EP4319952A1 - Method of additively manufacturing a component, load transfer element, reinforcement for use within a component, and actively manufactured component - Google Patents

Abstract

The invention relates to a method of additively manufacturing a component (1) from a building material (2), whereby a material output unit (3) deposits the building material (2) in layers along a defined print pathway (D). What is envisaged is that at least one load transfer element (7) extends into the print pathway (D). The material output unit (3) deposits the building material (2) onto the load transfer element (7) present in the print pathway (D), wherein a load transfer element (7') present in a movement pathway of the material output unit (3) is at least temporarily pushed out of the print pathway (D) by the material output unit (3) while the material output unit (3) deposits the building material (2) along the defined print pathway (D).

Description

Process for the additive manufacturing of a component. Load transfer element, reinforcement for use within a component and additively manufactured component

The present application claims the priority of German patent application no. 102021 108666.3, the content of which is incorporated herein by reference in its entirety.

The invention relates to a method for the additive manufacturing of a component from a building material, according to which a material dispensing unit separates the building material in layers, according to the preamble of claim 1.

The invention also relates to a computer program and an additively manufactured component.

Furthermore, the invention relates to a load transfer element according to the preamble of claim 22, and a reinforcement for use within a component, in particular within an additively manufactured component.

Methods for the additive manufacturing of three-dimensional objects are known for the manufacture of models, prototypes, tools and end products, for example. Starting materials in the form of liquids, powder or filaments made of thermoplastics are deposited by a print head attached to an end effector of an actuator device in order to build up the object layer by layer on the basis of 3D data of the object to be manufactured. Such a method is also referred to, among other things, as a “generative manufacturing method” or “3D printing”.

In the meantime it is also known to use additive manufacturing methods for the production of entire buildings or components of buildings (for example walls or formwork). The additive manufacturing of buildings or their components can significantly increase productivity in the construction industry. So-called "3D concrete printing" means that buildings can be produced more quickly and at lower cost. With the help of a 3D concrete printer, concrete structures can be realized quickly and inexpensively, with the greatest freedom of design at the same time.

So-called reinforcements are known from the construction industry for reinforcing components. The bonding of the building material with the reinforcement, for example a reinforcing steel, can result in an increased bearing capacity and/or tensile strength. The combination of a 3D printer and the use of reinforcement is sometimes difficult, especially when it comes to minimizing manual intervention as much as possible.

In order to establish a good connection between the building material and the reinforcement, it is known first to "print" formwork around the reinforcement and then to fill the formwork with an additional building material. The formwork is therefore initially usually completely free and is therefore susceptible to horizontal forces. The pressure of the additional building material filled into the formwork, for example concrete, can eventually push the formwork apart or even break it.

In order to increase the stability of classic formwork (e.g. wooden formwork), so-called formwork anchors are used in the construction industry, which extend from one formwork component to the opposite formwork component, i.e. from one side of the formwork to the other side of the formwork, in order to hold the formwork in place during To stabilize filling and curing of the additional component. The formwork anchors can then be removed again in order to detach the formwork from the finished component. These manual work steps are comparatively complex and cannot be carried out in the context of additive manufacturing of the formwork. In particular, there is the problem of the formwork anchors colliding with the material output unit of the 3D concrete printer.

Not least for this reason, additive manufacturing in construction, especially in the case of multi-storey structures with reinforcements, is not yet regularly used in today's practice.

In view of the known state of the art, the object of the present invention is to provide a method for the additive manufacturing of components that ensures additional reinforcement of the component and preferably high process reliability.

It is also an object of the invention to provide an improved load transfer element and an improved reinforcement for use within a component, in particular within an additively manufactured component.

The present invention is also based on the object of providing an advantageous computer program and a particularly robust, additively manufactured component that can preferably be produced quickly and inexpensively.

The object is achieved for the method with the features listed in claim 1. With regard to the computer program, the object is achieved by the features of claim 21. With regard to the load transfer element, the object is achieved by the features of claim 22, with regard to the reinforcement by the features of claim 23 and with regard to the additively manufactured component by claim 24.

The dependent claims and the features described below relate to advantageous embodiments and variants of the invention.

A method for the additive manufacturing of a component from a building material is provided.

The component to be manufactured can in particular be part of a building or a formwork that is also mentioned below. The component can also be a complete structure or a act complete formwork. In principle, any components can be additively manufactured according to the invention.

Within the scope of the invention, structures can be structures of all kinds, but in particular protective structures, such as buildings for housing and residence of people or animals, protective walls, dykes, shelters, enclosures, military and fortification systems, city walls and prison walls. However, a structure can also be a traffic structure, for example a street, a pedestrian walkway, a bridge or a tunnel. Supply and disposal structures such as wells, sewage treatment plants, dams, chimneys or temporary structures can also be manufactured additively within the scope of the invention.

Within the scope of the invention, a structural part of a structure can in particular be a functional component of a structure, in particular a functionally or geometrically connected part of the structure, such as a wall, a support or a staircase. A part of a building made up of several components of the building (for example a storey or floor of a building) can also be summarized under the term “component” within the scope of the invention. The formwork or formwork component described below can also be a component within the scope of the invention, in particular if the formwork component or formwork then forms part of the structure, for example the outer part of a wall of the structure.

