DE212022000273U1 - Additive manufacturing plant with binder jetting process - Google Patents

Abstract

Additive manufacturing device using binder jetting process, characterized in that it comprises:
- a powder feeding system which ensures that the powders to be fed and produced are stored in the chambers and used in dimensions suitable for processing,
- a powder distribution system (1) which enables the powder delivered by the powder feed system to be distributed in the thickness of a layer on the production platform (2),
- a jetting system (3) which allows the binder to be distributed onto the powder raw material after its distribution,
- a curing system (4) which ensures the curing of the binder added to the powder raw material from the jetting system (3) and which ensures that the powder raw material and the binder remain together,
- a subordinate control system that ensures the application of the amount of powder raw material, the type of binder and the type of binder distribution, the implementation of the curing with UV and/or infrared heating and the application of all parameters, such as the appropriate motor speed, according to the powder raw material of the device.

Description

Technical area

The present invention relates to an equipment design using the Binder Jetting Additive Manufacturing Method (BJAM), which is one of the additive manufacturing methods; refers to changing all parameters of the equipment consisting of the powder distribution system, the powder feeding and preparation system, the curing system, the jetting system, the binders and the control subsystem.

The present invention relates to the fact that the equipment design or device using the Binder Jetting Additive Manufacturing (BJAM) process can pre-cure by both UV and infrared heating and that it can harmonize with various binders.

State of the art

Additive manufacturing involves combining metals, ceramics, polymers and similar materials layer by layer to form three-dimensional parts using a suitable energy/binding source. Additive manufacturing technology itself encompasses various processes. Today, Binder Jetting Additive Manufacturing (BJAM) is generally used for parts such as pumps, turbines, heat exchangers, filter systems, powertrains, some prosthetics, etc. The BJAM process is generally preferred in these fields as it provides the parts with corrosion resistance, high wear resistance and strength. Compared to other metal additive manufacturing processes, it is a much faster and less expensive manufacturing process. Additive manufacturing is defined as manufacturing an object layer by layer. Various processes and technologies are used to produce the layers. Well-known additive manufacturing technologies work with many processes. The equipment used in the state of the art has disadvantages such as high costs for producing 3D parts, production of parts from a single type of material, low production speed, deformations due to high residual stresses in the manufactured parts and high workbench costs.

Material systems and methods for three-dimensional printing are disclosed in the prior art with patent number US7087109B2 described. The invention represents the final product with an inkjet structure. It uses the technology of interactive 3D printing with powder/binder. It has a print head and a cylinder powder application system and works with a single binder. The method involves generating cross-sections of a three-dimensional object and assembling individual cross-sectional sections layer by layer to form a final object. Individual cross-sectional sections are formed using an inkjet print head by applying an aqueous liquid to a particulate material comprising a first particulate material, a second particulate material and a third particulate material. The first and second particulate materials react. The presence of the liquid over a period of time causes the third particulate material to react in the presence of the liquid to form a solid over a longer period of time, thereby creating the structure.

Three-dimensional printing processes are described in the document with the number US5387380A from the prior art. The invention relates to the production of the final product from a powdered starting material with a binder. The method according to the invention consists in using an inkjet printer and employing the technology of three-dimensional printing with binders. The parameters of the product used cannot be changed product-specifically. It comprises the process steps for producing a component by applying a first layer of a powder material in a limited area and then applying a binder in selected areas of the powder material layer to create a bonded powder material layer in selected areas. These steps are repeated a certain number of times to create successive layers of selected areas of powder material that are bonded to form the desired component. Unbound powder material is then removed. In some cases, the processability of the component is improved, e.g. by heating to further strengthen the bond.

Methods for infiltration of a metal powder skeleton by a similar alloy with reduced melting point are described in document number US6719948B2 from the prior art. Products formed from multiple cement layers are described. Solid free-form productions of three-dimensional objects are described. It includes calcium, aluminate particles and polymeric binder particles. It includes the processes of dispersing the liquid containing an aqueous polyol in the mixing zone and hardening the hydrated cement. The raw materials used are different; the binder types have the property of using UV-curable binders.

Procedures for finishing ceramic moulds are described in the document number US6109332A described in the prior art. It is a method of smoothing and otherwise altering the surfaces of porous bodies, such as ceramic molds, which are manufactured using layer-building techniques such as three-dimensional printing. The surface finish of the mold can be smoothed by pouring a slip of fine particles onto the surface to form a generally flat and preferably non-conforming coating on the surfaces. Generally, the fine particles of the slip are filtered out of the liquid so that the fine particles remain at or near the surface of the molded body. The goal is to omit the surface coating of the mold. It is a mold casting process that includes ceramic coating processes using layer-building techniques. Metal powders and binders are not used and different raw materials are processed for this purpose.

