DE102019131629A1 - Process for the additive manufacturing of a three-dimensional object - Google Patents

Abstract

Method for the additive manufacture of a three-dimensional object (1, 1 '), in particular a vehicle component, in an additive manufacturing device (2) by successive selective solidification of a, in particular powdery, building material to form the three-dimensional object (1, 1'), comprising the following method steps - Building up a support structure (3) during the additive production of the three-dimensional object (1, 1 ') which supports the three-dimensional object (1, 1') at least in sections at a support location (4), - at least in sections separating the support structure (3) from the three-dimensional object (1, 1 ') and / or from the support location (4) after the additive production of the three-dimensional object (1, 1'), the at least section-wise separation of the support structure (3) by means of a separating agent (30) , which acts directly or indirectly on the support structure (3), so that it differs from the three-dimensional object (1, 1 ') and / or from de m support point (4) separates.

Description

The invention relates to a method for the additive production of a three-dimensional object, in particular a vehicle component.

Corresponding methods for the additive production of a three-dimensional object are basically known from the prior art. The European patent application EP 1 358 855 A1 shows a method for manufacturing metallic or non-metallic products by free-form laser sintering, in which the products are built up vertically in layers on a substrate plate by means of a data-controlled laser beam made of powdery material, with at least one support being built between the substrate plate and the outer surface of the product , which is connected to the outer surface of the product via a predetermined breaking point, the predetermined breaking point being formed by reducing the strength of the support along the outer contour of the product.

The invention is based on the object of specifying a method which, in particular with regard to a simple, fast and inexpensive measure, enables the support structure supporting the three-dimensional object with respect to a support location to be separated, in particular in the course of an automated process.

The object is achieved by a method for the additive production of a three-dimensional object, in particular a vehicle component, according to claim 1. The dependent claims relate to possible embodiments of the method.

The invention relates to a method for the additive manufacture of a three-dimensional object, in particular a vehicle component, in an additive manufacturing device by successive selective solidification of a, in particular powdery, building material to form the three-dimensional object, comprising the following method steps: (a) Building a support structure during additive manufacturing of the three-dimensional object which supports the three-dimensional object at least in sections at a support location and (b) at least in sections separating the support structure from the three-dimensional object and / or from the support location after the additive production of the three-dimensional object. The method is characterized in that the support structure is separated at least in sections by means of a separating means, which acts directly or indirectly on the support structure, so that it separates from the three-dimensional object and / or from the support location.

The support location can be designed as a base plate of the production device and / or as a carrier element built on a base plate of the production device and / or as a support section of the three-dimensional object to be built itself and / or as a further three-dimensional object built with the object actually being viewed or built . In other words, the three-dimensional object can be supported with respect to different elements by a support structure; this support can prove to be advantageous during the construction process and / or advantageous for transporting the three-dimensional object after its completion in the additive manufacturing system. So that the support structure can still be in the additive manufacturing device or afterwards, z. B. be separated from the three-dimensional object in a subsequent processing device or at a later factory and / or customer site of use of the three-dimensional object, in particular a vehicle component. An example of a customer-side place of use of a vehicle component can be a workshop in which the three-dimensional object is handed over to a customer or is installed in the vehicle. Here, the support structure that remains on the three-dimensional object for such a long time can form a transport protection for the three-dimensional object.

The additive manufacturing process used can be, for example, one of the following processes: stereolithography (SL), laser sintering (LS), laser beam melting (LBM), electron beam melting (EBM) ), Fused Layer Modeling / Manufacturing (FLM or also known as Fused Filament Fabrication (FFF)), Multi-Jet Modeling (MJM), Poly-Jet Modeling (PJM), 3-D printing (3DP) also known as Binder Jetting , Layer Laminated Manufacturing (LLM), Digital Light Processing (DLP), Thermal Transfer Sintering (TTS), Digital Light Processing (DLP), Digital Light Synthesis (DLS) and / or Continuous Liquid Interface Production processes, also known as CLIP processes . The Digital Light Synthesis (DLS) is a special form of the CLIP process, whereby the DLS process combines a CLIP process with "programmable" materials, whereby the chemical compounds of the materials can be changed by heat after 3D printing. Laser beam melting also includes the process known as selective laser melting (Selective Laser Melting = SLM), in which metal powder is melted or remelted under the action of a laser beam.

The support point at which the three-dimensional object is supported via the support structure can be a base plate of (aa) Manufacturing device and / or (ab) a carrier element (e.g. a carrier plate or substrate plate) built on a base plate of the manufacturing device and / or (ac) a support section of the three-dimensional object to be built and / or (ad) a further three-dimensional object built with it include or the support point be designed accordingly.

While the three-dimensional object is being built up, a support structure is built up at the same time or in parallel. The support structure serves to support the object in relation to a support location, in particular during the construction of the object. It can thus be achieved that, for. B. partially constructed, in particular filigree configured in this intermediate construction, sections of the object can be supported so that on these, in particular filigree, sections again constructed object areas can be built reliably. The support structures can also protect the filigree sections, particularly those present in an intermediate design, from mechanical influences, e.g. B. the mechanical action of a, for example designed as a squeegee, support coating and / or smoothing element. For example, a shifting or twisting of a section of the three-dimensional object due to a powder building material application movement of a coating and / or smoothing element taking place in its vicinity is prevented.

The support of the three-dimensional object or the support location can be on the base plate of the production device and / or on a support element (e.g. a support plate) built on the base plate of the production device and / or on a support section of the three-dimensional object to be built and / or on a further three-dimensional object built up or include one of the abovementioned support locations. After the additive production of the three-dimensional object, the support structure is separated at least in sections from the three-dimensional object and / or from the support location.