A base can be provided on which the component is reached. Within the scope of the invention, a subsoil can be understood in particular as a subsoil and/or a foundation on which the structure or component is erected. However, the underground can also be a floor of a multi-storey building or a mobile, movable underground. For example, it can be provided that the component including the subsurface is transported to its intended installation site after additive manufacturing. In principle, any surface on which the component can be erected (permanently or temporarily) can be used as a subsurface.

The proposed method can also be used to produce a plurality of components, possibly also components that are not connected to one another.

According to the invention, a material output unit separates the building material in layers along a predetermined print path.

The print path can be calculated based on the 3D data of the component. Corresponding process steps are already known from conventional 3D printing. The 3D data of the component can in particular be three-dimensional CAD data. The component can be represented in the data in particular by point clouds, edge models, surface models and/or volume models. A control device can be provided which controls and/or regulates the method or individual method steps.

For example, the control device can be set up to calculate the print path using the entered 3D data. The control device can be set up, for example, to calculate a virtual model of the component in the known STL format (“Standard Triangulation/Tessellation Language” format) from the 3D data of the component. Within the framework of the STL format, the component data can be described using triangular facets. The principle is known and is therefore not described in detail. An STL interface is a standard interface of many CAD systems. In the present case, the control device can be set up to initially calculate STL data for further processing from any 3D CAD data. However, the control device can also be set up to record and further process 3D data that is already in STL format. In principle, any other data format can also be provided.

Irrespective of whether the STL data was generated by the control device itself or was only transmitted to it, the control device can be set up to use the STL data (or other 3D data) to convert the component data into printer data for a 3D print ( or for additive manufacturing). For this purpose, it can be provided, among other things, to convert the 3D data or STL data into individual layers to be printed (so-called "slicing"), after which the print paths are calculated for the individual layers in order to specify the movements of the material output unit.

The control device can be set up to control the material output unit as a function of the printed webs and/or to regulate the application or the separation of the building material.

In particular, it can be provided that the material dispensing unit is designed as a nozzle, print head or extruder in order to dispense the building material.

According to the invention, at least one load transfer element extends into the pressure path (or beyond it, as will be described below). Finally, the material output unit separates the building material onto the load transfer element located in the print path. Provision is made for a load transfer element located in a displacement path of the material output unit to be at least temporarily pushed out of the print path by the material output unit, while the material output unit separates the building material along the specified print path.

In the proposed manner, the pressure or the movement of the material output unit can take place regardless of the positions of the load transfer elements. Unintentional damage to the material output unit or its actuators can be avoided in this way. Because the load transfer elements are displaced from the material output unit, the material output unit can finally work without interruption. This can lead to a reduced construction time. the Load transfer elements therefore do not have to be inserted manually or automatically in layers. This can be an advantage because the need to lay the load transfer elements in layers usually requires equal pressure on both sides of the reinforcement and/or may require the pressure to be temporarily interrupted. In a preferred embodiment, the load transfer elements can be designed to be flexible or at least partially flexible in order to enable displacement.

The at least one load transfer element is designed in particular to absorb and dissipate tensile forces. In this way, the load transfer element is able to stabilize the component particularly well, in particular a formwork that is then filled with an additional building material.

According to a particularly advantageous development of the invention, the pressure track runs at least in sections along a reinforcement, starting from which the at least one load transfer element extends into the pressure track.

However, it can also be provided that reinforcement is provided only partially or in sections or not at all. The load transfer elements can be positioned and/or attached to any mounts or objects.

Reinforcements are known in principle and can be used arbitrarily within the scope of the invention. Any kind of reinforcement or reinforcement can be provided that increases the load-bearing capacity in combination with the building material.

The load transfer elements are preferably introduced into the reinforcement or connected to the reinforcement before the additive manufacturing of the component. The load transfer elements can be attached to the reinforcement, for example. In principle, however, the load transfer elements can also be inserted loosely into the reinforcement - this is generally not preferred, however.

The reinforcement can be set up or laid by a specialist, preferably before the start of the building material separation by the material output unit. The reinforcement can optionally be connected to other components and/or to the subsoil with a connection reinforcement or in some other way. However, a free-standing, ie unconnected reinforcement can also be provided if necessary. The position of the reinforcement can be taken into account in the 3D data when calculating the pressure path.

By using the reinforcement and in particular by the connection between the reinforcement and the at least one load transfer element, the finished component can be significantly reinforced mechanically.

In an advantageous development of the invention, it can be provided that the proposed method for the additive manufacturing of a formwork component is used. In the case of the invention The component can therefore be a formwork component. In particular, the component can be a complete formwork (ie a hollow form in the manner of a casting mold) made up of two formwork components running parallel to one another.

The invention is very particularly advantageous for additive manufacturing of a formwork or at least one formwork component of a formwork. In principle, however, the use of the invention should not be understood to be limited to the additive manufacturing of a formwork or a formwork component.

Preferably, the aforesaid compression is performed from both sides of the reinforcement in order to erect a double-sided, so-called "lost formwork" around the reinforcement.