A method for powder distribution in binder jetting for additive manufacturing is described in the document number US2018304367A1 described in the prior art. It is a powder distributor for additive manufacturing with binder jetting. It consists of normal and vibrating powder distributors and leads to a better distribution of the powder. It has a device for binder jetting additive manufacturing with an impeller-like powder distributor with multiple rollers. The roller powder distributor enables the distribution of the powder. It has different processing and working principles with a top powder feed system, a powder distributor with a plurality of rollers and powder distribution in different directions. The device, systems and methods are used to distribute the powder to facilitate proper layer-by-layer manufacturing of three-dimensional objects created using binder jetting. As the distributor is moved across the volume, it creates a vibration so that the powder inside the volume of the distributor is compacted and this vibration is applied to the powder in layers to improve the density of the resulting three-dimensional object formed by the binder jetting process.

Additive manufacturing with multidirectional binder ejection (BJAM) is described in the document with the number US20210283693A1 which is prior art. It is based on the operation of multiple powder distributors in different directions using multidirectional binder jetting additive manufacturing. It uses a powder distributor with multiple roller channels and is a binder jetting additive manufacturing device that can be operated in different directions. It is distinguished by its top powder feed, its multiple and channel powder distributor and its ability to distribute powder in different directions. It does not have a roller powder distributor. The prior art devices, systems and methods relate to powder distribution and binder jetting processes for the proper and rapid layer-by-layer production of three-dimensional objects formed by binder jetting. Powder distribution, powder dispersion, thermal energy release and their combinations aim to increase the production rate of the three-dimensional object.

An additive manufacturing process and device for carrying out the additive manufacturing process is described in the document with the number WO2016019939A1 described in the prior art. In an additive manufacturing process, powder layers are formed in parts and then powder is removed from the layer in certain areas, thereby contouring the layer. Finally, the layer is fixed. To carry out an additive manufacturing process, a device is used that includes a support surface, a powder remover and a stabilizer to carry out the processes. A metal powder is used for this, which can be removed with a magnet. The powder can be reapplied later. Powder is then removed again in specific areas and then sintered. In this way, a three-dimensional object is produced layer by layer.

The method and apparatus for producing additive material from mineral powder is described in the document number CN106272881A from the prior art. It relates to an additive manufacturing method and a manufacturing apparatus in the field of additive manufacturing technology. It aims to provide a method and an apparatus for additive manufacturing using mineral powder. As the mineral powder, one or two or more types such as gypsum powder, zircon sand, quartz sand, marble sand or mica sand can be used. The binder is a water glass solution and diacetin is used as the catalyst. It uses the additive manufacturing of mineral powder and further develops the conventional method of additive manufacturing of powder, but the raw materials and binders are different.

The manufacturing process with metal part additives and the associated equipment are described in the document with the number CN109550959A from the prior art. A method for additive manufacturing and sintering of metal powders, in particular for the direct production of metal parts based on an additive manufacturing process, is described. The method is carried out by entering the three-dimensional model data of a component into the control system of a 3D printing device, creating a control command for the print head and generating the planned path of the work platform. The mixed materials of metal powder with rheological properties and the binder are sprayed from a print head. After heating the mixture to a sintering temperature below the melting point of the metal powder by means of a heat source and evaporating and degreasing the binder, the sintering of the metal powder is continued until the part has taken its shape. The sintering temperature is set lower than the melting point of the metal.

An automatic process control of a device for additive manufacturing is described in the document with the number US2015045928A1 from the prior art. It is designed to reduce the number of tools a user must use to control an additive manufacturing system by providing a single unified interface to inspect potential operations, to remotely monitor operations in real time, and to collect and evaluate process feedback during and after an operation. In addition, the system uses advanced computer vision and machine learning algorithms to automate processes for detecting and correcting system errors and inaccuracies and to enable tolerance control without user intervention.

Method and apparatus for additive manufacturing using filament modelling are described in the document number US2017274585A1 from the prior art. Fiber composite materials are used. The filament made of the fiber composite material is softened and then straightened and shaped by increasing the degree of stretching. Since the filament material according to the invention is not completely melted, the resin does not flow out of the carbon fiber. Therefore, the wetting loss that occurs during complete melting is prevented.

