3D printer for automated series production

Abstract

The invention relates to a 3D printer (1) comprising a temperature-adjustable, thermally insulated build space (2) for an object (3) to be manufactured and at least one print head (4a, 4b) movable along at least two axes (x, y), which print head is capable of locally additive manufacturing of a powdered, pasty or liquid material to the object (3) to be manufactured, wherein the thermal insulation of the build space (2) comprises a cover (6, 6a-6c) in at least two parts, which is movable with the print head (4a, 4b), wherein at least one first part (6a) of the cover (6) is fixedly coupled to the movement of the print head along the two axes (x, y), and wherein at least one second part (6b) of the cover (6) is couplable to the first part (6a) by means of at least one releasable coupling means (7a, 7b).

Description

Technical Field

[0001] This invention relates to a simplified series production 3D printer specifically designed for a particular object. Background Technology

[0002] In 3D printing additive manufacturing, material is gradually added to and solidified on the object to be manufactured. For this purpose, liquid or paste-like materials can be applied to the object at elevated temperatures from a printhead movable relative to it and solidified thereby by cooling. For example, a suitable printhead for a metallic initial material is known from DE 10 2015 218 375 A1.

[0003] These and other 3D printers are typically set up to keep the object to be manufactured at a base temperature in a temperature-controlled build-up space during manufacturing. Summary of the Invention

[0004] Within the scope of this invention, a 3D printer is developed. The 3D printer includes a temperature-controlled, thermally insulated construction space for an object to be manufactured and at least one print head movable along at least two axes. The print head is capable of locally additively forming the object to be manufactured from powdered, paste-like, or liquid materials.

[0005] Materials can be bonded to the object to be manufactured, in particular, through the action of temperature. Therefore, material flowing from the printhead in a hot, liquid state can, for example, bond to the object to be manufactured upon cooling. However, powdered or paste-like materials can also be bonded to the object to be manufactured, for example, through localized heating within the fabrication space, such as by means of a laser beam.

[0006] However, paste-like or liquid materials can also be cured onto the object to be manufactured by means of ultraviolet light activation or curing within the construction space, and thus by the temperature within the construction space.

[0007] The thermal insulation device for the constructed space includes a cover consisting of at least two parts that can move with the printhead. At least one first part of the cover is fixedly coupled to the movement of the printhead along two axes. At least one second part of the cover can be coupled to the first part by means of at least one releasable coupling device.

[0008] It has been recognized that using 3D printers in this way can significantly simplify the serial production of objects. Automated serial production typically requires the automated removal of the completed object from the 3D printer so that the manufacture of the next object can then begin. The construction space, surrounded by thermal insulation from all sides, is an obstacle to this.

[0009] Now, the second part of the cover can be decoupled from the movement of the print head. This second part can be placed, for example, in a designated stopping position, and then the first part can be moved away from the second part by the movement of the print head. In this way, an opening can be created in the fabrication space through which the manufactured object can be removed. Subsequently, the first part of the cover can move toward the second part of the cover, and thus the fabrication space can be closed again.

[0010] Therefore, the existing drive source of the printhead can be used. This can be achieved with less effort in terms of structural design and hardware technology compared to configuring the sidewalls of the construction space as flip-up or sliding doors.

[0011] The possibility of mass production using 3D printing allows for the creation of series of components whose shapes cannot be achieved through subtractive machining (such as turning, milling, or drilling), casting, or even a combination of these methods. Therefore, the range of objects that can actually be mass-produced is expanded to include those whose shapes can only be manufactured using 3D printing. These objects, in particular, can be those whose shapes are selected based on optimization algorithms or analytical calculations to best fulfill certain functionalities. In contrast, for objects that can be selectively manufactured using either 3D printing or conventional machining, conventional machining is generally faster for mass production. However, in this case, initial small batches for research and development and testing can also be reasonably manufactured using 3D printing. For cases where the final shape needs to be changed after testing, the equipment costs associated with conventional machining are not lost.