Even formwork that is not to be filled afterwards can advantageously be produced within the scope of the invention. Such formwork can be used, for example, in buildings or parts of buildings that do not have to have a high load-bearing capacity (e.g. individual walls). The cavity between such formwork can either remain free or be provided with insulation.

According to a development of the invention, it can be provided that the formwork is filled with an additional building material. For this purpose, conventional concrete is preferably introduced into the finished formwork.

The additional building material can be the same building material that is also used for the additive manufacturing of the component. However, it can also be a different building material. Preferably, the additional building material that is introduced into the formwork can be conventional concrete and the building material for additive manufacturing can be concrete that is specifically suitable for additive manufacturing. The concrete recipe can thus preferably differ. In principle, however, different types of materials can also be provided, such as plastic for manufacturing the formwork and concrete for filling the formwork. Any combination is possible.

According to a development of the invention, it can be provided that flowable mixed concrete ("fresh concrete") or mortar is used as the building material.

A concrete recipe with small aggregate is preferred. In particular, a concrete can be provided which sets quickly and in particular has a high green strength. Provision can also be made for the concrete to have one or more additives, for example to prevent drying out too quickly, to increase pumpability and/or to modify the colour. As an alternative to using concrete or mortar as a building material, however, any other building material can also be provided which can be suitable for the manufacture or construction of buildings or their components, in particular polymer concrete, gypsum, clay, a plastic, preferably a thermoplastic but also metals or alloys. In principle, any building materials can be provided within the scope of the invention.

In principle, the component can be made from one, two, three, four or even more starting materials or building materials. For example, different concrete mixtures, plastics, metals and/or alloys can be combined with one another as desired.

In a development of the invention, it can be provided that the pressure path runs parallel to the reinforcement, at least in sections.

Preferably, the pressure track is spaced from the reinforcement or is immediately adjacent to the reinforcement. However, the pressure web can also overlap with the reinforcement in order to bring the building material at least partially into the reinforcement during production. As a result, the stability of the component can optionally be further increased.

In a further development of the invention, it can be provided that the reinforcement is a reinforcement mat and/or a reinforcement cage and/or a reinforcement bar (in particular one or more quasi-free-standing reinforcement bars which are fastened to a substrate, for example) and/or a reinforcement wire or a reinforcement cable (e.g. one or more prestressed reinforcement wires/reinforcement cables).

The reinforcement can in particular be made of reinforcement steel or structural steel. However, the reinforcement can also have carbon or carbon fibers, glass fibers, wood and/or plastic or be formed from these materials. The reinforcement can have, among other things, so-called reinforcement mats (lattice-like structures) and/or reinforcement cages and/or reinforcement rods.

The reinforcement is preferably formed from at least one reinforcement cage or has at least one reinforcement cage, since a reinforcement cage can be set up freely with sufficient mechanical stability. Reinforcement cages are usually formed from two or more reinforcement mats that are connected parallel to one another with as much torsion resistance as possible to ensure that the reinforcement cage is stable after it has been set up and cannot or only insignificantly sway or "wobble". Normalized standard reinforcement cages can preferably be provided.

With the proposed method, a conventional reinforcement can be advantageously integrated into 3D-printed concrete structures and the reinforcement can be further increased by the load transfer elements. The reinforcement can have a number of horizontal struts and a number of vertical struts, particularly if it has a reinforcement mat or a reinforcement cage. Depending on how the reinforcement is set up, for example on the ground, the vertical struts preferably run in the perpendicular direction of the ground and the horizontal struts preferably run orthogonally to the vertical struts.

Insofar as a “vertical” or “horizontal” direction is spoken of within the scope of the invention, the vertical direction is to be understood in relation to the plumb to the substrate and the horizontal direction is to be understood at right angles thereto.

In an advantageous development of the invention, it can be provided that the at least one load transfer element is fastened to the reinforcement.

The at least one load transfer element can rest, for example, on two horizontal struts of the reinforcement that are offset from one another, for example on the horizontal struts of a reinforcement cage that are spaced apart from one another or on two adjacent reinforcement meshes of the same height level, and can optionally be fastened to one or more of the horizontal struts and/or vertical struts. However, the at least one load transfer element does not necessarily have to rest on the reinforcement and can then, for example, also be attached only to the side of the reinforcement.

Insofar as the at least one load transfer element is attached to the reinforcement, this attachment can in principle be of any type. Any form-fitting, force-fitting and/or material-fit fastening techniques can thus be provided, such as gluing, welding, suitable reshaping or fastening using additional aids such as lashing elements (e.g. cable ties). In special cases it can even be provided that the at least one load transfer element is designed in one piece with the reinforcement.

At this point it should be emphasized again that reinforcement is not absolutely necessary. Provision can also be made, for example, for the at least one load transfer element to be attached to a holder or other object and/or to rest on a holder or other object. Fastening to the subsoil on which the building is erected, or to a connecting reinforcement, can optionally be provided.

In a further development of the invention it can be provided that the reinforcement is arranged between two parallel pressure tracks.

In this case, load transfer elements preferably extend on both sides of the reinforcement into the respective pressure path. In this case, separate load transfer elements can be provided on each side of the reinforcement. However, a particularly good reinforcement can result if the at least one load transfer member extending from the first compression track to the second compression track through the reinforcement.