The separation of the support structure at least in sections takes place on the basis of the separating means and can additionally or additionally at least partially also take place on the basis of a vibration fracture by causing the support structure to vibrate at least in sections. For example, the assembly consisting of the three-dimensional object, the support structure and a carrier element or carrier plate is removed from the additive manufacturing device and subjected to an oscillation or vibration. By causing the assembly to vibrate, at least in sections or at least in regions on the support structure due to load changes, a fatigue fracture or a fatigue fracture on the support structure is caused. In other words, an oscillating load acts on the support structure via the vibrations introduced, which, in contrast to a force fracture, causes stresses on the material of the support structure due to swelling or oscillating loads that are in particular below the yield point in the elastic range. Under such alternating stresses, changes in the microstructure of the material can be determined with a sufficient number of load changes (backlash), which lead to fatigue and ultimately to breakage.

In this way, a targeted at least section-wise separation of the support structure from the three-dimensional object and / or from the support location can be achieved simply by causing the assembly to vibrate or in addition to the action of a separating agent. This separation process can also be easily integrated into an automated manufacturing process, for example. Alternatively or additionally, at least the support structure and / or an assembly at least consisting of the support structure and the three-dimensional object can already be set in oscillation or vibration within the additive manufacturing device in order to achieve a targeted fatigue fracture on the support structure at least in sections. At least a first part or a first area of the support structure inside the additive manufacturing device and a further part or a further area of the support structure outside the production device can also be separated. Finally, vibrating can also be used as part of the separation process. for example, by causing the assembly to vibrate, a change in material properties or a material aging is caused, which leads to the fact that in a separating process using the separating agent, the latter is simplified, e.g. B. with a lower release agent force or introduction force, can be executed.

In a preferred embodiment, it is provided that the support structure is provided with at least one predefined predetermined breaking point and the predetermined breaking point breaks during the action of the separating agent; the separating agent is preferably at least partially, in particular completely, built up with the supporting structure.

It is possible that the support structure is provided with at least one predefined predetermined breaking point and during the action of the separating agent the predetermined breaking point breaks or the supporting structure breaks from the three-dimensional object and / or from the support location. It can thus be achieved that the break initiation and / or the The course of the break or the break line takes place at a predefined location or at a predefined location on the support structure. For example, a support structure connecting the three-dimensional object and the support location has two predetermined breaking points or two predetermined breaking areas, with a first predetermined breaking point at the boundary area or at a transition area to the three-dimensional object and a second predetermined breaking point at a boundary area or at a transition area to the Support location is placed. Both predetermined breaking points can be designed in such a way that they separate or break open in a temporally and / or spatially offset manner with respect to one another due to the action of the separating agent. The two predetermined breaking points can be designed differently in such a way that they are each deliberately broken and / or weakened in the event of a different type and / or extent of the action of the separating agent and / or a vibration (e.g. in amplitude and / or frequency) can be.

Alternatively or in addition, it can be provided that the separating means is built up at least in sections, in particular completely, with the support structure. I. E. z. B. that the release agent is present as an additively manufactured element, which can be built up at least in sections, in particular completely, in the same additive construction process as the three-dimensional object and / or as the support structure. In other words, the separating means is formed at least in sections, in particular completely, at the same time or in situ with the additive building process of the three-dimensional object and / or the support structure.

It is possible that the separating means comprises a transmission means, in particular a tension and / or pressure body, which is acted upon by an introduction force, in particular an introduction tension and / or introduction pressure force, introduced at an introduction area, so that by indirect or direct Action of the transmission means, in particular the tension and / or pressure body, on the support structure, this is separated from the three-dimensional object and / or from the support location. In this case, by means of the introduced force, the support structure can at least partially, in particular completely, separate or detach from the three-dimensional object or support location. For example, the separating means has a contact area at which a pushing or pulling force is applied to the separating means manually or by a manipulator, for example an industrial robot. This introduction force can act on the support structure through the transmission means in the same way or in a different manner (rotatory and / or translational) in such a way that it is guided to a defined break or to a defined release.

The transmission means can for example at least partially, in particular completely, comprise a liquid and / or gaseous medium, in particular an incompressible liquid and / or gaseous medium. The separating means preferably has a media receiving area in which the liquid and / or gaseous medium is or can be arranged. The liquid and / or gaseous medium can be used as a force transmission means and / or force transmission means within the separating means. For example, the liquid and / or gaseous medium is guided within your media channel, the diameter or the passage area (e.g. perpendicular to the direction of movement of the medium) of the media channel having different cross-sections or cross-sectional areas, so that the relation between pressure force and movement path of the medium, depending on the area within the media channel, can be specifically changed, in particular set in a targeted manner. This can be used to create different compressive forces at defined locations of the media channel in order to initiate a targeted area-dependent material failure at defined locations of the media channel and / or at locations of the support structure.

Furthermore, it can be provided, for example, that the separating means comprises a connection area to which a connection means can be or will be connected at least temporarily, so that, in the connected state of the connection means, a liquid and / or gaseous medium or a liquid and / or gaseous medium Fluid is introduced from the connection means via the connection area into a media receiving area, in particular a media receiving channel, of the separating means. The media receiving area preferably extends from a connection area to a separation point of the support structure at which the support structure can be separated or is separated from the three-dimensional object and / or a support point. The media receiving area can be designed as a media receiving channel at least in sections, in particular completely.

In an optional and advantageous embodiment, the transmission means can consist of at least two, at least temporarily and / or at least in sections relatively movable transmission elements, with the at least two transmission elements at least in sections, in particular completely, executing a relative movement to one another during the action or action of the introduction force. The two transmission elements preferably perform a linear and / or rotary movement with respect to one another. The movement carried out can also include an at least partial superposition of a linear and / or rotary movement. Via the transmission medium, in particular via the moving at least two transmission elements, a force causing a break in the predetermined breaking point can transmit or transmit from a location remote from the separation location to a location near the separation location, in particular from a force introduction area to a separation location.