Object of the invention

The main objective of the present invention is to ensure the production of parts with different binders without being stuck to a single binder, by making the necessary measurements for the required powders through the use of a software with a subsystem for controlling all the parameters of the device with the Binder Jetting Additive Manufacturing process and setting all the parameters (heat, light, motor speed, etc.) according to the powder and binder to be processed through the definition of the data set prepared by determining the parameters of the Binder Jetting device.

Another object of the invention is to optimize the system by finding the most suitable operating conditions of the system by using the parameters influencing the system for the coordinated operation of all systems in the device (dispensing, jetting, pre-curing, etc.).

Another object of the present invention is to ensure that the apparatus employing the binder jetting additive manufacturing process provides both UV and infrared heating processes in the pre-curing process performed by the curing system, thereby ensuring that, unlike the prior art, the dispersed or sprayed binder cures and holds the raw material powders together.

Another object of the present invention is to provide software control and electronic communication of the device by creating and entering data sets into the control subsystem so that all parameters of the device and the machine applying the BJAM method can be changed and aligned with different binding agents.

Another object of the present invention is to disclose a self-rotating roller powder distributor that enables the powder in the powder feed chamber in the lower powder feed system to be distributed layer by layer onto the manufacturing platform.

Another aim of the present invention is to ensure that the device is ready for operation by extracting the optimal system parameters from the data memory, which ensure a harmonious functioning of the systems in the background by entering the criteria defined for production (layer thickness, binder type, etc.) into the corresponding the fields on the software screen.

• - ein Pulverzufuhrsystem, das dafür sorgt, dass die zuzuführenden und herzustellenden Pulver in den Kammern gelagert und in präzisen Abmessungen verwendet werden,
• - ein Pulververteilungssystem, das es ermöglicht, das vom Pulverzuführungssystem abgegebene Pulver in Dicke einer Schicht auf der Fertigungsplattform zu verteilen,
• - ein Ausstoßsystem (Jetting-System), das es ermöglicht, das Bindemittel in der für den Pulverrohstoff nach dessen Ausstoß geeigneten Geometrie und Menge auszustoßen,
• - wobei das Ausstoßsystem in Einklang mit jedem Bindemittel verwendet werden kann,
• - ein Aushärtesystem, das die Aushärtung des Bindemittels gewährleistet, das dem Pulverrohstoff aus dem Verteilsystem zugesetzt wird, und das dafür sorgt, dass der Pulverrohstoff und das Bindemittel zusammenbleiben,
• - ein untergeordnetes Steuersystem, das die Anwendung der Menge des Pulverrohstoffs, die Art des Bindemittels und die Art der Bindemittelverteilung, die Durchführung der Aushärtung mit UV- und/oder Infrarotheizen und die Anwendung aller Parameter wie die geeignete Motordrehzahl entsprechend dem Pulverrohstoff der Vorrichtung sicherstellt,
• - wobei das besagte untergeordnete Steuerungssystem für die Softwaresteuerung und die elektronische Kommunikation der Werkbank hinsichtlich der Definition der optimalen, als Ergebnis der Messungen erhaltenen Datensätze sorgt,
• - Druckkopf für die Verarbeitung mit UV-härtbaren und/oder durch Infrarotwärme gehärteten Bindemitteln aus dem Jetting-System.

The additive manufacturing device according to the invention with binder jetting method comprises the following:

• - a powder feeding system that ensures that the powders to be fed and produced are stored in the chambers and used in precise dimensions,
• - a powder distribution system that allows the powder delivered by the powder feed system to be distributed on the production platform in a layer thickness,
• - a jetting system that allows the binder to be ejected in the geometry and quantity appropriate for the powder raw material after its ejection,
• - the ejection system can be used in accordance with any binder,
• - a curing system that ensures the curing of the binder added to the powder raw material from the distribution system and that ensures that the powder raw material and the binder stay together,
• - a subordinate control system that ensures the application of the amount of powder raw material, the type of binder and the type of binder distribution, the implementation of the curing with UV and/or infrared heating and the application of all parameters such as the appropriate motor speed according to the powder raw material of the device,
• - said subordinate control system provides the software control and electronic communication of the workbench with regard to the definition of the optimal data sets obtained as a result of the measurements,
• - Print head for processing with UV-curable and/or infrared heat-cured binders from the jetting system.

A further object of the present invention is to ensure that the powder in the powder feed chamber is distributed layer by layer in the production chamber by means of a powder distribution system with a rotating roller in the device.