In an advantageous development of the invention, it can be provided that the at least one load transfer element extends beyond the pressure path in order to protrude or protrude laterally from the finished component after the building material has been separated. However, the load transfer elements can also end within the pressure path or end with the side surface of the component.

In particular, if the load transfer elements protrude beyond the pressure track, they can be color-coded so that the extent of the building material cover or concrete cover, i.e. the lateral overlap of the load transfer element with the building material, is made visible in the finished component (e.g. a wall or a formwork component). becomes. For example, a load transfer element that is still visible can indicate insufficient building material coverage and suggest rework.

Optionally, it can be provided that the load transfer elements, if they later protrude laterally from the finished component, have a thread or other fastening option for a flat support element, such as a support element, at least on their protruding, free ends. B. have a support plate or a washer. In this way, the horizontal forces can be dissipated even more gently by the load transfer elements.

In an advantageous development of the invention, it can be provided that several of the load transfer elements are distributed along the pressure path.

Provision can also be made for several of the load transfer elements to be distributed over several of the layers to be deposited.

By distributing the load transfer elements over as large an area as possible, a particularly stable reinforcement of the component and gentle force dissipation through the load transfer elements can be possible.

In an advantageous development of the invention, it can be provided that one load transfer element is used for each layer to be deposited.

Provision can also be made for at least one of the load transfer elements to be used per vertical strut of the reinforcement, which extends from the respective vertical strut into the pressure path.

For example, it can be provided that 0.1 to 20 load transfer elements are provided per square meter of formwork, e.g. B. 0.2 to 10 load transfer elements, 0.4 to 5 load transfer elements or exactly one load transfer element, the number of load transfer elements depending on the diameter and/or the material of the load transfer elements and accordingly more or fewer load transfer elements per square meter of formwork can be provided.

In a development of the invention, it can be provided that the load transfer element, which is pushed out of the printing path, is a load transfer element that is located in the displacement path of the material delivery unit and is of a building material layer to be subsequently deposited, which is pushed at least temporarily out of the printing path by the material delivery unit, while the material dispensing unit deposits the building material along the predetermined print path of a (vertically) underlying layer of building material.

However, it can also be provided that there is no underlying layer of building material, for example if the current printing web is the first printing web.

According to a development of the invention, it can be provided that the at least one load transfer element is connected to the reinforcement via an articulated connection. The articulated connection can be designed, for example, in the manner of a film hinge, ie in particular by a cross-sectional narrowing of the load transfer element.

Alternatively or additionally, it can be provided that the at least one load transfer element is designed to be elastic at least in sections (e.g. in the area of one of its ends or also in a central area), in particular to enable the load transfer element to be deflected transversely to its longitudinal axis.

In a development of the invention, it can be provided that the articulated connection and/or the sectionally elastic section of the load transfer element are designed to enable the section of the load transfer element extending into the pressure path to be displaceable by the material output unit.

The deformability or the elasticity of the load transfer element or the articulation can be selected in such a way that the load transfer element can be displaced by the material dispensing unit out of the displacement path of the material dispensing unit and can bend sufficiently and reversibly for this purpose, preferably, but not necessarily, without an (irreversible) plastic experience deformation.

Preferably, when the material output unit has moved further along the print path, the at least one load transfer element then experiences a restoring force and moves independently at least substantially, particularly preferably completely, back into the original position and alignment. According to a development, it can be provided that the articulated connection and/or the sectionally elastic section of the load transfer element are designed to enable the section of the load transfer element that has been displaced from the printed web by the material dispensing unit to reset itself.

The at least one load transfer element can preferably be pivoted at least in the direction of the pressure path or counter to the direction of the pressure path. For this purpose, the at least one load transfer element can have a vertically running pivot axis, which preferably runs parallel to the vertical struts of the reinforcement or to the plumb line on the ground.

The load transfer element can be pivotable or the vertical pivot axis can be positioned in such a way that the load transfer element can be pivoted out of the displacement path of the print head. The load transfer elements can thus be in a resting state in a plan view of the subsoil in the pressure path (sometimes independently of the actual altitude).

In an advantageous development of the invention, it can be provided that the at least one load transfer element is made of a rustproof material.

The use of a rustproof material for the configuration of the at least one load transfer element has proven to be particularly suitable, since the building material or concrete cover of the load transfer element is usually comparatively small, since the load transfer element extends into the pressure path (or even beyond). The load transfer element can thus be particularly susceptible to subsequent corrosion. In order to prevent the corrosion from spreading along the load transfer element and into the reinforcement, the use of a rustproof material can be advantageous. However, the use of a rustproof material is also not absolutely necessary, for example if the reinforcement itself is made of a rustproof material or if subsequent corrosion of the load transfer element is not important.

In an advantageous development of the invention, it can be provided that the at least one load transfer element is made of a plastic, a sheet metal material, a textile, a metal (e.g. steel or iron) or a combination of the materials mentioned. This list is not to be understood as conclusive.

The at least one load transfer element can also be formed from individual fibers or fiber strands (e.g. from glass fibers, carbon fibers etc.), even from fibers of a fundamentally brittle material.

