR-B region, or using lamps in the visible or IR-A, and/or IR-B region

f) cooling of the molten and non-molten regions to a temperature which allows the moldings to be removed intact

g) removal of the moldings.

28. The process as claimed in claim 27,

wherein

step e) is first car ed out once, and then steps a) to d) are carried out once, and then step b) is carried out and step a) is carried out again once, and then the other steps are carried out in the sequence c), d), a), b), and e).

29. The process as claimed in claim 27,

wherein

the pulverulent substrate used has a median grain size of from 10 to 150 μ

m.

30. The process as claimed in claim 27,

which

uses radiative heater in the near or middle infrared region.

31. The process as claimed in claim 27,

which

uses a lamp in the IR region or in the visible-light region.

32. The process as claimed in claim 27,

which

uses an incandescent lamp.

33. The process as claimed in claim 27,

which

uses a gas discharge lamp.

34. The process as claimed in claim 27,

wherein

the energy from the source is emitted in spot, linear, or spread form.

35. The process as claimed n claim 27,

wherein

the absorber comprises colorants.

36. The process as claimed in claim 35,

wherein

the colorants comprise pigments.

37. The process as claimed in claim 35,

wherein

the colorants comprise dyes.

38. The process as claimed in claim 27,

wherein

the absorber comprises carbon black, CHP, animal, charcoal, graphite, carbon fibers, chalk, or interference pigments.

39. The process as claimed in claim 27,

wherein

the absorber comprises other components alongside carbon black, CHP, animal charcoal, graphite, carbon fibers, chalk, or interference pigments.

40. The process as claimed in claim 27,

wherein

the absorber comprises flame retardants based on phosphorus or melamine cyanurate.

41. The process as claimed in claim 35,

wherein

the absorber also comprises distilled water, or alcohol, or solvent.

42. The process as claimed in claim 35,

wherein

the absorber also comprises at least one selected from the group consisting of a surfactant, a wetting agent, a biocide and a moisture retainer.

43. The process as claimed in claim 27,

wherein

the pulverulent substrate used comprises polymers.

44. The process as claimed in claim 27,

wherein

the pulverulent substrate used comprises sand, metal particles, or ceramic articles, which have been encapsulated by a polymeric material.

45. The process as claimed in claim 43,

wherein

the polymer comprises a homo- or copolymer selected from the group consisting of polyester, polyvinyl chloride, polyacetal, polypropylene, polyethylene, polystyrene, polycarbonate, polybutylene terephthalate, polyethylene terephthalate, polysulfone, polyarylene ether, polyurethane, thermoplastic elastomers, polylactides, polyoxyalkylenes, poly(N-methylmethacrylimides) (PMMI), polymethyl methacrylate (PMMA), ionomer, polyamide, copolyester, copolyamides, silicone polymers, terpolymers, acrylonitrile-butadiene-styrene copolymers (ABS), polyether sulfone, polyaryl sulfone, polyphenylene sulfide, polyaryl ether ketone, polyimide, polytetrafluoroethylene, and a mixture of these.

46. The process as claimed in claim 43,

wherein

use is made of a pulverulent substrate which comprises from 0.05 to 5 by weight of a powder-flow aid.

47. The process as claimed n claim 43,

wherein

use is made of a pulverulent substrate which comprises inorganic fillers.

48. The process as claimed in claim 47,

wherein

the filler used comprises glass beads.

49. The process as claimed in claim 43,

wherein

use is made of a pulverulent substrate which comprises inorganic or organic pigments.