[0012] With the first part of the cover coupled to the second part of the cover, the two parts of the cover can, for example, engage with each other, be adjacent to each other, or overlap in a sliding protective manner. One of these parts can also overlap with the other part, for example, in a sliding protective manner.

[0013] In a particularly advantageous configuration, the first and second portions of the cover, coupled together, define a through-passage into the construction space. The printhead can be guided into the construction space through this through-passage. In particular, the heating element of the printhead can, for example, be located within the construction space. The heat generated by the printhead can then be largely retained within the construction space.

[0014] In another particularly advantageous configuration, the 3D printer further includes a base plate arranged within the build space for receiving the object to be manufactured. This base plate is capable of movement along at least one axis, which is linearly independent of the print head along its movable axis. In particular, the base plate can, for example, be capable of movement perpendicular to the print head along its movable axis.

[0015] In another particularly advantageous configuration, the 3D printer further includes a conveying device capable of removing the object to be manufactured and / or the base plate from the construction space with a first portion of the cover spaced apart from a second portion of the cover. The 3D printer can then manufacture objects one after another without human intervention. The conveying device can be configured, for example, as a gripper or a robotic arm.

[0016] What is particularly advantageous here is that instead of grasping the object itself, one grasps the base plate. Regardless of which object is being manufactured in detail, the base plate can always be grasped in the same way. This simplifies switching from one object to be manufactured to a different or varying object within serial production.

[0017] Furthermore, it is easier to mechanically separate the manufactured object from the base plate outside the construction space. In particular, there is no risk of damage to the 3D printer or its machinery from the force required to peel the object from the base plate. In addition, the base plate can be cleaned of material residue outside the construction space, allowing for the repeated manufacture of other objects starting from a clean base plate.

[0018] In a particularly advantageous configuration, at least one releasable coupling device is a locking mechanism that locks as the first portion of the cover approaches the second portion and unlocks when the first portion moves rapidly and forcefully from a predetermined minimum speed. The locking mechanism can be specifically sized such that it remains locked as the print head moves at a speed set during 3D printing. This makes it particularly convenient to position the second portion of the cover in a predetermined stopping position and then allow the first portion to move away from the second portion.

[0019] Opening the construction space in this manner can be further aided by a blocking device that at least secures the second portion of the cover when it is in a predetermined parking position. This blocking device can also work in conjunction with other releasable coupling devices. Regardless of the detailed configuration of the releasable coupling devices, a force sufficient for release can be applied to the coupling devices via the first portion of the cover.

[0020] In another particularly advantageous configuration, at least one releasable coupling device is a locking connection that locks into the second part when the first part of the cover approaches. An additional actuator is provided that can unlock the locking connection. In this way, the unlocking process is more repeatable by applying force to the coupling device alone, compared to using a control device. The force required for the "disengagement" of the coupling device can be varied, for example, by tilting or bonding. Furthermore, the full power of the printhead drive source can be utilized to move the printhead as quickly as possible, and objects can be formed accordingly quickly.

[0021] Advantageously, the actuator is not part of the cover, and the locking mechanism can be unlocked precisely when the second part of the cover is in a predetermined stopping position. Then, the actuator does not change its position during printhead movement, making it easier to supply power to and control the actuator in the structural design.

[0022] For example, the coupling device may include a spring-loaded lever on one part of the cover and a slot mounted on another part of the cover. This slot may have, for example, vertical sides, and an inclined ramp may be guided from outside the slot toward at least one such side. As the two parts of the cover move toward each other, the lever can slide on the inclined ramp toward the slot. If the two parts of the cover are arranged so that the cover is nominally closed, the lever moves over the slot and is pressed into the slot by the spring force. Further movement of one part of the cover then causes the lever to actuate with the vertical side of the slot, or vice versa, causing the other parts of the cover to move as well. The lever can then be lifted by an actuator to allow free relative movement between the two parts of the cover.

[0023] In another particularly advantageous configuration, at least one releasable coupling device includes at least one permanent magnet or electromagnet on one portion of the cover and at least one ferromagnetic element on another portion of the cover. The permanent magnet coupling device can also be released by forceful and / or rapid movement of the first portion of the cover, and in this case, it is completely wear-free compared to a locking connection. The electromagnetic coupling device can also be released more easily by deactivating the electromagnet.

