Device and method for constructing a laminar body comprising at least one position adjustable body defining the working area

• US 9,242,413 B2
• Filed: 10/14/2011
• Issued: 01/26/2016
• Est. Priority Date: 01/05/2011
• Status: Active Grant

• Current Assignee: Voxeljet AG
• Original Assignee: Voxeljet AG
• Inventors: Hartmann, Andreas, Schmid, Dominik
• Primary Examiner(s): Theisen, Mary F
• Application Number:
  US13/883,397
• Publication Number:
  US 20130234355A1
• Time in Patent Office: 1,565 Days
• Field of Search: None
• US Class Current: 1/1
• CPC Class Codes: B22F 10/00 Additive manufacturing of workpieces or articles from metallic powder apparatus or devices therefor B22F12/00
• CPC Class Codes: B22F 10/14 by jetting of binder onto a bed of metal powder
• CPC Class Codes: B22F 10/16 by embedding the binder within the powder bed
• CPC Class Codes: B22F 10/68 Cleaning or washing
• CPC Class Codes: B22F 12/47 parallel to the deposition plane
• CPC Class Codes: B22F 12/55 Two or more means for feeding material
• 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 64/20 Apparatus for additive manufacturing; Details thereof or accessories therefor
• CPC Class Codes: B29C 64/209 Heads; Nozzles
• CPC Class Codes: B29C 64/35 Cleaning
• CPC Class Codes: B29K 2105/16 Fillers
• CPC Class Codes: B29K 2509/00 Use of inorganic materials not provided for in groups B29K2503/00 - B29K2507/00, as filler
• 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

Abstract

The invention relates to a device (13) for constructing a laminar body (5) from a plurality of superimposed layers of free-flowing material, in particular particulate material, an a build platform (6) within a working area (11). The layers are solidified in locally predetermined regions by the action of binders and are joined together so that at least one molded body (4) is formed by the solidified and joined regions of the layers. The device comprises a discharging device (1) movable back and forth over the working area (11) in at least one discharge direction and having at least one discharge opening (14) from which the free-flowing material can be discharged in individual superimposed layers during the movement of the discharging device (1). According to the invention at least one body (8, 8a) defining the working area (11) in at least one discharge direction of the discharging device (1) and the build platform (6) are adjustable vertically relative to each other in accordance with the specific progress with which the laminar body (5) is being constructed, in such a manner that a surface of the at least one body (8, 8a) facing the discharge opening (14) is aligned flush with a laminar body (5) topmost layer that is yet to be produced or has already been produced, in order to dose the discharge opening (14) of the discharging device (1) and prevent the discharging device from discharging free-flowing material or in order to discharge free-flowing material not used for laminar construction into a collecting container (7) when the discharge opening (14) is located above the body (8, 8a).

Claims

1. A device for constructing a layered body from a plurality of superimposed layers of free-flowing material, on a build platform within a build space, the layers being solidified and joined together in locally predetermined areas by the action of a binder, so that at least one molding is formed by the solidified and joined areas of the layers, the device comprising:

a discharging device movable back and forth over the build space in at least one horizontal direction and having at least one discharge opening for discharging the free-flowing material in individual superimposed layers during the movement of the discharging device,

wherein at least one body delimiting the build space in at least one horizontal direction and the build platform are adjustable vertically relative to each other in such a way that a surface of the at least one body facing the discharge opening is aligned flush with a topmost layer of the layer body yet to be produced or already produced, in order to close the discharge opening of the discharging device and to prevent the discharging device from discharging free-flowing material or to discharge free-flowing material that is not used for layering into a collecting container when the discharge opening is located above the body,

wherein the at least one body is designed to be adjustable parallel to the build platform to variably delimit the build space within a horizontal plane.

2. The device according to claim 1, wherein the discharging device is displacement-controlled with regard to a discharge route extending from a starting position at one edge of the build space to a reversing position at an opposite edge of the build space.

3. The device according to claim 2, wherein the reversing position is predefined by the particular position of the at least one body, and the starting position is stationary.

4. The device according to claim 2, wherein the starting position is predefined by the particular position of the at least one body, and the reversing position is stationary.

5. The device according to claim 2, wherein the device includes a filling device and the starting position is a filling position at which the discharging device is fillable or refillable with free-flowing material by means of the filling device.

6. The device according to claim 1, wherein a print head which is movable back and forth over the build space is provided for selectively applying the binder to at least one discharged layer;

wherein the at least one body is a flat, plate-shaped body with or without a through-opening; and

wherein the collecting container is disposed at the reversing position or at the starting position for the free-flowing material.

7. The device according to claim 6, wherein at least one body is disposed at the starting position and at least one other body is disposed at the reversing position, means being provided in the one body or in the ether body for introducing or conducting free-flowing material into the collecting container.

