Method and device for producing three-dimensional models

• US 10,589,460 B2
• Filed: 02/28/2013
• Issued: 03/17/2020
• Est. Priority Date: 03/06/2012
• Status: Active Grant

• Current Assignee: Voxeljet AG
• Original Assignee: Voxeljet AG
• Inventors: Gunther, Johannes, Gunther, Daniel, Hartmann, Andreas
• Primary Examiner(s): Malekzadeh, Seyed Masoud
• Assistant Examiner(s): Cummins, IV, Manley L
• Application Number:
  US14/382,197
• Publication Number:
  US 20150042018A1
• Time in Patent Office: 2,574 Days
• Field of Search: None
• CPC Class Codes: B22F 10/28 Powder bed fusion, e.g. selective laser melting [SLM] or electron beam melting [EBM]
• CPC Class Codes: B22F 10/70 Recycling
• CPC Class Codes: B22F 12/22 Driving means
• CPC Class Codes: B22F 12/224 for motion along a direction within the plane of a layer
• CPC Class Codes: B22F 12/30 Platforms or substrates
• CPC Class Codes: B22F 12/60 Planarisation devices; Compression devices
• 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 64/227 Driving means
• CPC Class Codes: B29C 64/245 Platforms or substrates support structures intended to be sacrificed after manufacture B29C64/40
• 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: Y02P 10/25 Process efficiency

Abstract

The present invention relates to a method for producing three-dimensional objects based on computer data by repeated application in layers of a medium containing particulate material and selective solidification of the medium, whereby a feedstock made of medium in a build space is provided and a layer application of the medium takes place on a surface of the feedstock bordering the build space at an angle β and a solidification according to computer data occurs by use of a solidification unit, characterized in that the feedstock is not moved during build-up of the object.

Claims

1. A method for producing one or more three-dimensional components based on computer data comprising steps of:

repeatedly applying layers, including sequential layers, of a medium containing a particulate material with a coating unit on a build surface of a feedstock made of the medium;

selectively solidifying the medium with a solidification unit,

wherein the feedstock is supported by a support surface, and the build surface has a build angle, α

, relative to the support surface, wherein the build angle is an acute angle greater than 0 degrees; and

wherein the feedstock is stationary during application of sequential layers of the medium;

wherein the coating unit moves on a coordinate system placed at the build angle, angle α

, relative to the support surface while applying one of the layers; and

wherein the coating unit moves in a direction parallel to the support surface between the sequential layers.

2. The method of claim 1, wherein the feedstock has two bordering surfaces adjacent to the build surface, wherein each of the two bordering surfaces has an angle ß

relative to a horizontal plane, wherein the angle ß

is an acute angle greater than 0 degrees, and the method includes moving the coating unit and the solidification unit in the direction parallel to the support surface and away from the feedstock between application of the sequential layers.

3. The method of claim 1, characterized in that limiting walls are built as the process proceeds.

4. The method of claim 1, wherein a movement of the solidification unit essentially proceeds horizontally.

5. The method of claim 1, wherein supplemental structures are formed that hinder a slipping down of the medium.

6. The method of claim 1, wherein the solidification unit has a droplet generator.

7. The method of claim 1, wherein the coating unit rests on walls that the process the coating unit builds as it proceeds.

8. The method of claim 1, wherein the solidification unit has the angle α

relative to the support surface and is moved in relation to the feedstock between the sequential layers.

9. The method of claim 8, wherein

i) the build space is a work bay floor of a production facility,

ii) the build space has a build platform,

iii) the build space includes slidable floors,

iv) the build space has an intermittent conveyor belt along linear guides,

v) or any combination of (i) through (iv);

and wherein the coating unit and solidification unit are horizontally moved on tracks.

10. The method of claim 9, wherein the coating unit rests on walls that the process the coating unit builds as it proceeds.

11. The method of claim 2, characterized in that limiting walls are built as the process proceeds.

12. The method of claim 11, wherein a movement of the solidification unit essentially proceeds horizontally.

13. The method of claim 12, wherein the solidification unit moves on the same or a different coordinate system placed at the angle α

to the support surface while applying droplets on the particulate material and wherein the solidification unit moves parallel to the support surface between building of two sequential layers.

14. The method of claim 10, wherein the coating unit and the solidification unit move on the coordinate system placed at the angle α

to the support surface while building one of the layers including the steps of applying and solidifying and parallel to the support surface between building of two sequential layers.

15. The method of claim 14, wherein supplemental structures are formed that hinder a slipping down of the medium.

16. The method of claim 6, wherein the coating unit and the solidification unit move on the coordinate system placed at the angle α

to the support surface while building one of the layers including the steps of applying and solidifying and parallel to the support surface between building of two sequential layers.

17. The method of claim 2, wherein each of the bordering surfaces is neither orthogonal nor parallel with the build surface;

and wherein each of the bordering surfaces extends from the support surface to a top surface of the feedstock.

18. The method of claim 1, wherein the support surface is a planar surface of a build platform, and the coating unit advances in a direction parallel to the planar surface of the build platform after applying one of the layers of the particulate material.

19. The method of claim 1, wherein the solidification unit has a radiation source.

20. The method of claim 2, herein the solidification unit has a radiation source.