Alternatively or additionally, it can be provided, for example, that during the movement of the at least one transmission element, in particular all transmission elements, at least one further transmission element, at least in sections, in particular completely, a (a) by means of a guide area arranged on the separating means side and / or (b) by means of a at least one further transmission element and / or a three-dimensional object and / or a support location that is functionally connected, in particular connected, joint, executes a defined, in particular guided or steered movement. Here, at least one transmission element, in particular all transmission elements, can be connected to a joint having at least one degree of freedom with a further transmission element and / or a three-dimensional object and / or a support location. This guided or steered movement leads to the at least one transmission element executing a defined movement at least in sections, in particular completely, relative to a further transmission element and / or a three-dimensional object and / or a support location.

A guide area can be characterized, for example, at least in sections by an area having a smooth or low-friction surface, with a low friction prevailing for a transmission element in contact with this surface. Furthermore, a guide surface or a guide channel can have at least one opening on its guide surface, which is arranged or designed in such a way that non-solidified, in particular powdery, building material located within the guide channel can escape from the guide channel so that a free space is reserved for the movement of the at least one transmission element becomes.

The at least one opening can also serve, for example, for air compensation in order to reduce the resistance for a transmission element to be introduced into the guide channel and / or moving within the guide channel.

It can optionally be provided that during the movement of at least one first transmission element in a first direction of movement, a further transmission element is moved in a second direction of movement that is different from the first direction of movement; the first transmission element preferably acts as a movement initiator on the further transmission element, which is particularly preferred the further transmission element is set in motion by contact with the first moving transmission element. In this way, a coupled movement or a forced movement or dependent movement behavior of the further transmission element can be achieved with the first transmission element or when the first transmission element moves.

It is possible that the release agent comprises a solvent or that the release agent is designed as a solvent which is brought into contact with the support structure, in particular with a predetermined breaking point area of the support structure, so that the support structure acts on the support structure either directly or indirectly is separated, in particular released, from the three-dimensional object and / or from the support location. The solvent or a property which dissolves the building material and / or at least changes the strength of the building material can thus have. For example, the solvent has an acidic property.

The separating means can preferably have a connection area to which a connection means can be connected at least temporarily, so that in the connected state of the connection means a solvent in the form of a liquid and / or gaseous medium is introduced from the connection means via the connection area into a media receiving area, in particular a media receiving channel, of the separating means is or can be brought in. The connection means and / or the connection area can for example comprise a sealing element which, in the assembled or attached state of connection means to the connection area, seals this interface from the environment and thus prevents the escape of liquid and / or gaseous medium.

Furthermore, for example, as an alternative or in addition, the media receiving area can extend from a connection area to a separation point of the support structure at which the support structure can be separated or is separated from the three-dimensional object and / or a support point. In this case, a media guide channel can be provided between the connection area and the separation point, at least as part of the media receiving area. This media guide channel can, for. B. in an additive manufacturing process, in particular at the same time with the construction of the support structure and / or at the same time with the construction of the three-dimensional object. At least in sections, in particular completely, the support structure can be separated or detached from the three-dimensional object and / or from the support location.

It is possible that the transfer means at least partially, in particular completely, comprises a liquid and / or gaseous medium, in particular an incompressible liquid and / or gaseous medium; the separating means preferably has a media receiving area in which the liquid and / or gaseous medium is arranged or can be arranged. In the case of a pressure-transmitting liquid or gaseous medium, the wall thickness and / or the design and / or dimensioning of the region of the separating means carrying the medium is designed in such a way that a reliable pressure transmission can be carried out. Here, the space receiving the medium can have a rigid and / or limited elastic behavior as long as the receiving space does not form any undesired leakage points, in particular during the pressure build-up or the pressure transmission through the medium.

In the case of a media receiving area carrying a solvent, this can be designed in such a way that the transfer or transport of the solvent to a target release area or to a predetermined breaking point can be carried out. Here, the area of the media receiving area that is not to be detached can have more material or be thick-walled than the area to be specifically detached or the area of the media receiving area arranged or formed near the predetermined breaking point or the intended release area. It can thus arise that areas of the media receiving area are also "loosened" that do not correspond to the predetermined breaking point or where no loosening behavior is generally desired or intended, but the deliberately dissolving area is designed in such a way that due to the action of the As a result of the solvent, the area to be specifically dissolved exhibits a more unstable behavior with regard to the acting solvent than the other areas. For example, due to a geometric configuration, the dwell time of a solvent reaching the area to be loosened can be increased so that a material failure can occur there earlier. The wall thickness of the more unstable areas can also be reduced compared to the other areas.

It is possible for the support structure to include at least one oscillating element which is designed to oscillate and which oscillates when the support structure is set into oscillation, in particular is excited in such a way that at least one predefined predetermined breaking point, in particular adjacent to the oscillating element, is caused to oscillate the support structure at least in sections, in particular completely, breaks and / or is weakened. In this way, the separation or detachment of the support structure from the three-dimensional object and / or from the support location can be generated in addition to the use of the separating means by the vibration element or by a vibration element causing and / or supporting a vibration fracture.

Preferably, the vibrating element can be designed differently in comparison to at least one predetermined breaking point or to at least one predetermined breaking point by means of a targeted mass accumulation and / or mass distribution. The oscillating element is particularly preferably designed as an accumulation of mass arranged or formed between two predetermined breaking points. Here, the predetermined breaking points can have a resilient or less rigid behavior than the oscillating element. The fact that a vibrating element is arranged or formed opposite the three-dimensional object and opposite the support point via a resilient behavior having predetermined breaking points, it is achieved that the vibrating element is swingably or to a limited extent movably attached or supported via the predetermined breaking points. This mobility enables the oscillating element to be deflected due to the external excitation by means of an oscillation or vibration. Due to the targeted accumulation of mass on the oscillating element, higher forces can be applied to the individual load change during oscillation. These higher forces lead to a reliable and / or better adjustable material failure or material weakening due to the backlash at the predetermined breaking points of the support structure. The fatigue strength, or the fatigue strength and / or the fatigue strength, of a piece structure can also be adjusted in a targeted manner through a targeted setting or a targeted design of the mass of the mass elements and / or the elasticity and / or the spring constant of the predetermined breaking points. During the oscillation of the support structure, the oscillation in frequency and / or amplitude can be selected in such a way that an oscillation element is excited, in particular an excitation coordinated to the natural frequency of the oscillation element occurs through the oscillation.

