Method for additive manufacturing and rinsing and / or dehydration product

Abstract

The invention relates to a method (100) for the additive manufacturing, in particular a fused deposition process, of a treatment and / or dehydration product (10) or of an element (12) of the treatment and / or dehydration product (10) by means of an additive manufacturing device (14), wherein the device (14) comprises a base unit (16) as a reference plane and at least one application unit (18) for the selective application (110) of an additive material (20), wherein the at least one application unit (18) is positioned such that a first layer (22) in a first layer plane of the additive material (20) is applied to the base unit, wherein the application of the additive material (20) is repeated layer by layer until an nth layer (24) in an nth layer plane is completed to form the treatment and / or dehydration product (10) or the element (12) of the treatment and / or dehydration product. (10) is achieved.The invention proposes that the additive material (20) of the respective layer is continuously dispensed (110) by the at least one dispensing unit (18) during a layer transition (26) between two successive layer levels.

Description

[0001] The invention relates to a method for the additive production of a treatment and / or dehydration product and / or an element of the treatment and / or dehydration product, as well as an element of a treatment and / or dehydration product and a treatment and / or dehydration product.

[0002] The most well-known method in the field is the additive manufacturing of prototypes using Fused Deposition Modeling (FDM), also known as fused layer printing. This process uses a thermoplastic material (usually plastic) in the form of a wire, also called filament. The printing process involves melting the filament in a heated nozzle and depositing it layer by layer onto the build platform. The printer moves the nozzle along paths defined by a previously designed 3D model prepared for the FDM process. The printer's nozzle builds the desired shape layer by layer. After a layer is completed, the build platform lowers or the nozzle rises to deposit the next layer. The plastic hardens quickly at room temperature and bonds with the layers below.

[0003] To achieve layer-by-layer printing, the current state of the art defines a starting point coordinate whose height is shifted depending on the respective layer. This means the printer or nozzle pauses for each layer to begin printing anew, resulting in more additive material being deposited at these points. This creates tactilely perceptible and visible transitions, which are disruptive when the printed product is used directly. Furthermore, so-called support structures are built up in shapes with overhangs. These support structures must subsequently be removed. Both the transitions and the removal of the support structures lead to disruptive areas that are detrimental to both the appearance and function of the printed components or prototypes, necessitating post-processing.Due to the additional work steps, this leads to an increase in both the time required and the cost of production.

[0004] The invention is based on the objective of providing a method for the additive manufacturing of a treatment and / or dewatering product or an element thereof, which reduces manufacturing costs and production times. Additionally, the invention aims to provide a treatment and / or dewatering product or an element thereof that can be manufactured quickly and cost-effectively.

[0005] To solve this problem, the invention proposes a method for the additive manufacturing, in particular a fused deposition process, of a treatment and / or dehydration product or an element of the treatment and / or dehydration product according to claim 1, a method according to claim 10, as well as an element for a treatment and / or dehydration product according to claim 12 and a treatment and / or dehydration product according to claim 13 or 14.

[0006] A first aspect of the invention is a method for the additive manufacturing, in particular a fused deposition process, of a treatment and / or dewatering product or an element thereof, carried out by means of an additive manufacturing device. This additive manufacturing device has a base unit as a reference plane and at least one dispensing unit for the selective dispensing of an additive material. The at least one dispensing unit is positioned such that a first layer of the additive material is dispensed onto the base unit in a first layer plane. The dispensing of the additive material is repeated layer by layer until an nth layer is reached in an nth layer plane to complete the treatment and / or dewatering product or the element thereof. "n" is understood to be a natural number.In this process, the additive material of each layer is continuously applied by at least one application unit during a layer transition between two successive layer levels.

[0007] The continuous application of the additive material during a layer transition, as used here, means that the at least one application unit applies the additive material without interruption. Accordingly, in the process according to the invention, there is no starting point that is merely shifted in height from layer to layer, thus preventing material from accumulating at this starting point. The continuous application of the additive material during the layer transition therefore prevents the formation of visible and tactile layer transitions, eliminating the need for complex post-processing to adjust and modify the shape of the manufactured element or dewatering product. This eliminates at least one process step, thereby reducing both production time and costs.

[0008] In this process, it is particularly advantageous if, during the application of the layers, a ramp with a gradient is generated by the at least one application unit at the layer transition, so that a height difference to the adjacent layer is created.