A fiber composite, for example a combination of a plastic and textile fibers, such as Kevlar fibers, can be particularly suitable. Kevlar fibers and fiber bundles can generally be well suited, as they are not able to stretch much in length. A composite material with a plastic matrix can also be sufficiently flexible.

According to a development of the invention, it can be provided that the material output unit is attached to an end effector of an actuator device and is moved by the actuator device along the print path.

The end effector is preferably designed as a trolley of an actuator device designed as a gantry crane unit. Such a system is also known under the term “portal printer”.

However, the end effector can also be designed as the end effector of a robot, in particular an industrial robot. For example, a six-axis robot or another movement system, for example a hexapod or a five-axis system or a combination of several movement units can be provided in order to move the material output unit.

The material dispensing unit can be moved in at least one translational degree of freedom, preferably in at least two translational degrees of freedom, in order to dispense the building material, in particular by the actuator device. Due to the possibility of movement along two translational degrees of freedom, for example, a straight wall of a building or a formwork component of a formwork can be manufactured additively.

Provision is preferably made for the material delivery unit to be moved in all three translational degrees of freedom in order to deliver the building material. In particular, a material output unit that can be moved along all translational degrees of freedom enables a flexible production of any three-dimensional structures or three-dimensional components of structures on the subsoil.

The material dispensing unit can even be moved in at least four degrees of freedom, in particular in all three translational degrees of freedom and at least one rotational degree of freedom. A movement along five degrees of freedom (preferably all three translational degrees of freedom and two rotational degrees of freedom) and very particularly preferably along all six degrees of freedom can particularly preferably be provided. In particular, if the material output unit is movable in all translational degrees of freedom and additionally in one or more rotational degrees of freedom, the individual printed webs can be deposited with the greatest flexibility. In this way, the geometry of the component can be specified in almost any way. For example, a tilting of the material delivery unit and/or a rotation of the material delivery unit during the separation of the building material can be provided.

In an advantageous development of the invention, it can be provided that the material dispensing unit is aligned vertically or orthogonally to the substrate on which the component is erected, while the material dispensing unit is moved along the printing path and separates the building material. A vertical separation of the building material is technically particularly easy to implement and usually leads to a particularly good result. In particular, if the at least one load transfer element can be displaced out of the displacement path by the material dispensing unit, a vertical separation of the building material can be advantageously suitable within the scope of the invention.

In an advantageous development of the invention, it can be provided that the material dispensing unit is aligned at an angle to parallel to the substrate on which the component is erected, while the material dispensing unit is moved along the pressure path and separates the building material in the direction of the reinforcement.

An oblique separation of the building material can be provided in particular when the at least one load transfer element is rigid. A collision with the material output unit can then be avoided by oblique or parallel deposition, in which case the building material can still be deposited on the load transfer elements of the current layer that are located in the printing path.

The material delivery unit can be designed to deliver the building material in a defined form, for example in printed webs with rectangular or rounded edges. The individual printed webs can, for example, be applied with a rectangular (square or oblong), round or oval cross-section. The material dispensing unit preferably dispenses the building material in the intended wall thickness of the component to be printed.

The material dispensing unit can optionally have lateral guide legs, in particular two opposing guide legs, in order to laterally stabilize and/or shape the building material during discharge.

Provision can be made for the material output unit to be designed to selectively separate print webs with different cross-sectional geometry and/or for the material output unit to be exchangeable manually or preferably automatically, with each material output unit being set up to separate print webs with a specific cross-sectional geometry.

It can optionally also be provided that the material output unit is designed to selectively separate print webs from different building materials and/or that the material output unit can be exchanged manually or preferably automatically, with each material output unit being set up to separate a specific building material. The flexibility of the method can be further improved by the possibility of depositing different building materials and/or different cross-sectional geometries. The invention also relates to a computer program, comprising control commands which, when the program is executed by a control device, cause the latter to carry out a method according to the statements above and below.

The control device can be designed as a microprocessor. Instead of a microprocessor, any other device for implementing the control device can also be provided, for example one or more arrangements of discrete electrical components on a printed circuit board, a programmable logic controller (PLC), an application-specific integrated circuit (ASIC) or another programmable circuit, for example also a field programmable gate array (FPGA), a programmable logic array (PLA), and/or a commercial computer.

The invention also relates to a load transfer element, which extends along a longitudinal axis, for load transfer along the longitudinal axis, preferably for use within an additively manufactured component. Provision is made for the load transfer element to have an articulated connection and/or at least one elastic section in order to enable a pivoting movement of the load transfer element transversely to the longitudinal axis.

The invention also relates to a reinforcement for use within a component, in particular within an additively manufactured component, having at least one load transfer element protruding laterally from the reinforcement.

Provision can be made for the at least one load transfer element to be connected to the reinforcement via an articulated connection and/or to be elastic at least in sections.

The invention also relates to an additively manufactured component, produced by a method according to the above and following statements, having a reinforcement that is encased by a building material applied in layers.

Finally, the invention also relates to a device for additively manufacturing a component from a building material, which is set up to carry out a method according to the above and following statements. In particular, the device has a material dispensing unit for the building material in order to deposit the building material in layers along a predetermined printing path.