Another object of the present invention is to ensure that the binder is sprayed with a print head in the jetting system according to the layer shape of the 3D part previously determined with the aid of a cutting program after the distribution of each powder layer.

A further object of the present invention is to dry the binder sprayed onto the powder by means of a curing system and to ensure the adhesion of the powder and the binder to each other.

An object of the present invention is to provide additive manufacturing by repeating all steps over and over again until the three-dimensional part is obtained by repeating the powder distribution process after producing the first layer.

The structural and characteristic features of the present invention will be clearly understood from the following drawings and the detailed description made with reference to these drawings, and therefore the evaluation should be made in consideration of these figures and the detailed description.

Character description

• 1 is the general view of systems using the additive manufacturing device with the binder jetting method and the processes applied.

Description of reference symbols:

1

Powder distribution system

2

Manufacturing platform

3

Jetting system

4

Curing system

Detailed description of the invention

The apparatus for additive manufacturing using the binder jetting method comprises a powder distribution system (1), a manufacturing platform (2), a jetting system (3), a curing system (4), a powder feeding system and a control subsystem. In the apparatus for additive manufacturing using the binder jetting method, the general view of the manufacturing and systems in As shown, the powder is applied layer by layer to the production platform (2) in the powder feed system using a powder distribution system (1) with a rotating roller. After each powder layer has been distributed, the binder is sprayed on with a print head in the jetting system (3) according to the layer shape of the three-dimensional part determined using a cutting program. The binder sprayed onto the powder is then dried and the powder and the binder bond together using an intermediate curing system (4). The curing system (4) can accelerate the curing process using of UV or infrared heating. Then the process starts again from the beginning, the steps are repeated until the three-dimensional part is created, with the powder raw materials again distributed on the same part. In this way, all the layers are additively bonded together. The subordinate control system of the device that performs additive manufacturing by binder jetting ensures the application of the amount of powder raw material, the type of binder and the type of binder jetting, the implementation of the curing by UV and/or infrared heating and the application of all parameters, such as the appropriate motor speed, according to the powder raw material of the device.

The powder distribution system (1) allows the powder delivered by the powder feed system to be distributed on the manufacturing platform (2) in a layer thickness. The powder feed system ensures that the powders to be fed and produced are stored in the chambers and distributed on the manufacturing platform (2) by acting in precise dimensions. The curing system (4) ensures that the sprayed binder hardens by curing and holds the raw material powder together. The jetting system (3) ensures that the binder is sprayed onto the powdered raw material in a specific geometry with the help of the print head. The print head is configured to work with any type of binder. The print head is configured for both UV-curing and infrared heat-curing binders. The control subsystem provides software control and electronic communication of the workbench.

• - ein Pulverzuführsystem, das dafür sorgt, dass die zuzuführenden und herzustellenden Pulver in den Kammern gelagert und in präzisen Abmessungen verwendet werden,
• - ein Pulververteilsystem (1), das es ermöglicht, das aus dem Pulverzuführsystem austretende Pulver in einer Schichtdicke auf der Fertigungsplattform zu verteilen,
• - ein Jetting-System (3), das es ermöglicht, das Bindemittel nach dem Verteilen des pulverförmigen Rohstoffs in der für den Pulverrohstoff geeigneten Geometrie und Menge auszustoßen,
• - wobei das Sprühsystem (3) in Einklang mit jedem Bindemittel zusammenarbeiten kann,
• - ein Aushärtesystem (4), das die Aushärtung des dem pulverförmigen Rohstoff aus dem Jetting-System (3) hinzugefügten Bindemittels gewährleistet und dafür sorgt, dass dieser pulverförmige Rohstoff und das Bindemittel zusammenbleiben,
• - Steuerungs-Untersystem, das die Anwendung der Menge des pulverförmigen Rohstoffs, die Art des Bindemittels und die Art der Bindemittelverteilung, die Durchführung der Aushärtung mittels UV- und/oder Infrarotheizen und die Anwendung aller Parameter wie die geeignete Motordrehzahl entsprechend dem pulverförmigen Rohstoff der Vorrichtung sicherstellt,
• - das besagte Steuerungs-Untersystem sorgt für die Softwaresteuerung und elektronische Kommunikation der Werkbank in Hinsicht auf die Definition der optimalen Datensätze, die als Ergebnis der Messungen erhalten wurden,
• - Druckkopf für die Verarbeitung mit UV-härtbaren und/oder durch Infrarotwärme gehärteten Bindemitteln aus dem Jetting-System (3).