[0009] The ramp at the layer transition makes it particularly easy to continuously apply the additive material using the application unit, thus avoiding tactilely perceptible and visible transitions between individual layers. The ramp can be incorporated during the geometry preparation for the additive manufacturing process, thereby reducing the number of process steps and thus lowering production time and costs.

[0010] The ramp advantageously has a slight gradient, i.e., the ramp has an acute angle, so that the length of the ramp (adjacent side) is at least 10 times, preferably at least 50 times, and more preferably at least 100 times, greater than the height of the ramp (opposite side), where the height corresponds to the layer thickness or the height difference to the adjacent layer.

[0011] The process is particularly advantageous if at least individual layers of the n-layers are continuously and uninterruptedly applied via optimized pressure paths using at least one application unit.

[0012] The optimized pressure paths prevent the dispensing unit from settling, thus essentially eliminating material buildup caused by the unit(s) settling and re-engaging. This eliminates the need for a post-processing step. Simultaneously, the pressure paths can also be time-optimized, further reducing manufacturing time.

[0013] In this process, it can be advantageous if the additive material is dispensed by the at least one dispensing unit with a dispensing direction, wherein the dispensing direction during the dispensing of the layer transition essentially corresponds to the dispensing direction of the preceding layer.

[0014] If the application direction of the two layers is the same, this has a positive effect on the efficiency of the printing process and on the adhesion between the individual layers, as the strength increases along the layer transitions. At the same time, the surface structure of the element being produced, or the hydration and dewatering product, is uniform.

[0015] Alternatively, it is conceivable that the application direction during the application of the layer transition is opposite to the application direction of the preceding layer.

[0016] By using opposite application directions during layer transitions, pressure tolerances and unevenness can be easily compensated for. At the same time, changing the application direction can prevent warping or deformation and increase the overall structure's stability.

[0017] Accordingly, it can be advantageous for an element or a drainage and irrigation product if some layer transitions are applied in the same application direction and other layer transitions in the opposite application direction by the application unit.

[0018] Furthermore, it can be advantageous in the process if, in a step preceding the application, the geometry of the product to be treated and / or dewatered, or of the element of the product to be treated and / or dewatered, is adapted in such a way that the product or element of the product is produced and requires no further processing.

[0019] In this context, "post-processing-free" means that the geometry is adapted in such a way that it has no support structures that would require time-consuming removal. The geometry may already be designed so that overhangs and undercuts are formed by (non-removable) arcs and shapes that support the geometry itself. The geometry may also feature variable wall thicknesses, which serve as support structures or bridges to create overhangs and undercuts.

[0020] For example, in this step the ramp of the respective layer transitions can be defined and individually adjusted and / or the application direction of the layer transitions can be set and / or the pressure path of the respective geometry can be optimized.

[0021] In this preceding step, the geometry can therefore be prepared in such a way that the additive material is applied in a time-efficient and cost-efficient manner during the process.

[0022] In a further advantageous embodiment of the process, it is conceivable that at least one electronic component is integrated into the hydration and / or dewatering product or the element of the hydration and / or dewatering product to be produced during the application of the additive material. Alternatively or additionally, it is possible that at least one sensor element is integrated into the hydration and / or dewatering product or the element of the hydration and / or dewatering product to be produced during the process.

[0023] This can be done manually or using a dedicated manipulator. Integrating the electronic component or sensor has the advantage that cavities created by the geometry and those formed during additive manufacturing, which are also sealed, can be used effectively without affecting the function of the drainage product or element. The electronic components or sensors are not visible after the drainage product is finished and therefore do not influence the flow of any medium through it.

[0024] Furthermore, it can be advantageous in the process if the at least one application unit applies several additive materials simultaneously, the additive materials differing in their properties.

[0025] For this purpose, different nozzles for the respective additive material can be provided in the dispensing unit. It is also conceivable that one nozzle is provided to dispense different additive materials, in which case it is advantageous if this nozzle is cleaned before each material change.

[0026] The use of different materials increases the variability of geometries and their applications. So-called multi-material printing makes it possible to integrate different material properties, such as hardness and elasticity, into a single component. For example, it is conceivable that an element, such as a seal, could be printed from a softer material into an undercut or onto a surface to form a kind of sealing lip.

[0027] In this process, it can be particularly advantageous if at least one further application unit is provided, wherein the at least one application unit and the at least one further application unit are controlled separately from each other.