Features that have been described in connection with one of the objects of the invention, namely given by the method according to the invention, the computer program, the reinforcement, the additively manufactured component and the device, can also be advantageously implemented for the other objects of the invention. Likewise, advantages that were mentioned in connection with one of the objects of the invention can also be understood in relation to the other objects of the invention. In addition, it should be pointed out that terms such as "comprising", "having" or "with" do not exclude any other features or steps. Furthermore, terms such as "a" or "that" which indicate a singular number of steps or features do not exclude a plurality of features or steps - and vice versa.

In a puristic embodiment of the invention, however, it can also be provided that the features introduced in the invention with the terms “comprising”, “having” or “with” are listed exhaustively. Accordingly, one or more listings of features may be considered complete within the scope of the invention, e.g. considered for each claim. The invention can consist exclusively of the features mentioned in claim 1, for example.

It should be mentioned that designations such as "first" or "second" etc. are primarily used for reasons of distinguishing between respective device or method features and are not necessarily intended to indicate that features are mutually dependent or related to one another.

Furthermore, it should be emphasized that the values and parameters described here are deviations or fluctuations of ±10% or less, preferably ±5% or less, more preferably ±1% or less, and very particularly preferably ±0.1% or less of the respectively named Include value or parameter, provided that these deviations are not excluded in the implementation of the invention in practice. The specification of ranges by means of initial and final values also includes all those values and fractions that are enclosed by the range specified in each case, in particular the initial and final values and a respective mean value.

The invention also relates to a method, independent of claim 1, for the additive manufacturing of a component from a building material, according to which a material output unit deposits the building material in layers along a predetermined printing path. It is provided that at least one load transfer element extends into the pressure path, with the material dispensing unit depositing the building material onto the load transfer element located in the pressure path. The further features of claim 1 and the dependent claims as well as the features described in the present description relate to advantageous embodiments and variants of this method. In particular, as an alternative or in addition to the displacement of the at least one load transfer element by the material output unit as described in claim 1, the material output unit can also be displaceable when it comes into contact with a load transfer element.

Exemplary embodiments of the invention are described in more detail below with reference to the drawing.

The figures each show preferred exemplary embodiments in which individual features of the present invention are shown in combination with one another. Features of an embodiment are can also be implemented detached from the other features of the same exemplary embodiment and can accordingly easily be connected by a person skilled in the art to further meaningful combinations and sub-combinations with features of other exemplary embodiments.

Elements with the same function are provided with the same reference symbols in the figures.

They show schematically:

FIG. 1 shows a material dispensing unit during the separation of a building material according to the invention for the additive manufacturing of a formwork component in several layers of building material along a reinforcement with several load transfer elements extending into the pressure path;

FIG. 2 shows the additive manufacturing of a formwork around a reinforcement, with the load transfer elements according to the invention;

FIG. 3 shows a material dispensing unit which deposits the building material vertically adjacent to the reinforcement;

FIG. 4 shows a material dispensing unit which separates the building material obliquely adjacent to the reinforcement; and

FIG. 5 shows an individual illustration of a load transfer element connected to a vertical strut of the reinforcement via an articulated connection.

In FIG. 1, the principle of the method according to the invention is indicated schematically and by way of example. For the additive manufacturing of a component 1 from a building material 2, a material dispensing unit 3 is provided, which separates the building material 2 in layers along a predetermined print path D. The print path D is shown in dashed lines in FIG. 1 and the movement of the material output unit 3 is indicated by an arrow.

The additively manufactured component can in particular be formwork 1 made from two formwork components 1' running parallel to one another (cf., for example, FIGS. 3 and 4). In principle, however, the invention is suitable for the production of any desired component 1 or even an entire building and is therefore not to be understood as being limited to the production of a formwork 1 or a formwork component 1′. However, the invention is particularly advantageous for the production of a so-called "lost" formwork 1, which is optionally (but not necessarily) filled with an additional building material (not shown) and which forms part of the later component. The building material 2 for additive manufacturing and/or the additional building material can in particular be a flowable mixed concrete. In principle, however, any building material 2 can be provided, for example a plastic or gypsum.

The component 1 can be erected on a substructure 4 . The pressure path D runs at least in sections along a reinforcement 5, which can have, for example, a reinforcement mat (cf. FIG. 1) or an entire reinforcement cage (cf. FIGS. 2 to 4). The reinforcement 5 can be set up on the base 4 and optionally connected to the base 4, for example via a so-called connection reinforcement (not shown).

The pressure track D is preferably spaced apart from the reinforcement 5, as shown in FIGS. But this is not necessarily the point.

At least one load transfer element 7 is provided, which extends from the reinforcement 5 into the pressure path D, with the material output unit 3 separating the building material 2 onto the load transfer element 7 located in the pressure path D, which can be seen particularly well in Figure 1.

The reinforcement 5 can be arranged between two parallel pressure tracks D, as is shown in FIG. 2, for example. At least one load transfer element 7 can then be provided on each side of the reinforcement 5 . However, load transfer elements 7 can also be provided, which extend from one side of the reinforcement 5 to the other side of the reinforcement 5, ie protrude into both pressure paths D. This is indicated in FIG. 2 by dashed lines.