The vibration fracture behavior of the support structure can be adjusted by means of geometrical measures (e.g. the geometrical shape) and / or by means of internal material measures (e.g. material properties). The material properties can be, for. B. by the targeted area-dependent different use of different building materials and / or by a targeted area-dependent change of process parameters of the additive manufacturing device. For example, the energy input per unit area in the building material for liquefying or solidifying the building material is changed depending on the area, to z. B. to influence the brittleness of the support structure in specific areas.

The setting of the support structure in vibration and the design of the support structure can be carried out in such a way that a specific frequency or a specific frequency band and / or a specific amplitude or a specific amplitude range is tuned so that the vibrating element is excited to vibrate. In this case, for example, a coordination can take place in such a way that an excitation coordinated to the natural frequency of the support structure, in particular of the oscillating element, takes place through the oscillation.

In an advantageous embodiment, it can be provided, for example, that the support structure comprises at least one first support element group that supports the three-dimensional object against a first support location and the support structure comprises a second support element group that supports the three-dimensional object against a second support location, the support element groups being different are designed so that during the action of the separating means, at least in sections, in particular completely, the first support element group at least in sections, in particular completely, from the three-dimensional object and / or from the first support location at least in sections, in particular completely, prior to the separation of the at least one further support element group , separates from the three-dimensional object and / or the second support location. It can thus be achieved that different groups of support elements can be separated selectively with a time offset.

For example, the separating means has a first and at least one further separating element, the separating elements being movable independently of one another and / or in a predefined manner dependent on one another. A first release agent can be activated via a first point of application and a further release agent can be activated via a further point of application. In this way, the respective separating elements can optionally be separated or released at any point in time or at the same time.

In other words, the breaking behavior or breaking of at least two, in particular several, supporting elements initiated by the separating means can be set differently such that breaking or separating of the supporting elements takes place in a predefined sequence or depending on initiations carried out separately from one another. One or each group of support elements can comprise at least one support element, preferably at least two support elements, particularly preferably a multiplicity of support elements.

It is possible that the support structure comprises at least one first support element group comprising at least one first support element, wherein the first support element group supports the three-dimensional object against a first support location and a further support element group comprising at least one further support element supports the three-dimensional object against a second support location, wherein the at least one first support element of the first support element group is so different from the at least one further support element of the further support element group that during the action of the separating means on the support structure for at least partial separation, the at least one first support element of the first support element group breaks or is separated and the at least one further support element of the further support element group does not break during the action of the separating agent on the support structure. In other words, the further support element is not separated from the three-dimensional object or the support location by the action of the separating means in a first movement phase or at a first force value, or is separated in time, but by a different mechanical action or by a second movement phase of the separating means and / or by a second force value of the separating means, which has a higher force value than the first force value.

Different mechanical effects can also be provided, these different mechanical effects such. B. a machining (z. B. sawing) or non-machining or action (z. B. bending) of the three-dimensional object. The different separation mechanisms for different support elements have the advantage that, due to different separation mechanisms or separation principles, depending on the application of the respective separation mechanism or separation principle, they enable a specific area-dependent separation. For example, after using a first separation mechanism, a different type of separation of the at least one further support element can take place in a subsequent step. The defined position and / or alignment of the object relative to the support location leads to better manageability of the partially separated object.

The action of the release agent on the support structure can be carried out, for example, while the three-dimensional object is located within the additive manufacturing device in which the three-dimensional object was produced. For this purpose, the additive manufacturing device can be a A manipulator unit which makes it possible, in particular in a targeted manner, to contact or move areas actuating the separating means in a defined manner.

It can prove to be advantageous if, after the construction of the three-dimensional object in the additive manufacturing device, the three-dimensional object with the support structure is at least partially removed from the additive manufacturing device and fed or transferred to a processing device, the support structure at least in sections in or on the processing device , in particular completely, is separated or can be separated at least in sections, in particular completely, from the three-dimensional object and / or from the support location under the action of the separating agent.

In addition to causing the support structure to vibrate, the processing device can, for example, also carry out further upstream and / or downstream steps. The processing device can thus carry out a processing step processing the surface of the three-dimensional object, a coating step coating the surface of the object and / or a packaging step packaging the three-dimensional object. For example, the three-dimensional object with a carrier plate (also referred to as substrate plate) built up in the additive manufacturing process is removed from the additive manufacturing device and fed to the processing device. Here, the carrier plate can, for. B. serve to temporarily fix the three-dimensional object in the processing device.

It is possible that during gripping, in particular by gripping, an assembly consisting or formed of at least one three-dimensional object and a support structure by means of a gripping device is used to separate the support structure from the three-dimensional object and / or from the support location. In particular, the gripper acts on the separating means, so that a separation of the support structure from the three-dimensional object and / or from the support location takes place or can be carried out or is carried out. In other words, the gripper acts on the separating means in such a way that it separates the support structure from the three-dimensional object and / or from the support location.