[0028] The use of two separately controlled dispensing units in an additive manufacturing process offers significant advantages in terms of flexibility and print quality. This technique allows different materials or colors to be combined in a single print job, expanding design possibilities. Multi-material printing, in particular, makes it possible to integrate various material properties, such as hardness and elasticity, into a single component. Another advantage is the time savings, as both nozzles can operate in parallel and at different positions, enabling the faster production of complex structures. Furthermore, the independent control prevents unintentional mixing of colors or materials, thus increasing precision.

[0029] The process may be advantageous if at least one of the following additive materials is used. - Polylactide (PLA) - Acrylonitrile butadiene styrene copolymer (ABS) - Acrylonitrile-styrene-acrylate copolymer (ASA) - Polyamide (PA) - Polycarbonate (PC) - Polypropylene (PP) - Glycol-modified polyethylene terephthalate (PETG) - Thermoplastic elastomers based on urethane (TPU).

[0030] These materials can be used to create the necessary and desired properties in terms of strength, stability or flexibility of the element or the drainage product.

[0031] A second aspect of the invention is a method for producing the rinsing and / or dewatering product, wherein at least one first element for a rinsing and / or dewatering product and at least one second element for a rinsing and / or dewatering product are each produced by a method according to the first aspect of the invention. In this process, a first additive material for the at least one first element is applied from a first to an nth layer level by means of the at least one application unit. In this process, a second additive material for the at least one second element is applied at least sectionally in at least one layer level, preferably in several successive layer levels, of the first additive material, in addition to the first additive material, by means of the at least one application unit.

[0032] It is conceivable that additional dispensing units, in particular a second, third, or more, may be added during the entire additive manufacturing process. The different materials can each be dispensed by a separate dispensing unit. These dispensing units can dispense their respective additive material simultaneously or sequentially. Sequential dispensing may well result in a time lag. Depending on the geometry and its complexity, the number of different materials, and the respective optimal pressure paths of the various dispensing units, this time lag can be small, i.e., between 1 ms and 120 s, preferably between 2 ms and 90 s, and more preferably between 3 ms and 60 s, or comparatively large, i.e., less than 10 h, preferably less than 8 h, and more preferably less than 6 h.

[0033] It is also conceivable that the various additive materials are dispensed using a single dispensing unit, which, in turn, requires cleaning of the unit or its nozzle before each material change. This typically results in a significant time lag, i.e., less than 10 hours, preferably less than 8 hours, and even more preferably less than 6 hours.

[0034] In the process for producing the rinsing and / or dewatering product from two additively manufactured elements, it can be particularly advantageous if the first additive material differs from the second additive material in at least one material property.

[0035] A third aspect of the invention is an element for a rinsing and / or drainage product produced by a method according to the first aspect.

[0036] This element has the advantage that it can be manufactured easily and inexpensively.

[0037] A fourth aspect of the invention is a rinsing and / or drainage product produced by a method according to the first aspect or according to the second aspect of the invention.

[0038] This drainage and / or irrigation product has the advantage of being easy and inexpensive to manufacture.

[0039] A fifth aspect of the invention is a rinsing and / or drainage product comprising at least a first element according to the third aspect of the invention.

[0040] A sixth aspect of the invention is a rinsing and / or drainage product comprising at least one element with n layers of at least one additive material in n layer planes, wherein at least one layer transition between two successive layer planes includes a ramp with a slope.

[0041] Advantageously, in a drainage and / or irrigation product according to the fifth or sixth aspect, at least one second element according to the third aspect is provided, made of at least one second additive material. Alternatively, it is conceivable that at least one second element is provided with several layers of at least one second additive material in several layer planes. In both alternatives, the at least one second element is integrated, at least sectionally, in at least several successive layer planes of the first additive material, complementing the first additive material into which the at least one first element is integrated.

[0042] The invention will below be described with regard to further features and advantages using exemplary embodiments, which are explained in more detail with reference to an illustration.

[0043] This shows: Fig. 1 a schematic representation of a first process (100) for the additive production of a dehydration and irrigation product; Fig. 2 a schematic representation of a first process step (a) and an nth process step (b), Fig. 3 a schematic representation of various superimposed layer transitions in a section A from Fig. 1b, Fig. 4. Schematic representation of a drainage and irrigation product consisting of two elements in a top view. Fig. 5 Schematic representation of a drainage product with an integrated electronic component.

[0044] In Fig. 1 and Fig. Figure 2 shows schematic representations of a process 100 for additive manufacturing, in particular a fused deposition process, of a hydration and / or dehydration product 10 comprising two elements 12.