The at least one load transfer element 7 can be fastened to the reinforcement and/or rest on two horizontal struts 8 of the reinforcement 5 that are offset from one another.

Provision can be made for the at least one load transfer element 7 to extend beyond the pressure path D in order to protrude laterally from the finished component 1 after the building material 2 has been separated (cf. FIGS. 1 and 2). The load transfer element 7 can also be completely covered laterally by the building material 2, which is generally preferred.

Preferably, several of the load transfer elements 7 are distributed along the print path D and are distributed over several layers to be deposited. The use of as many load transfer elements 7 as possible can lead to an even and gentle load transfer. In particular, it can be provided that several load transfer elements 7 are provided for each layer to be deposited, preferably one respective load transfer element 7 per vertical strut 9 of the reinforcement 5, as can be seen clearly in FIG. But it can z. B. it can also be provided that only for every second vertical strut 9 of the reinforcement 5 a load transfer element 7 is provided, only for every third vertical strut 9 of the reinforcement 5, or only for every fourth vertical strut of the reinforcement 5. All the information provided is to be understood as an example only.

At this point it should be mentioned that the number or density of the load transfer elements 7 in the subsequent component 1 can result from the diameter of the load transfer elements 7 . The smaller the diameter of the load transfer elements 7, the more load transfer elements 7 can usually be advantageously provided.

In a preferred variant, it can be provided that a load transfer element 7' (see Figure 1) of a subsequent or higher building material layer located in the acute displacement path of the material output unit 3 can be pushed at least temporarily out of the printing web D by the material output unit 3, while the material output unit 3 the building material 2 along the current pressure path D separates. FIG. 1 shows an example of how the material output unit 3 shifts or bends one of the load transfer elements 7′ out of its movement path. The load transfer element 7' can then move back into its original position due to an elastic restoring force.

The load transfer elements 7 can, for example, be connected to the reinforcement 5 via an articulated connection 10 . An example of a joint connection 10 in the manner of a film hinge is shown in FIG. The articulated connection 10 or the film hinge can be formed by a cross-sectional reduction and in particular enable a movement in or against the print web D/advance direction of the material output unit 3 (cf. arrows in FIG. 5).

Provision can also be made for the load transfer elements 7 to be elastic at least on a section of their longitudinal axis L (cf. FIG. 5), in particular to enable bending/pivoting transversely to the longitudinal axis L. In principle, the load transfer elements 7 can also be designed to be completely elastic—however, an elastic design of one of the ends or of a central part can already be sufficient.

In principle, the load transfer element 7 can be connected to the reinforcement 5, for example a vertical strut 9 of the reinforcement 5, in any desired manner. A welded connection 11 is indicated in FIG.

Optionally, as is also indicated in FIG. 5, the load transfer element 7 can have cross braces 12 or other anchor elements in order to create an even better connection with the respective building material layer. Recesses or cross-sectional tapering can also be optionally provided.

The load transfer element 7 is preferably made of a rustproof material. For example, the load transfer element 7 can be made of a plastic, a sheet metal material (in particular a stainless sheet metal material), a textile or a composite material, in particular a combination of the materials mentioned.

The material output unit 3 can be attached to an end effector (not shown) of an actuator device (also not shown). A corresponding device for the additive manufacturing of the component can be designed, for example, as a so-called portal printer. The actuator device is able to move the end effector or the material output unit 3 along the print path D in preferably several degrees of freedom.

In order to separate the building material 2, provision can be made for the material dispensing unit 3 to be aligned vertically with respect to the substrate 4 on which the component 1 is erected (cf. FIG. 3). For the sake of simplicity, the load transfer elements 7 are not shown in FIGS. Vertical separation is particularly suitable when the load transfer elements 7 are designed to be flexible and can be displaced by the material dispensing unit 3, as shown in FIG.

Particularly if the load transfer elements 7 are rigid, an oblique to parallel orientation of the material delivery unit 3 relative to the substrate 4 can also be suitable in order to deposit the building material 2 in the direction of the reinforcement 5, as indicated in FIG. In this way, a collision between the material dispensing unit 3 and the load transfer elements 7 of higher building material layers can be avoided.

In particular, it can also be provided that the orientation of the material output unit 3 can be flexibly adjusted during additive manufacturing.