For this purpose, the gripper can have an actuator, e.g. B. an extendable stamp which interacts directly or indirectly with the release agent or touches it and / or pushes or moves it. The separating means can thus be actuated by appropriate control of the gripper and thus the separating process, which can be carried out at least in sections, in particular completely, via the separating means to separate the three-dimensional object from the support structure and / or from the support location can be carried out by activating the gripper. Thus, at least in sections, in particular completely, the support structure can be separated from the three-dimensional object and / or from the support location and thus at least in sections, in particular completely, the building structure can be isolated or the actual three-dimensional object can be brought into its target geometry.

In addition to the method for additive manufacturing of a three-dimensional object, the invention also relates to a support structure for supporting a three-dimensional object described herein from a support location, the support structure being designed such that the support structure can be separated from a support location by the action of a separating agent. The invention also relates to a three-dimensional object, in particular a vehicle component, produced using a method described herein for the additive production of a three-dimensional object.

All advantages, details, designs and / or features of the method according to the invention can be transferred or applied to the support structure according to the invention and / or to the three-dimensional object according to the invention.

• 1 eine Prinzipdarstellung einer Baugruppe bestehend aus einem dreidimensionalen Objekt, einer Stützstruktur und einem Abstützort im verbundenen Zustand gemäß einem Ausführungsbeispiel;
• 2 eine Prinzipdarstellung einer Baugruppe gemäß 1 in einem Zustand, in welchem das dreidimensionale Objekt von der Stützstruktur und von dem Abstützort abgetrennt ist;
• 3 eine Prinzipdarstellung einer Baugruppe bestehend aus einem dreidimensionalen Objekt, einer Stützstruktur und einem Abstützort im verbundenen Zustand gemäß einem Ausführungsbeispiel;
• 4 eine Prinzipdarstellung einer Baugruppe gemäß 3 in welchem das dreidimensionale Objekt von der Stützstruktur und von dem Abstützort abgetrennten ist;
• 5 eine Prinzipdarstellung eines Anschlussmittels, bzw. einer Fluidzuführvorrichtung, und einer Baugruppe bestehend aus einem dreidimensionalen Objekt, einer Stützstruktur und einem Abstützort;
• 6 eine Prinzipdarstellung einer an eine Baugruppe gemäß 5 angesetzte Fluidzuführvorrichtung ;
• 7 eine Prinzipdarstellung einer Stützstruktur und innerhalb der Stützstruktur beweglich angeordneter Übertragungselemente.

The invention is explained in more detail using exemplary embodiments in the drawings. It shows:

• 1 a schematic representation of an assembly consisting of a three-dimensional object, a support structure and a support location in the connected state according to an embodiment;
• 2 a schematic diagram of an assembly according to 1 in a state in which the three-dimensional object is separated from the support structure and from the support location;
• 3rd a schematic representation of an assembly consisting of a three-dimensional object, a support structure and a support location in the connected state according to an embodiment;
• 4th a schematic diagram of an assembly according to 3rd in which the three-dimensional object is separated from the support structure and from the support location;
• 5 a schematic diagram of a connection means, or a fluid supply device, and an assembly consisting of a three-dimensional object, a support structure and a support location;
• 6th a schematic representation of a to an assembly according to 5 attached fluid supply device;
• 7th a schematic representation of a support structure and within the support structure movably arranged transmission elements.

In the following figures, the method is described by way of example using a digital light synthesis method (DLS method) using a building material in powder form and made of plastic. That for the formation of the three-dimensional object 1 , 1' The underlying additive manufacturing process can be any additive manufacturing process that uses plastic and / or metal and / or resin as a building material.

1 shows two three-dimensional objects created in an additive manufacturing process 1 , 1' , particularly vehicle components that are used in an additive manufacturing device 2 were produced by successive selective solidification of a, in particular powdery, building material. Below is at least one three-dimensional object 1 , 1' Referred to, in which in the 1 to 4th embodiment shown on a support structure 3rd and at a support location 4th exemplary two three-dimensional object 1 , 1' be supported. In the process, a support structure is built up 3rd during the additive manufacturing of the at least one three-dimensional object 1 , 1' , the support structure 3rd the three-dimensional object 1 , 1' at least in sections to a support location 4th supports. The support location 4th can - as shown - also at least in sections directly the three-dimensional object 1 , 1' prop up.

In the 1 to 4th is a base plate 5 or a base platform of the manufacturing device 2 shown. Alternatively, this can be done in 1 as a base plate 5 the manufacturing device 2 element also shown as one on the base plate 5 the manufacturing device 2 built-up support element 6th (e.g. as a carrier plate), this optional version is shown with a dashed reference line.

Alternatively or additionally, the support location 4th be designed as a support area of a further, additively with built-up three-dimensional object (not shown). It can be provided that a three-dimensional object 1 , 1' at different support locations 4th is supported, d. h z. B. that a three-dimensional object 1 , 1' on the carrier element 6th and at the same time is supported on a further three-dimensional object (not shown).

After the additive manufacturing of the three-dimensional object 1 , 1' the support structure is separated at least in sections 3rd from the three-dimensional object 1 and / or from the support location 4th . Here, for example, the three-dimensional object can be separated at least in sections 1 , 1' from the support location 4th respectively. Separating the support structure at least in sections 3rd or the three-dimensional object 1 , 1' takes place by means of a release agent 30th which directly or indirectly affect the support structure 3rd acts so that it differs from the three-dimensional object 1 , 1' and / or from the support location 4th separates.

The support structure 3rd is with at least one predefined breaking point 10 , 10 ' provided, during the action of the release agent 30th the predetermined breaking point 10 , 10 ' breaks up or separates, so that afterwards the three-dimensional object 1 at least in sections separated from the support structure 3rd and / or separate from the support location 4th is present.

The release agent 30th can at least partially, in particular completely, with the support structure 3rd have been built with. This allows the release agent 30th at least in sections in an additive manufacturing process together with the support structure 3rd and the three-dimensional object 1 , 1' have been built with.