[0045] Both representations can also show the production of only one element 12 of the rinsing and / or dewatering product 10; in that case, the path with the application unit 18 is sufficient (right-hand process path in Fig. 1) However, this representation can also show the production of the irrigation and / or drainage product 10.

[0046] A device 14 for additive manufacturing is provided. This device 14 has a base unit 16 as a reference plane and at least one dispensing unit 18 for the selective dispensing 110 of an additive material 20. Starting from the reference plane, the respective dimensions of the final product, i.e., height, width, length, are built up using the device 14 in order to produce the dewatering and irrigation product 10.

[0047] The at least one application unit 18 is positioned such that a first layer 22 of the additive material 20 is applied to the base unit 16 in a first layer plane, as shown in Fig. 2a shown.

[0048] The application 110 of the additive material 20 is repeated layer by layer until an nth layer 24 is reached in an nth layer plane to complete the entrainment and / or dewatering product 10 or the element 12 of the entrainment and / or dewatering product 10, as shown in Fig. 2b shown.

[0049] In order to reduce the costs and time of post-processing, the additive material 20 of the respective layer 22, 23, 24 is continuously applied by at least one application unit 18 110 during a layer transition 26 between two successive layer levels. The layer transition 26 is carried out gradually and continuously, so that an abrupt change and associated problems, such as material accumulation, etc., are prevented.

[0050] As in Fig. 2b and enlarged in Fig. As shown in Figure 3, the at least one application unit 18, or the first application unit, during the application 110 of layers 22, 23, 24 at the layer transition 26, creates a ramp 28 with a gradient such that a height difference to the adjacent layer 23 is generated. The longitudinal extent of the ramp 28 is at least 10 times greater than the resulting height difference to the next adjacent layer 23.

[0051] In addition to the first application unit 18, as in Fig. 2a and Fig. As shown in Figure 2b, at least one further dispensing unit 38, also referred to here as the second dispensing unit 38, is provided. The at least one dispensing unit 18 and the at least one further dispensing unit 38 are controlled separately 140 to dispense interlocking structures or elements 12. The two dispensing units 18, 38 dispense different materials 20. In the exemplary embodiment, the materials 20 used are a urethane-based thermoplastic elastomer TPU as the first additive material 20 and polyamide as the second additive material 20. However, other thermoplastics, such as polylactic acid (PLA), acrylonitrile butadiene styrene copolymer (ABS), acrylonitrile styrene acrylate copolymer (ASA), polycarbonate (PC), polypropylene (PP), or glycol-modified polyethylene terephthalate (PETG), can also be used for both the first and the second additive material 20.

[0052] In Fig. Figure 2b additionally shows the possibility that only one dispensing unit 18 is provided, which is capable of performing multi-material printing. This means that the at least one dispensing unit 18 dispenses several additive materials 20 simultaneously, whereby the additive materials 20 differ in their properties.

[0053] In the illustrated embodiment, the additive material 20 is dispensed by the first dispensing unit 18 with a dispensing direction 32, wherein the dispensing direction 32 during the dispensing 110 of the layer transition 26 essentially corresponds to the dispensing direction 32 of the preceding layer 22, 23. Additionally, the dispensing direction 32 during the dispensing 110 of the layer transition 26 can be opposite to the dispensing direction 32 at a location of the element or of the entrainment and / or dewatering product of the preceding layer 22, 23 that is not explicitly shown.

[0054] In Fig. Figure 4 shows a coating and / or dewatering product whose individual layers 23, or all layers of the n-layers 22, 23, 24, were continuously and uninterruptedly applied 110 by means of at least one application unit 18 via optimized pressure paths 30. In a step preceding the application 110, the geometry of the coating and / or dewatering product 10 to be produced, or of the element 12 of the coating and / or dewatering product 10 to be produced, was adapted 120 such that the produced coating and / or dewatering product or the produced element 12 of the coating and / or dewatering product 10 requires no post-processing. During the adaptation 120, the pressure paths 30 are adjusted to the geometry and optimized so that the application unit 18 does not have to stop orthat the materials of the first and second application unit 18, 38 are dispensed into each other in a transition area 110 in such a way that the strength and stability of the final product is ensured, i.e. that the materials 20 dispensed into each other are not detachably connected to each other without damage.