Claims

P atentClaims 1. A method for the additive manufacturing of a component (1) from a building material (2), according to which a material output unit (3) deposits the building material (2) in layers along a predetermined print path (D), since by c e n n n e t i c h n e t that at least one load transfer element (7) to extends into the print path (D), with the material delivery unit (3) depositing the building material (2) onto the load transfer element (7) located in the print path (D), with a load transfer element (7 ') is at least temporarily pushed out of the print path (D) by the material output unit (3), while the material output unit (3) separates the building material (2) along the predetermined print path (D). 2. The method according to claim 1, d a d u r c h g e k e n n z e i c h n e t that the pressure track (D) runs at least in sections along a reinforcement (5), starting from which the at least one load transfer element (7) extends into the pressure track (D). 3. The method according to claim 1 or 2, d a d u r c h g e k e n n z e i c h n e t that a formwork component (1 ') is manufactured, in particular two mutually parallel formwork components (1') to form a formwork (1). 4. The method according to claim 3, d a d u r c h g e k e n n z e i c h n e t that the formwork (1) is filled with an additional building material. 5. The method according to any one of claims 1 to 4, d a d u r c h g e k e n n z e i c h n e t that flowable mixed concrete or mortar is used as building material (2). 6. The method according to any one of claims 2 to 5, d a d u r c h g e k e n n z e i c h n e t that the printed web (D) runs at least in sections parallel to the course of the reinforcement (5) on a base (4), and is preferably spaced apart from the reinforcement (5). 7. The method according to any one of claims 2 to 6, characterized in that the reinforcement (5) comprises a reinforcement mat and / or a reinforcement cage and / or a reinforcing bar and / or a reinforcing wire. 8. The method according to any one of claims 1 to 7, d a d u r c h g e k e n n z e i c h n e t that the at least one load transfer element (7) is attached to the reinforcement (5) and/or rests on two horizontal struts (8) of the reinforcement (5) that are offset from one another and/or is attached to a bracket and / or rests on a bracket. 9. The method according to any one of claims 2 to 8, d a d u r c h g e k e n n z e i c h n e t that the reinforcement (5) is arranged between two parallel pressure tracks (D), wherein a) at least one of the load transfer elements (7) extends from the first pressure track to the second pressure track extends through the reinforcement (5); and/or b) separate load transfer elements (7) are provided on each side of the reinforcement (5), each of which extends into the associated pressure path (D). 10. The method according to any one of claims 1 to 9, d a d u r c h g e k e n n z e i c h n e t that the at least one load transfer element (7) extends beyond the pressure web (D) in order to protrude laterally after the building material (2) has been separated from the finished component (1). 11. The method according to any one of claims 1 to 10, d a d u r c h g e k e n n z e i c h n e t that several of the load transfer elements (7) are distributed along the printing path (D) and/or are arranged distributed over several of the layers to be deposited. 12. The method according to any one of claims 1 to 11, d a d u r c h g e k e n n z e i c h n e t that the load transfer element (7′) pushed out of the printed web (D) is a load transfer element (7′) of a building material layer to be subsequently deposited, which is is pushed out of the print web (D), while the material output unit (3) deposits the building material (2) along the predetermined print web (D) of a lower-lying building material layer. 13. The method according to any one of claims 1 to 12, d a d u r c h g e k e n n z e i c h n e t that the at least one load transfer element (7) is connected to the reinforcement (5) via an articulated connection (10) and/or is designed to be elastic at least in sections in the direction of the pressure path (D). . 14. The method according to claim 13, characterized in that the articulated connection (10) and/or the sectionally elastic section of the load transfer element (7) are designed to enable the section of the load transfer element (7) extending into the pressure path (D) to be displaced by the material output unit (3). 15. The method according to claim 13 or 14, d a d u r c h g e k e n n z e i c h n e t that the articulated connection (10) and/or the sectionally elastic section of the load transfer element (7) are designed in order to automatically reset the material discharged from the printed web (D) by the material output unit (3). To allow section of the load transfer element (7). 16. The method according to any one of claims 1 to 15, d a d u r c h g e k e n n z e i c h n e t that the at least one load transfer element (7) is made of a stainless material. 17. The method according to any one of claims 1 to 16, d a d u r c h g e k e n n z e i c h n e t that the at least one load transfer element (7) is made of a plastic, a sheet metal material, a textile, a metal or a combination of the materials mentioned. 18. The method according to any one of claims 1 to 17, d a d u r c h g e k e n n z e i c h n e t that the material output unit (3) is attached to an end effector of an actuator device and is moved by the actuator device along the print path (D). 19. The method according to any one of claims 1 to 18, d a d u r c h g e k e n n z e i c h n e t that the material output unit (3) is aligned vertically to a base (4) on which the component (1) is erected, while the material output unit (3) moves along the print path (D ) is moved and the building material (2) separates. 20. The method according to any one of claims 2 to 19, characterized in that the material output unit (3) is aligned obliquely to parallel to a substrate (4) on which the component (1) is erected, while the material output unit (3) along the print path (D) is moved and the building material (2) is deposited in the direction of the reinforcement (5). 21. A computer program comprising control instructions which, when the program is executed by a control device, cause the latter to carry out the method according to one of claims 1 to 20. 22. Load transfer element (7), which extends along a longitudinal axis, for load transfer along the longitudinal axis, since the load transfer element (7) has an articulated connection (10) and/or at least one elastic section in order to cause a pivoting movement of the load transfer element (7). allow transverse to the longitudinal axis. 23. Reinforcement (5) for use within a component (1), in particular within an additively manufactured component (1), having at least one load transfer element (7) protruding laterally from the reinforcement (5) according to claim 22. 24. Additively manufactured component (1), produced by a method according to one of claims 1 to 20, having a reinforcement (5), which is encased by a building material (2) applied in layers, d a r c h e n n n s e i c h n e t that the reinforcement (5) has at least one has a load transfer element (7) which protrudes laterally from the reinforcement (5) and extends into the building material (2).