The release agent 30th can at least one transmission medium 31 , in particular a pulling and / or pushing body, which by an at an introduction area 32 initiated introductory force 33 , in particular an initial tensile and / or initial compressive force, is applied in such a way that by direct or indirect action of the transmission means 31 , in particular of the tension and / or pressure body, on the support structure 3rd this from the three-dimensional object ( 1 ) and / or from the support location ( 4th , 20th ) is separated. In the in the 1 and 2 The embodiment shown comprises the transmission means 31 a first and a second transmission element 34 , 35 that are so moveable within a storage structure 36 the support structure 3rd are stored so that they have an introductory force upon contact 33 on an introductory area 32 bringing in pen 37 or an introduction means at least one, in particular radially outwardly directed, evasive movement 38 , 38 ' executes. Through this evasive movement 38 , 38 ' For example, a compressive force can be exerted on the support structure 3rd facing surface of the three-dimensional object 1 , 1' be applied, which is a break of the three-dimensional object 1 , 1' with the support structure 3rd connecting predetermined breaking points 10 , 10 ' evokes. This allows the three-dimensional object 1 , 1' from the support structure 3rd and / or from the support location 4th be separated.

The release agent 30th can for example be a connection area 39 include to the one Connection means 40 , in particular a fluid guide device or a fluid feed device, can be connected at least temporarily in such a way that in the connected state of the connection means 40 a liquid and / or gaseous medium 41 from the connection means 40 via the connection area 39 into a media receiving area 42 , in particular a media receiving channel, of the release agent 30th can be brought in. The media receiving area preferably extends 42 from a connection area 39 up to a separation point 43 , 43 ' , 43 '' or up to a predetermined breaking point 10 , 10 ' the support structure 3rd on which or on which the support structure 3rd from the three-dimensional object 1 and / or from a support location 4th is separable or will be separated. The ones in the 5 and 6th media receiving areas shown 42 form part of the support structure 3rd so that at this the at least one three-dimensional object 1 , 1' (in 5 and 6th not shown) are supported. By breaking open the media receiving area 42 at a separation point 43 , 43 ' , 43 '' can the three-dimensional object 1 , 1' from the support location 4th be separated.

The liquid and / or gaseous medium 41 can have a dissolving, ie, at least partially decomposing, effect on the support structure 3rd have so the support structure 3rd is changed in its strength and / or rigidity properties at least in sections, in particular weakened. This change or weakening can lead to a different behavior of the support structure 3rd lead, which is the cause of the breakage of the predetermined breaking point 10 , 10 ' or a target resolution point of the support structure 3rd can be.

Alternatively or additionally, the gaseous and / or liquid medium can 41 can be used to transmit a compressive force, in particular a pulse, with the action of this compressive force breaking the predetermined breaking point 10 , 10 ' is executable or is being executed. Here, the media receiving area 42 be designed such that the predetermined breaking point 10 , 10 ' for example directly to the media receiving area 42 adjoins and with a defined pressurization of the medium 41 or the fluid, a targeted material failure or a targeted material weakening at the predetermined breaking point 10 , 10 ' is caused.

The means of transmission 31 can, for example, consist of at least two, at least temporarily and / or at least in sections relatively movable transmission elements 34 , 35 exist, whereby during the action of the introductory force 33 the at least two transmission elements 34 , 35 execute a movement relative to one another, preferably the two transmission elements lead 34 , 35 to each other a linear and / or rotary movement. According to the 1 and 2 embodiment shown, the transmission elements 34 , 35 , provided that this is a predominantly stiff or completely stiff material behavior during the breaking of the predetermined breaking points 10 , 10 ' assumed a linear evasive movement 38 , 38 ' To run. On the other hand, at least areas of the 3rd and 4th transmission elements shown 34 , 35 a rotational movement performed relative to one another.

Here, during the movement of the at least one transmission element 34 , 35 , especially during the movement of all transmission elements 34 , 35 , the at least one transmission element 34 , 35 or all transmission elements 34 , 35 at least in sections, in particular completely, a (a) by means of a guide region arranged on the separating agent side 43 , 43 ' , 43 '' (see. 1 and 2 and / or (b) by means of one with at least one further transmission element 34 , 35 and / or a three-dimensional object 1 , 1' and / or a support location 4th actively connected joint 44 , 44 ' (see. 3rd and 4th ), perform a defined, in particular guided or steered movement.

During the movement of at least one transmission element 34 A further transmission element can move in a first direction of movement 35 be moved in a second direction of movement different from the first direction of movement. The first transmission element preferably acts 34 as a movement initiator on the at least one further transmission element 35 , 45 the at least one further transmission element is particularly preferred 35 , 45 by contact with the first moving transmission element 34 set in motion, cf. 7th . This becomes the further transmission medium 35 against a three-dimensional object 1' pressed and pushes this so from the support structure 3rd away that at the predetermined breaking point 10 a break occurs, so that the three-dimensional object 1' from the connecting web of the support structure 3rd solves and is thus released. Alternatively or additionally, the three-dimensional object 1 , 1' also directly with a support location 4th be connected, this connection also being carried out by the transmission element 35 the three-dimensional object 1' imposed movement is broken away.

The support structure 3rd can comprise at least one oscillating element (not shown) which is embodied to oscillate and which, when the support structure is set oscillating at least in sections 3rd vibrates in such a way, in particular is excited in such a way that at least one predefined predetermined breaking point, in particular formed adjacent to the vibrating element 10 , 10 ' due to the vibrating of the support structure 3rd breaks or at least becomes weakened. The targeted breaking of the Predetermined breaking point 10 , 10 ' the vibration can thus, at least in sections, partly through a fatigue fracture using a vibrating element and partly through the use of a separating means described herein 30th respectively.