[0024] In another particularly advantageous configuration, at least one releasable coupling device includes at least one protrusion on one portion of the cover and at least one recess on another portion of the cover corresponding to the protrusion. By raising or lowering at least a portion of the cover, the protrusion can disengage from its engagement with the recess. Such a coupling device combines reliable coupling on the one hand with a wear-free release process on the other. Attached Figure Description

[0025] Further measures to improve the invention are described in detail below with reference to the accompanying drawings, together with the description of preferred embodiments of the invention.

[0026] The attached diagram shows:

[0027] Figure 1 An embodiment of 3D printer 1 with construction space 2 closed;

[0028] Figure 2 With construction space 2 open, in Figure 1 The state of 3D printer 1 shown;

[0029] Figure 3 Examples of releasable coupling devices 7a, 7b having a lever 12 and an actuator 11 for release;

[0030] Figure 4 :exist Figure 3 The coupling devices 7a and 7b shown are in the loosened state. Detailed Implementation

[0031] Figure 1 An embodiment of a 3D printer 1 is shown. An object 3 is to be manufactured on a base plate 9 within a thermally isolated construction space 2. The base plate 9 is movable along the z-axis via a drive 9a. Material can be locally added to the object 3 to be manufactured using two print heads 4a and 4b, which are movable perpendicular to the z-axis along the x and y axes via a drive system 5.

[0032] The structural space 2 is enclosed upwards by a covering 6. This covering 6 consists of three parts: 6a, 6b, and 6c. The first part 6a and the second part 6b are abutted against each other, forming two notches. Figure 1 In the illustrated state, the printhead 4a in use is guided into the construction space 2 through one of the notches. Since the printhead 4b is not currently in use, the other notch is closed by the insulating flap 8b. As the printheads 4a and 4b and the first portion 6a of the cover 6 move toward the third portion 6c, the second portion 6b of the cover 6 moves above the third portion 6c in a sliding protective manner. As the printheads 4a and 4b and the first portion 6a of the cover 6 move away from the third portion 6c, the second portion 6b is assisted by spring elements 6d and 6e to move in the opposite direction above the third portion 6c to follow the first portion 6a.

[0033] The first part 6a and the second part 6b of the cover 6 are in Figure 1 In the state shown, they are coupled to each other through releasable coupling devices 7a and 7b.

[0034] Figure 2 The following state is shown for the 3D printer 1, in which the construction space 2 is open. For this purpose, the second part 6b of the cover 6 is moved to a maximum position 10 above the third part 6c, in which the second part 6b is positioned... Figure 2 The blocking device, not shown, is fixed in place. Subsequently, the releasable coupling devices 7a and 7b are released, and the first portion 6a of the cover 6 is moved to its stop in the positive y-direction to create the largest possible gap with the second portion 6b.

[0035] In this state, the two print heads 4a and 4b also move out of the construction space 2. Therefore, in Figure 1 The central printhead 4a, which was guided through the gap in the construction space 2, is now also closed by the isolation flap 8a.

[0036] Furthermore, the actuator 9a of the base plate 9 has moved upward to its maximum extent in the Z direction. In this position, the base plate 9, along with the object 3 manufactured thereon, can be removed and replaced by a new base plate 9'. Thereafter, the manufacture of the next object 3 can begin directly on the new base plate 9', while the previously manufactured object 3 is removed from the base plate 9, and the base plate 9 is cleaned.

[0037] Figure 3 An embodiment of the releasable coupling devices 7a, 7b in the coupled state is shown. The coupling devices 7a, 7b include a spring-loaded lever 12 on the second portion 6b of the cover 6 and a fork-shaped member 13a with a groove 13 on the first portion 6a of the cover 6. Figure 3 In the indicated state, lever 12 engages in slot 13. Therefore, when the first portion 6a of cover 6 moves, it carries the second portion 6a via the fork 13a and lever 12. A separate actuator 11 is provided to release the coupling devices 7a, 7b, which does not participate in the movement of either the first portion 6a or the second portion 6b of cover 6.