The device according to the invention for additive manufacturing using binder jetting processes comprises the following:

• - a powder feeding system that ensures that the powders to be fed and produced are stored in the chambers and used in precise dimensions,
• - a powder distribution system (1) which enables the powder emerging from the powder feed system to be distributed in a layer thickness on the production platform,
• - a jetting system (3) which enables the binder to be ejected after the powdered raw material has been distributed in the geometry and quantity appropriate for the powdered raw material,
• - the spray system (3) can work in harmony with any binder,
• - a curing system (4) which ensures the curing of the binder added to the powdered raw material from the jetting system (3) and ensures that this powdered raw material and the binder remain together,
• - Control subsystem that ensures the application of the amount of powdered raw material, the type of binder and the type of binder distribution, the implementation of the curing by means of UV and/or infrared heating and the application of all parameters such as the appropriate motor speed according to the powdered raw material of the device,
• - said control subsystem provides software control and electronic communication of the workbench with a view to defining the optimal data sets obtained as a result of the measurements,
• - Print head for processing with UV-curable and/or infrared heat-cured binders from the jetting system (3).

It should be ensured that all systems of the device, such as the powder distribution system (1), the jetting system (3), the curing system (4) and similar systems, are coordinated with each other to ensure manufacturing. Therefore, each system must first function and be optimized within itself. For example, it is necessary to optimize the motor speed of the powder distribution system (1) and the speed of the powder distribution system (1) in order to distribute the powder evenly and adequately. A data memory is created in which different motor speeds and distribution speeds are combined to find the optimal values. The optimal operating parameters are entered into the control subsystem after the parameters most suitable for manufacturing are determined in the data memory. In this way, the most suitable operating conditions for the system are created and entered into the control subsystem by using the parameters that optimally affect the system.

The optimum number of parameters is also specified as more than one because the number of parameters affecting the system is more than one. On the other hand, the criteria determined for production are generated similarly to the determination of the optimum values before starting production. Examples are the layer thickness, the binder type, the beam angle of the binder, the UV or infrared heating values to be used in the curing phase of the binder. These values are also entered into the software screen of the control subsystem. The software makes the device ready for production by taking the optimum system parameters from the data memory, which ensure the harmonious operation of the systems in the background according to the entered criteria.

QUOTES INCLUDED IN THE DESCRIPTION

This list of 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 accepts no liability for any errors or omissions.

Cited patent literature

• US 7087109 B2 [0004]
• US 5387380 A [0005]
• US 6719948 B2 [0006]
• US 6109332 A [0007]
• US 2018304367 A1 [0008]
• US 20210283693 A1 [0009]
• WO 2016019939 A1 [0010]
• CN106272881A [0011]
• CN109550959A [0012]
• US 2015045928 A1 [0013]
• US 2017274585 A1 [0014]

Claims (5)

Additive manufacturing device with binder jetting process, characterized in that it comprises: - a powder feeding system which ensures that the powders to be fed and produced are stored in the chambers and used in dimensions suitable for processing, - a powder distribution system (1) which enables the powder delivered by the powder feeding system to be distributed on the manufacturing platform (2) in the thickness of a layer, - a jetting system (3) which enables the binder to be distributed on the powder raw material after it has been distributed, - a curing system (4) which ensures the curing of the binder added to the powder raw material from the jetting system (3) and which ensures that the powder raw material and the binder remain together, - a subordinate control system which controls the application of the amount of powder raw material, the type of binder and the type of binder distribution, the implementation of the curing with UV and/or infrared heating and the application of all parameters, such as the appropriate Motor speed, according to the powder raw material of the device. Additive manufacturing device with binder jetting process according to Claim 1 , characterized in that it comprises: a subordinate control system for the software control and electronic communication of the workbench with regard to the definition of the optimal data sets obtained as a result of the measurements. Additive manufacturing device with binder jetting process according to Claim 1 or 2 , characterized in that it comprises the following: a print head for processing with UV-curable and/or infrared heat-cured binders from the jetting system (3). Additive manufacturing device with binder jetting process according to one of the preceding claims, characterized in that the curing system (4) works with both UV and infrared heating. Additive manufacturing apparatus with binder jetting method according to one of the preceding claims, characterized in that it comprises the following: the subordinate control system which enables the additive manufacturing apparatus with the binder jetting method to be designed for manufacturing using the measured and recorded optimal system parameters from the data storage.

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