The support structure 3rd may comprise at least a first support element group which the three-dimensional object 1 , 1' compared to a first support location 4th and a second group of support elements comprise the three-dimensional object 1 , 1' compared to a second support location 4th supported, the support element groups can be designed differently in such a way that during the action of the separating agent 30th at least in sections, in particular completely, the first support element group at least in sections, in particular completely, from the three-dimensional object 1 , 1' and / or first support location 4th temporally before the separation of the at least one further support element group, at least in sections, in particular completely, from the three-dimensional object 1 , 1' and / or the second support location 4th separates. In other words, at least one release agent can do this 30th be designed in such a way that while it is acting, for example while it is moving, initially a first three-dimensional object 1 from the support structure 3rd is separated or released and only in the further course of the movement of the release agent 30th the further three-dimensional object 1' from the support structure 3rd is separated or solved. In this way, a defined sequence can be achieved during the separation of the assembly.

Analogously to this, a property of the release agent that dissolves or chemically weakens the support structure at least in sections, in particular completely, can act in such a way that initially a defined first area of the support structure 3rd is dissolved or weakened and only in the further course of time or afterwards a second area of the support structure 3rd is dissolved or weakened. This allows a defined sequence of the separating, in particular dissolving or weakening areas of the support structure 3rd can be achieved. In this way it can also be achieved that a first three-dimensional object 1 defined in front of another three-dimensional object 1' from the support structure 3rd is separated.

The action of the release agent 30th on the support structure 3rd For example, can be run while the three-dimensional object 1 , 1' within the additive manufacturing device 2 in which the three-dimensional object 1 , 1' was established. Here, the additive manufacturing device 2 for example, a manipulator (not shown), which a targeted contacting or a targeted manipulation of the release agent 30th can perform. For example, an in or on or near the additive manufacturing device 2 arranged manipulator on a contact element, which specifically, in particular automated, controlled in contact with the release agent 30th can be moved, the action of the release agent through the contact element 30th on the support structure 3rd he follows.

Alternatively or additionally it can be provided that after the construction of the three-dimensional object 1 , 1' in the additive manufacturing device 2 the three-dimensional object 1 , 1' at least partially with the support structure 3rd from the additive manufacturing device 2 is removed and fed to a processing device (not shown), the support structure in or on the processing device 3rd under the action of the release agent 30th from the three-dimensional object 1 and / or from the support location 4th is at least partially, in particular completely, separated. The processing device can thus comprise a manipulator, for example a robot, which is suitable for targeted manipulation of the release agent 30th execute, in particular to enable a defined movement of a release agent component and / or a supply of a liquid or gaseous medium.

During a gripping, in particular by a gripping, one of at least one three-dimensional object 1 , 1' and a support structure 3rd existing assembly by means of a gripping device (not shown) the support structure 3rd for example from the three-dimensional object 1 and / or from the support location 4th are separated, in particular the gripper (not shown) of a gripping device acts on the separating means 30th indirectly or directly, so that this separates the support structure 3rd from the three-dimensional object 1 , 1' and / or from the support location 4th can be done. The gripper can form part of a manipulator mentioned above, in particular a robot. The support structure 3rd and / or the support location 4th , in particular the construction platform, can provide a gripping area (not shown) which has a geometry and / or dimensions that can be gripped by a gripper, whereby by changing the type of gripping, i.e. e.g. by changing an applied gripping force (force of the tongs ) and / or by changing a defined contact surface or gripping surface, the separation of the support structure 3rd through the release agent 30th can be achieved in a targeted manner.

The additive process for manufacturing the three-dimensional object 1 , 1' and thus optionally also the additive process for manufacturing the support structure 3rd and / or to produce the support location 4th For example, a stereolithography process (SL), a laser sintering process (LS), a Laser beam melting process (LBM), in particular a selective laser melting process (SLM), an electron beam melting process (EBM), a fused layer modeling / manufacturing process (FLM / FFF), a multi-jet modeling process (MJM), a poly-jet Modeling process (PJM), a binder jetting process, a layer laminated manufacturing process (LLM), a digital light processing process (DLP), a digital light synthesis process (DLS) and / or a thermal transfer sintering process Procedure (TTS).

The invention also relates to a support structure 3rd for supporting a three-dimensional object produced according to one of the preceding claims 1 , 1' from a support location 4th , the support structure 3rd is designed such that the support structure 3rd by the action of a release agent 30th from a support location 4th and / or from the three-dimensional object 1 , 1' is separable.

The invention also relates to a three-dimensional object 1 , 1' , in particular a vehicle component which was produced in a method described herein.

List of reference symbols

1, 1 '

three-dimensional object

2

Manufacturing device

3

Support structure

4th

Support location

5

Base plate

6th

Carrier plate

10

Predetermined breaking point

30th

Release agent

31

Means of transmission

32

Introductory area

33

Introductory force

34

first transmission element

35

second transmission element

36

Storage structure

37

pen

38, 38 '

Evasive movement

39

Connection area

40

Connection means

41

medium

42

Media receiving area

43, 43 ', 43 "

Leadership area

44, 44 '

joint

QUOTES INCLUDED IN THE DESCRIPTION

This list of the documents listed by the applicant was generated automatically and is included solely for the better information of the reader. The list is not part of the German patent or utility model application. The DPMA assumes no liability for any errors or omissions.