[0038] Figure 4 Shown in Figure 3 An embodiment of the coupling devices 7a and 7b shown in the released state. Figure 4 In the shown state, the second part 6b of the cover 6 is in the parking position 10. Figure 3 In contrast, actuator 11 moves upward and lifts lever 12. This disengages lever 12 from its engagement with slot 13. This allows the first portion 6a of cover 6 to disengage from the second portion 6b, while the second portion 6b remains in the parking position 10. (As in...) Figure 4As shown, the actuator 11 can also function as a blocking device, which holds the second part 6b of the cover 6 in the parking position 10.

Claims

1. A 3D printer (1) comprising a temperature-controlled, thermally insulated construction space (2) for an object (3) to be manufactured, and at least one print head (4a, 4b) movable along at least two axes (x, y), the print head being capable of locally additively fabricating said object (3) from powdered, paste-like, or liquid materials, wherein, The thermal insulation portion of the constructed space (2) includes at least two parts of a cover (6, 6a-6c) that can move with the printhead (4a, 4b), wherein at least one first part (6a) of the cover (6) is fixedly coupled to the movement of the printhead along two axes (x, y), and wherein at least one second part (6b) of the cover (6) can be coupled to the first part (6a) by means of at least one releasable coupling device (7a, 7b). The 3D printer (1) further includes a blocking device that can at least hold the second part (6b) of the cover (6) in place when it is in a predetermined parking position (10). At least one releasable coupling device (7a, 7b) is a locking device that locks when the first part (6a) of the cover (6) approaches the second part (6b). An additional actuator (11) is provided that can unlock the locking device. The actuator (11) is not part of the cover (6) and the locking device is unlocked when the second part (6b) of the cover (6) is in the predetermined parking position.

2. The 3D printer (1) according to claim 1, wherein, The first part (6a) and the second part (6b) of the cover (6) are coupled to each other and defined in the through portion of the construction space (2), through which the print head (4a, 4b) can be guided into the construction space (2).

3. The 3D printer (1) according to any one of claims 1 to 2, further comprising a base plate (9) disposed within the construction space (2) for receiving the object to be manufactured (3), the base plate being movable at least along an axis (z), wherein, The axis (z) is linearly independent of the axis (x, y) along which the printhead (4a, 4b) can move.

4. The 3D printer (1) according to any one of claims 1 to 3 further includes a conveying device, which is capable of removing the manufactured object (3) and / or base plate (9) from the construction space (2) when the first portion (6a) of the cover (6) is spaced apart from the second portion (6b) of the cover (6).

5. The 3D printer (1) according to any one of claims 1 to 4, wherein, At least one releasable coupling device (7a, 7b) is a locking connection device that locks when the first part (6a) of the cover (6) approaches the second part (6b) and unlocks when the first part (6a) moves rapidly and forcefully from a predetermined minimum speed.

6. The 3D printer (1) according to claim 1, wherein, The coupling device (7a, 7b) includes a spring-loaded lever (12) on one part (6a, 6b) of the cover (6) and a groove (13) mounted on the other part (6a, 6b) of the cover (6), such that when the parts (6a, 6b) move relative to each other, the lever (12) can move over the groove (13) and can be pressed into the groove (13) by spring force.

7. The 3D printer (1) according to any one of claims 1 to 6, wherein, At least one releasable coupling device (7a, 7b) includes at least one permanent magnet or electromagnet on one portion (6a, 6b) of the cover (6) and at least one ferromagnetic element on another portion (6a, 6b) of the cover (6).

8. The 3D printer (1) according to any one of claims 1 to 7, wherein, At least one releasable coupling device (7a, 7b) includes at least one protrusion on one portion (6a, 6b) of the cover (6) and at least one recess on another portion (6a, 6b) of the cover (6) corresponding to the protrusion, wherein the protrusion is disengaged from engagement with the recess by raising or lowering at least one portion (6a, 6b) of the cover (6).

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