Method for producing a green body layer by layer from pulverous material by means of insert elements arranged in a defined manner

Patent metadata

Field	Value
Publication number	US-11155003-B2
Application number	US-201716471651-A
Country	US
Kind code	B2
Filing date	Nov 29, 2017
Priority date	Dec 22, 2016
Publication date	Oct 26, 2021
Grant date	Oct 26, 2021

Abstract

A method for the layered production of a green body (10) from powdery material, including insert elements which are placed at defined positions in the powdery material, in which the green body (10) is segmented in a building direction (16) into N, N≥2 consecutive, cylindrical cross-sectional areas (11, 12, 13, 14, 15) made up of a two-dimensional cross-sectional surface and a layer thickness. Setting areas for the insert elements are defined in the cross-sectional areas of the green body (10) which include the defined positions for the insert elements, and loose powder particles surrounding the setting elements are at least partially bonded to each other before the insert elements are placed into the powdery material.

First claim

What is claimed is:

1. A method for layered production of a green body from powdery material, including insert elements arranged at defined positions in the powdery material, based on three-dimensional data of the green body, the method comprising the steps of:
segmenting the green body in a building direction into N, N>2, consecutive, cylindrical cross-sectional areas, each of the cross-sectional areas being formed from a two-dimensional cross-sectional surface perpendicular to the building direction and a layer thickness parallel to the building direction;
applying N powder layers of the powdery material to a building plane perpendicular to the building direction;
arranging the insert elements at the defined positions in the powdery material;
defining setting areas for the insert elements in the cross-sectional areas including the defined positions for the insert elements; and
at least partially bonding the loose powder particles surrounding the setting areas to each other before the insert elements are placed into the powdery material;
wherein the loose powder particles surrounding the setting areas for the insert elements are bonded to each other in a non-closed support structure.

2. The method as recited in claim 1 wherein the non-closed support structure includes multiple support sections, the support sections being arranged around the insert elements.

3. The method as recited in claim 1 wherein the non-closed support structure includes at least one support section, the support section being situated on a side of the insert elements facing away from the application direction of the next powder layer.

4. The method as recited in claim 1 wherein a base element is defined for a first cross-sectional area of the cross-sectional areas and including a base surface corresponding to a first cross-sectional surface of the first cross-sectional area and having a height corresponding to a first layer thickness of the first cross-sectional area, and the loose powder particles of the powdery material being bonded to each other in the base element.

5. The method as recited in claim 1 wherein a first limiting ring is defined for each cylindrical lateral surface of a first cross-sectional area of the cross-sectional areas, and having a geometry corresponding to a cylindrical lateral surface of the first cross-sectional area and a height corresponding to a first layer thickness of the first cross-sectional area, a first powder layer of the powder layers being applied to a substrate, and the first limiting rings being connected to the substrate.

6. The method as recited in claim 4 wherein support structures are connected to the base element.

7. The method as recited in claim 5 wherein support structures are connected to the substrate.

8. The method as recited in claim 5 wherein a second to Nth-1 limiting ring is defined for each cylindrical lateral surface of the second to Nth-1 cross-sectional area and having a geometry corresponding to the cylindrical lateral surface of the second to Nth-1 cross-sectional area and a height corresponding to a layer thickness of the second to Nth-1 cross-sectional area.

9. The method as recited in claim 8 wherein the loose powder particles of the second to Nth-1 limiting rings are bonded to each other, and the second to Nth-1 limiting rings are each connected to an underlying base element or to the underlying first to Nth-2 limiting rings.

10. The method as recited in claim 8 wherein an Nth limiting ring is defined for each cylindrical lateral surface of the Nth cross-sectional area and has a geometry corresponding to the cylindrical lateral surface of the Nth cross-sectional area and a height corresponding to the Nth layer thickness of the Nth cross-sectional area, the loose powder particles of the Nth limiting rings being bonded to each other, and the Nth limiting rings being connected to the underlying Nth-1 limiting rings.

11. The method as recited in claim 8 wherein a cover element is defined for the Nth cross-sectional area and includes a cover surface corresponding to the Nth cross-sectional surface of the Nth cross-sectional area and a height corresponding to the Nth layer thickness of the Nth cross-sectional area, the loose powder particles of the powdery material being bonded to each other in the cover element, and the cover element being connected to the underlying Nth-1 limiting rings.

Assignees

• Hilti Ag

Inventors

• Zivcec Maria
• Spring Robert
• Schneider Roland

Classifications

• B28B1/008 Primary

  made from two or more materials having different characteristics or properties (casting for producing layered articles B28B1/16; feeding several succesive layers, optionally of different materials B28B13/022; coating B28B11/04; applying material to surfaces to form a permanent layer thereon B28B19/00) · CPC title

• B28B1/001 Primary

  Rapid manufacturing of 3D objects by additive depositing, agglomerating or laminating of material (selective deposition modelling of metallic powder B22F10/00; rapid manufacturing of 3D objects in general and in particular of plastics B29C64/00) · CPC title

• B22F10/47

  characterised by structural features · CPC title

• B22F10/10

  Formation of a green body · CPC title

• B22F10/14 Primary

  by jetting of binder onto a bed of metal powder · CPC title