Patent literature cited

• EP 1358855 A1 [0002]

Claims (15)

Method for the additive manufacture of a three-dimensional object (1, 1 '), in particular a vehicle component, in an additive manufacturing device (2) by successive selective solidification of a, in particular powdery, building material to form the three-dimensional object (1, 1'), comprising the following method steps - Building up a support structure (3) during the additive production of the three-dimensional object (1, 1 ') which supports the three-dimensional object (1, 1') at least in sections at a support location (4), - at least in sections separating the support structure (3) from the three-dimensional object (1, 1 ') and / or from the support location (4) after the additive manufacture of the three-dimensional object (1, 1'), characterized in that the at least section-wise separation of the support structure (3) by means of a separating agent ( 30) takes place, which acts directly or indirectly on the support structure (3), so that it differs from the three-dimensional object kt (1, 1 ') and / or separates from the support location (4). Procedure according to Claim 1 , characterized in that the support structure (3) is provided with at least one predefined predetermined breaking point (10) and during the action of the separating agent (30) the predetermined breaking point (10) breaks at least in sections, in particular completely, preferably the separating agent (30) is at least in sections, in particular completely, with the support structure (3) built up. Procedure according to Claim 1 or 2 , characterized in that the separating means (30) comprises a transmission means (31), in particular at least one pulling and / or pushing body, which is activated by an introducing force (33), in particular an introducing pulling and / or Introducing pressure force is applied so that by direct or indirect action of the transmission means (31), in particular the tension and / or pressure body, on the support structure (3) it is removed from the three-dimensional object (1, 1 ') and / or from the support location ( 4) is separated. Procedure according to Claim 3 , characterized in that the separating means (30) comprises a connection area (39) to which a connection means (40) is connected at least temporarily, with a liquid and / or gaseous medium from the connection means (40) in the connected state of the connection means (39) ) via the connection area (39) into a media receiving area (42), in particular a media receiving channel, of the separating agent (30), preferably the media receiving area (42) extends from a connection area (39) to a separation point (4) of the support structure ( 3), on which the support structure (3) is separated from the three-dimensional object (1, 1 ') and / or a support location (4). Procedure according to Claim 3 or 4th , characterized in that the transmission means (31) consists of at least two, at least temporarily and / or at least in sections relatively movable transmission elements (34, 35) and during the action of the introduction force (33) the at least two transmission elements (34, 35) one Carry out a relative movement to one another, preferably the two transmission elements (34, 35) carry out a linear and / or rotary movement to one another. Procedure according to Claim 5 , characterized in that during the movement of the at least one transmission element (34, 35), in particular all of the transmission elements (34, 35), this guides at least in sections, in particular completely, one - by means of a guide region (43, 43 ', 43 "arranged on the separating agent side) ) and / or - by means of at least one joint (44, 44 ') operatively connected to at least one further transmission element (35) and / or a three-dimensional (object 1,1') and / or a support location (4), a defined, in particular guided or directed, movement from. Procedure according to Claim 5 or 6th , characterized in that during the movement of at least one first transmission element (34) in a first direction of movement, a further transmission element (35) is moved in a second direction of movement different from the first direction of movement, the first transmission element (34) preferably acts as a movement initiator on the further transmission element (35), particularly preferably the further transmission element (35) is set in motion by contact with the first moving transmission element (34). The method as claimed in one of the preceding claims, characterized in that the support structure (3) comprises at least one oscillating element which is designed to be oscillatable and which oscillates, in particular is excited, when the support structure (3) is set in motion, so that at least one predefined, in particular formed adjacent to the oscillating element , Predetermined breaking point (10, 10 ') breaks and / or is weakened at least in sections due to the setting in vibration of the support structure (3). Method according to one of the preceding claims, characterized in that the support structure (3) comprises at least one first support element group which supports the three-dimensional object (1, 1 ') in relation to a first support location (4) and the support structure (3) comprises a second support element group which supports the three-dimensional object (1, 1 ') against a second support location (4), the support element groups being designed differently so that at least in sections, in particular completely, during the action of the separating agent (30) , the first support element group at least partially, in particular completely, from the three-dimensional object (1, 1 ') and / or from a first support location (4) at least partially, in particular completely, from the three-dimensional object prior to the separation of the at least one further support element group (1, 1 ') and / or the second support location (4) separates. Method according to one of the preceding claims, characterized in that the action of the separating agent (30) on the support structure (3) is carried out while the three-dimensional object (1, 1 ') within the additive manufacturing device (2) in which the three-dimensional Object (1, 1 ') is located. Method according to one of the preceding claims, characterized in that after the construction of the three-dimensional object (1, 1 ') in the additive manufacturing device (2), the three-dimensional object (1, 1') at least partially with the support structure (3) from the additive Production device (2) is removed and fed to a processing device, the support structure (3) in or on the processing device, at least in sections, in particular completely, from the three-dimensional object (1, 1 ') and / or from the Support location (4) is at least partially, in particular completely, separated. Method according to one of the preceding claims, characterized in that during a gripping, in particular by gripping, an assembly consisting of at least one three-dimensional object (1, 1 ') and a support structure (3) by means of a gripping device, the support structure (3) from the three-dimensional object (1, 1 ') and / or is separated from the support location (4), in particular the gripper acts on the separating means (30), so that through this the support structure (3) is separated from the three-dimensional object (1, 1') and / or is separated from the support location (4). Method according to one of the preceding claims, characterized in that the additive method for producing the three-dimensional object (1, 1 ') is a stereolithography method (SL), a laser sintering method (LS), a laser beam melting method (LBM) , in particular a selective laser melting process (SLM), an electron beam melting process (EBM), a fused layer modeling / manufacturing process (FLM / FFF), a multi-jet modeling process (MJM), a poly-jet modeling process (PJM) , a binder jetting process, a layer laminated manufacturing process (LLM), a digital light processing process (DLP), a thermal transfer sintering process (TTS), a digital light processing process (DLP) and / or a Digital Light Synthesis Process (DLS) is. Support structure (3) for supporting a three-dimensional object (1, 1 ') produced according to one of the preceding claims from a support location (4), the support structure (3) being designed in such a way that the support structure (3) is released by the action of a separating agent (30 ) can be separated from a support location (4) and / or from the three-dimensional object (1, 1 '). Three-dimensional object (1, 1 '), in particular a vehicle component, produced in a method according to one of the Claims 1 to 13th .

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