Device and method for producing three-dimensional models

• US 9,333,709 B2
• Filed: 03/29/2011
• Issued: 05/10/2016
• Est. Priority Date: 03/31/2010
• Status: Active Grant

• Current Assignee: Voxeljet AG
• Original Assignee: Voxeljet AG
• Inventors: Hartmann, Andreas Dominik
• Primary Examiner(s): Thomas, Binu
• Application Number:
  US13/634,099
• Publication Number:
  US 20130000549A1
• Time in Patent Office: 1,869 Days
• Field of Search: None
• US Class Current: 1/1
• CPC Class Codes: B05C 11/023 Apparatus for spreading or distributing liquids or other fluent materials already applied to a surface B05C11/021, B05C11/04 take precedence
• CPC Class Codes: B05C 19/04 the particulate material being projected, poured or allowed to flow onto the surface of the work B05C19/02 takes precedence; involving spraying or electrostatic projection B05B B05C19/005 takes precedence
• CPC Class Codes: B05C 19/06 Storage, supply or control of the application of particulate material; Recovery of excess particulate material
• CPC Class Codes: B22F 10/14 by jetting of binder onto a bed of metal powder
• CPC Class Codes: B22F 10/34 of powder characteristics, e.g. density, oxidation or flowability
• CPC Class Codes: B22F 12/222 for motion along a direction orthogonal to the plane of a layer
• CPC Class Codes: B22F 12/38 Housings, e.g. machine housings
• CPC Class Codes: B28B 1/001 Rapid manufacturing of 3D objects by additive depositing, agglomerating or laminating of material selective deposition modelling of metallic powder B22F10/00; rapid manufacturing of 3D objects in general and in particular of plastics B29C64/00
• CPC Class Codes: B28B 13/022 Feeding several successive layers, optionally of different materials
• CPC Class Codes: B29C 31/02 Dispensing from vessels, e.g. hoppers into a mould cavity B29C31/04; large containers characterised by discharge means B65D88/28, B65D88/54
• CPC Class Codes: B29C 64/10 Processes of additive manufacturing
• 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 64/321 Feeding
• CPC Class Codes: B29C 64/329 using hoppers
• CPC Class Codes: B29K 2105/251 Particles, powder or granules expandable particles B29K2105/046
• 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

The present invention relates to a device for manufacturing three-dimensional models by means of a 3D printing process, whereby a build platform for application of build material is provided and a support frame is arranged around the build platform, to which said support frame at least one device for dosing the particulate material and one device for bonding the particulate material is attached via the guiding elements and the support frame is moveable in a Z direction, which essentially means perpendicular to the base surface of the build platform. In so doing, the device provides a material feeding device having a particle material container to supply particulate material in batches from the storage area to the dosing apparatus and to do so with the least possible amount of shearing forces and without significant interaction with the atmosphere.

Claims

1. An apparatus for manufacturing three-dimensional models by means of a 3D printing process comprising:

a build platform having a base surface for application of a build material including a particulate material and a liquid material;

a support frame arranged around the build platform having guiding elements, to which said support frame is attached;

i) at least one coater device for dosing the particulate material onto the build platform;

ii) a receiving container for receiving the particulate material and for filling the coater device with the particulate material; and

iii) a print head device for printing the liquid material using individually controlled nozzles for bonding the particulate material;

at least two vertical positioning units for moving the support frame in a Z direction perpendicular to the base surface of the build platform;

a stationary material storage device for storing the particulate material, and

a material feeding device for supplying the particulate material in batches from the material storage device to the receiving container with the least possible amount of shearing forces to the particulate material and without significant Interaction of the particulate material with atmosphere;

wherein the coater device and the print head are attached to the support frame via the guiding elements; and

wherein the coating device, the print head and the receiving container move in the Z direction with the movement of the support frame;

wherein the material feeding device has a fixed feeding location positioned below the stationary material storage device and a discharge location positioned above the receiving container and movable in at least the Z direction with an incline angle that adjusts as the build frame moves vertically;

wherein the material feeding device includes an incline angle that adjusts as the build frame moves vertically, or the material feeding device includes a lifting device having a linear actuator that moves a conveying crucible to a height that adjusts as the build frame moves vertically.

