Device for producing three-dimensional models

• US 9,815,243 B2
• Filed: 11/02/2015
• Issued: 11/14/2017
• 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:
  US14/929,922
• Publication Number:
  US 20160052166A1
• Time in Patent Office: 743 Days
• Field of Search: None
• 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. A method for manufacturing three-dimensional models using a 3D printing process comprising the steps of:

a) transporting a first amount of a particulate material from a stationary material storage device to a first vertical position using a material feeding device for delivering the particulate material to a receiving container that is attached to a support frame so that the receiving container moves with the support frame in a vertical direction;

b) filling a dosing unit on the support frame with the particulate material in the receiving container;

c) depositing one or more layers of the particle material from the dosing unit onto a stationary build platform;

d) elevating the support frame, the dosing unit, and the receiving container in the vertical direction after depositing each layer of the particulate material by one particle layer thickness; and

e) transporting a second amount of the particulate material from the material storage device to a second vertical position using the material feeding device for delivering the particulate material to the receiving container, wherein the second vertical position is offset from the first vertical position;

wherein the method includes mixing the particulate material with a liquid prior to transporting the particulate material from the material storage device.

2. The method of claim 1, wherein the dosing device is a coater device that moves over the build platform in a horizontal direction.

3. The method of claim 2, wherein the material feeding device includes a lifting device having a linear actuator.

4. The method of claim 3, wherein the material feeding device includes a crucible and the particulate material is transported from the material storage device to the receiving container in the crucible.

5. The method of claim 1, wherein the process avoids a generation of frictional heat during the transport of the particulate material from the material storage device to the receiving container.

6. The method of claim 1, wherein during the step of transporting the particulate material with the material feeding device, the particulate material is at least partially covered so that evaporation of the liquid is reduced or eliminated.

7. The method of claim 1, wherein high air currents of a pneumatic conveyor are avoided during the transport of the particulate material from the material storage device to the receiving container.

8. The method of claim 1, wherein the material feeding device includes one or more covered crucibles for transporting the mixture of the particulate material and the liquid.

9. The method of claim 1, wherein the method includes preparing multiple batches of a mixture of the particulate material and the liquid.

10. The method of claim 1, wherein the liquid is a hardening material.

11. A method for manufacturing three-dimensional models using a 3D printing process comprising the steps of:

a) transporting a first amount of a particulate material from a stationary material storage device to a first vertical position using a material feeding device for delivering the particulate material to a receiving container that is attached to a support frame so that the receiving container moves with the support frame in a vertical direction;

b) filling a dosing unit on the support frame with the particulate material in the receiving container;

c) depositing one or more layers of the particle material from the dosing unit onto a stationary build platform;

d) elevating the support frame, the dosing unit, and the receiving container in the vertical direction after depositing each layer of the particulate material by one particle layer thickness; and

e) transporting a second amount of the particulate material from the material storage device to a second vertical position using the material feeding device for delivering the particulate material to the receiving container, wherein the second vertical position is offset from the first vertical position;

wherein the dosing device is a coater device that moves over the build platform in a horizontal direction;

the particulate material being transported by the material feeding device includes many individual particles, wherein the many individual particles generally move together at the same instantaneous velocity, and

the many individual particles are supported by one or more surfaces of the material feeding device and move with the support surface at the same instantaneous velocity.

12. A method for manufacturing three-dimensional models using a 3D printing process comprising the steps of:

a) transporting a first amount of a particulate material from a stationary material storage device to a first vertical position using a material feeding device for delivering the particulate material to a receiving container that is attached to a support frame so that the receiving container moves with the support frame in a vertical direction;

b) filling a dosing unit on the support frame with the particulate material in the receiving container;

c) depositing one or more layers of the particle material from the dosing unit onto a stationary build platform;

d) elevating the support frame, the dosing unit, and the receiving container in the vertical direction after depositing each layer of the particulate material by one particle layer thickness; and

e) transporting a second amount of the particulate material from the material storage device to a second vertical position using the material feeding device for delivering the particulate material to the receiving container, wherein the second vertical position is offset from the first vertical position;

wherein the dosing device is a coater device that moves over the build platform in a horizontal direction; and

wherein the particulate material is mixed with a liquid medium prior to being deposited as a layer over the build surface.

13. A method for manufacturing three-dimensional models using a 3D printing process comprising the steps of:

a) transporting a first amount of a particulate material from a stationary material storage device to a first vertical position using a material feeding device for delivering the particulate material to a receiving container that is attached to a support frame so that the receiving container moves with the support frame in a vertical direction;

b) filling a dosing unit on the support frame with the particulate material in the receiving container;

c) depositing one or more layers of the particle material from the dosing unit onto a stationary build platform;

d) elevating the support frame, the dosing unit, and the receiving container in the vertical direction after depositing each layer of the particulate material by one particle layer thickness; and

e) transporting a second amount of the particulate material from the material storage device to a second vertical position using the material feeding device for delivering the particulate material to the receiving container, wherein the second vertical position is offset from the first vertical position;

wherein the dosing device is a coater device that moves over the build platform in a horizontal direction; and

wherein the material feeding device has an incline angle, wherein the incline angle changes as the vertical position of the coater device is changed.

14. The method of claim 13, wherein the method includes selectively dropping a liquid binder material over a deposited layer of particulate material.

15. The method of claim 13, wherein the particulate material being transported by the material feeding device includes many individual particles, wherein the many individual particles generally move together at the same instantaneous velocity.

16. The method of claim 13, wherein the material feeding device includes a conveyor belt.

17. The method of claim 13, wherein the material feeding device includes a chain trough conveyor.

18. The method of claim 13, wherein the method includes repeatedly layerwise depositing the particulate material onto the build surface and selectively printing a binder material onto the layer of the particulate material until the three-dimensional models are a 3D article is printed.

19. The method of claim 18, wherein the method includes removing loose particulate material from the three-dimensional models.

20. The method of claim 13, wherein the dosing device is a coater device that moves over the build platform in a horizontal direction.

21. The method of claim 20, wherein the particulate material being transported by the material feeding device includes many individual particles, wherein the many individual particles generally move together at the same instantaneous velocity.

22. The method of claim 13, wherein the particulate material is mixed with a liquid medium prior to being deposited as a layer over the build surface.