8. A device for constructing a layered body from a plurality of superimposed layers of free-flow no material, on a build platform within a build space, the layers being solidified and joined together in locally predetermined areas by the action of a binder, so that at least one molding is formed by the solidified and joined areas of the layers, the device comprising:

a discharging device movable back and forth over the build space in at least one horizontal direction and having at least one discharge opening for discharging the free-flowing material in individual superimposed layers during the movement of the discharging device,

wherein at least one body delimiting the build space in at least one horizontal direction and the build platform are adjustable vertically relative to each other in such a way that a surface of the at least one body facing the discharge opening is aligned flush with a topmost layer of the layer body yet to be produced or already produced, in order to close the discharge opening of the discharging device and to prevent the discharging device from discharging free-flowing material or to discharge free-flowing material that is not used for layering into a collecting container when the discharge opening is located above the body,

wherein the build platform is designed to be adjustable vertically relative to the at least one body and the discharging device, and the at least one body and the discharging device are designed to be adjustable horizontally relative to the build platform.

9. A method for constructing a layered body from a plurality of superimposed layers of free-flowing material, on a build platform (6) within a build space, the layers being solidified and joined together in locally predetermined areas by the action of a binder, so that at least one molding is formed by the solidified and joined areas of the layers, a discharging device being movable back and forth over the build space in at least one discharge direction and having at least one discharge opening from which the free-flowing material is discharged in individual superimposed layers during the movement of the discharging device,

wherein at least one body delimiting the build space in at least one discharge direction of the discharging device and the build platform are adjusted vertically relative to each other as the construction of the layer body progresses, in such a way that a surface of the at least one body facing the discharge opening is aligned flush with a topmost layer of the layer body yet to be produced or already produced, in order to close the discharge opening of the discharging device and to prevent the discharging device from discharging free-flowing material or to collect free-flowing material that is not used for layering when the discharge opening is located above the at least one body;

wherein the at least one body is adjusted to variably delimit the build space within a horizontal plane parallel to the build platform.

10. The method according to claim 9, wherein the discharging device is displacement-controlled with regard to a discharge route extending from a starting position at one edge of the build space to a reversing position at an opposite edge of the build space.

11. The method according to claim 10, wherein the discharging device is filled with a quantity of free-flowing material which corresponds to an integral multiple of the quantity of free-flowing material that is needed for constructing an entire layer of the layer body.

12. The method according to claim 11, wherein the reversing position of the discharging device is predefined by the particular position of the at least one body on the horizontal plane, and the starting position is stationary.

13. The method according to claim 12, wherein the method includes the following steps:

a) positioning the at least one body, the discharging device and the build platform vertically relative to each other in such a way that, on the one hand, the surface of the at least one body facing the discharge opening and, on the other hand, the discharge opening are disposed higher than the currently topmost layer of the layer body by a distance of one layer thickness;

b) filling or refilling the discharging device with free-flowing material at the starting position for producing at least two layers of the layer body;

c) moving the discharging device from the starting position to the reversing position while discharging free-flowing material for constructing a layer;

d) providing a locally predetermined area of at least the discharged layer with binder;

e) positioning the at least one body, the discharging device and the build platform vertically relative to each other in such a way that, on the one hand, the surface of the at least one body facing the discharge opening and, on the other hand, the discharge opening of the discharging device are disposed higher than the currently topmost layer of the layer body by a distance of one layer thickness;

f) moving the discharging device from the reversing position to the starting position while discharging free-flowing material for constructing another layer;

g) collecting any unused free-flowing material at the starting position;

h) providing a locally predetermined area of the additional discharged layer with binder;

i) repeating steps a) through h) until the layer body is completely created.

14. The method according to claim 10, wherein the starting position is predefined by the particular position of the at least one body on the horizontal plane, and the reversing position is stationary.

15. The method according to claim 14, wherein the method includes the following steps:

a) positioning the at least one body, the discharging device and the build platform vertically relative to each other in such a way that, on the one hand, the surface of the at least one body facing the discharge opening and, on the other hand, the discharge opening of the discharging device are disposed higher than the currently topmost layer of the layer body by a distance of one layer thickness;

b) filling or refilling the discharging device with free-flowing material at the starting position for producing at least one layer of the layer body;

c) moving the discharging device from the starting position to the reversing position while discharging free-flowing material for constructing a layer;

d) collecting any unused free-flowing material at the reversing position;

e) providing a locally predetermined area of the discharged layer with binder;

f) moving the emptied discharging device from the reversing position to the starting position;

g) repeating steps a) through f) until the layer body (5) is completely created.

16. The method according to claim 10, wherein the starting position is a filling position at which the discharging device is fillable or refillable with free-flowing material.

17. The method according to claim 10, wherein the collection of excess free-flowing material takes place at the reversing position or at the starting position.

18. The method according to claim 10, wherein the build platform is moved vertically relative to the at least one body and the discharging device, and the at least one body and the discharging device are moved horizontally relative to the build platform.

19. The method of claim 9, wherein the method includes building a boundary wall adjacent to the at least one body.

20. The method of claim 19, wherein the step of building the boundary wall includes selectively printing binder material adjacent the at least one body.