2. The apparatus according to claim 1, wherein each of the batches contains less particulate material than is required for depositing all layers on the build platform.

3. The apparatus according to claim 1, wherein one batch is sufficient to deposit at least one layer of particulate material to the build platform.

4. The apparatus according to claim 1, wherein the material feeding device includes a conveying crucible for moving the particulate material vertically.

5. The apparatus according to claim 1, wherein the material feeding device includes a chain trough conveyor for moving the particulate material vertically.

6. The apparatus according to claim 1, wherein the material feeding device has a conveyor bet for moving the particulate material vertically.

7. The apparatus according to claim 4, wherein the conveying crucible has a cover.

8. The apparatus according to claim 2, wherein one batch is sufficient to deposit at least one layer of particulate material to the build platform.

9. The apparatus according to claim 2, wherein the material feeding device includes a conveying crucible for moving the particulate material vertically.

10. The apparatus according to claim 8, wherein the material feeding device includes a conveying crucible for moving the particulate material vertically.

11. The apparatus according to claim 2, wherein the material feeding device includes a chain trough conveyor for moving the particulate material vertically.

12. The apparatus according to claim 10, wherein the material feeding device includes a chain trough conveyor for moving the particulate material vertically.

13. The apparatus according to claim 2, wherein the material feeding device has a conveyor belt for moving the particulate material vertically.

14. The apparatus according to claim 8, wherein the material feeding device has a conveyor bet for moving the particulate material vertically.

15. The apparatus according to claim 1, wherein the apparatus includes a spiral conveyor for distributing the particulate material across the width of the coater device.

16. The apparatus according to claim 1, wherein the apparatus includes a mixing device for mixing the particulate material with a liquid medium prior to being transported by the material feeding device.

17. The apparatus according to claim 1, wherein the receiving device is permanently attached to the support frame so that the receiving container only moves in the vertical direction.

18. The apparatus of claim 8, wherein

i) the apparatus includes a spiral conveyor for distributing the particulate material across the width of the coater device;

and

ii) the apparatus includes a mixing device for mixing the particulate material with a liquid medium prior to being transported by the material feeding device; and

iii) the receiving device is permanently attached to the support frame so that the receiving container only moves in the vertical direction.

19. An apparatus for manufacturing three-dimensional models by means of a 3D printing process comprising:

a build platform having a base surface for application of a build material including a particulate material and a liquid material;

a support frame arranged around the build platform having guiding elements, to which said support frame is attached;

i) at least one coater device for dosing the particulate material onto the build platform;

ii) a receiving container for receiving the particulate material and for filling the coater device with the particulate material; and

iii) a print head device for printing the liquid material using individually controlled nozzles for bonding the particulate material;

at least two vertical positioning units for moving the support frame in a Z direction perpendicular to the base surface of the build platform;

a stationary material storage device for storing the particulate material, and

a material feeding device for supplying the particulate material in batches from the material storage device to the receiving container, wherein the material feeding device has a fixed feeding location positioned below the stationary material storage device, and a discharge location positioned above the receiving container and movable in at least the Z direction with an incline angle that adjusts as the build frame moves vertically;

wherein the coater device and the print head are attached to the support frame via the guiding elements;

wherein the coating device, the print head and the receiving container move in the Z direction with the movement of the support frame; and

wherein the material feeding device includes

i. a conveying crucible for moving the particulate material vertically and a lifting device having a linear actuator that moves the conveying crucible to a height that adjusts as the build frame moves vertically;

or

ii. a chain trough conveyor for moving the particulate material vertically and includes an incline angle that adjusts as the build frame moves vertically;

or

iii. a conveyor belt for moving the particulate material vertically and includes an incline angle that adjusts as the build frame moves vertically.