[0055] In order to be able to carry out measurements during the operation of the treatment and / or dewatering product, at least one electronic component 34 and at least one sensor 36 are integrated into the treatment and / or dewatering product 10 or the element 12 of the treatment and / or dewatering product 10 to be produced, respectively, during the application 110 of the additive material 20, as shown in 130. Fig. 5 shown. For this purpose, the device 14 can have a further manipulator (not shown) which integrates the electronic component 34 and the sensor 36 into a newly formed and enclosed cavity 40 during the layer-by-layer application 110 of the additive material 20.

[0056] As in Fig. 4, indicated by the dashed circle and briefly mentioned above, this drainage and / or irrigation product is formed by several elements 12. At least one or all of the elements 12, as shown in Fig. 2b and Fig. 4 shown, as described above and in the Fig. The processes shown in 1 to 5 are used.

[0057] As an example, Fig. 2b and Fig. 4 also process 200 for producing the treatment and / or dewatering product 10, wherein at least one first element 12 for a treatment and / or dewatering product 10 is produced by a process 100 described above, and wherein at least one second element 12 for a treatment and / or dewatering product 10 is also produced by a process 100 described above. The first additive material 20 for the at least one first element 12 is applied from a first to an nth layer level 22, 23, 24 by means of the at least one application unit 18. Additionally, the second additive material 20 for the at least one second element 12 is applied at least sectionally in at least one layer level 23, preferably in several successive layer levels, of the first additive material 20, supplementing the first additive material 20, by means of the at least one application unit 18 or the second application unit 38, as e.g., in Fig.2b shown.

[0058] If an application unit 18 is used, the materials 20 can be applied successively to the respective layer 23 110. For this purpose, the application unit 18 has a nozzle for each material.

[0059] It is also conceivable that several layers 23 of the first material 20 are applied first, then the application unit 18 is cleaned, in order to subsequently apply several layers 23 of the second material 20. This material change can be repeated several times. Several hours can then elapse between the application 110 of the layers 23 to allow for proper cleaning.

[0060] If two or more application units 18, 38 are used, then the application 110 of the different materials 20 can be carried out essentially simultaneously or with a slight time offset in the range of 3ms to 60s.

[0061] As described above, in this process too, the first additive material 20 differs from the second additive material 20 in at least one material property. Reference symbol list 100 procedures 110 Spreading 120 Adjust 130 Integrate 140 taxes 200 procedures 10. Irrigation and / or drainage product 12 Element 14 Device 16 basic unit 18 first application unit 20 additive materials 22 first shift 23rd shift 24 nth shift 26 Shift transition 28 Ramp 30 Print path 32 Application direction 34 electronic component 36 Sensor 38 second application unit 40 cavity

Claims

[1] A method (100) for the additive manufacturing, in particular a fused deposition method, of a treatment and / or dewatering product (10) or of an element (12) of the treatment and / or dewatering product (10) by means of an additive manufacturing device (14), wherein the device (14) comprises a base unit (16) as a reference plane and at least one dispensing unit (18) for the selective dispensing (110) of an additive material (20), wherein the at least one dispensing unit (18) is positioned such that a first layer (22) in a first layer plane of the additive material (20) is dispensed onto the base unit, wherein the dispensing of the additive material (20) is repeated layer by layer until an nth layer (24) in an nth layer plane is completed to form the treatment and / or dewatering product (10) or the element (12) of the treatment and / or dewatering product. (10) is achieved, characterized by, that the additive material (20) of the respective layer is continuously dispensed (110) by the at least one dispensing unit (18) during a layer transition (26) between two successive layer levels. [2] Method (100) according to claim 1 characterized by , that during the application (110) of the layers (22, 23, 24) a ramp (28) with a slope is generated by the at least one application unit (18) in the layer transition (26) so that a height difference to the adjacent layer (23) is created. [3] Method (100) according to claim 1 or 2 characterized by , that at least individual layers (23) of the n layers (22, 23,24) are continuously and without interruption applied (110) by means of optimized pressure paths (30) using at least one application unit (18). [4] Method (100) according to any one of the preceding claims characterized by, that the additive material (20) is dispensed by the at least one dispensing unit (18) with a dispensing direction (32), wherein the dispensing direction (32) during the dispensing (110) of the layer transition (26) is substantially the same as the dispensing direction (32) of the preceding layer (22, 23) or wherein the dispensing direction (32) during the dispensing (110) of the layer transition (26) is opposite to the dispensing direction (32) of the preceding layer (22, 23). [5] Method (100) according to any one of the preceding claims characterized by , that in a step preceding the application (110), a geometry of the treatment and / or dewatering product (10) to be produced or of the element (12) of the treatment and / or dewatering product (10) to be produced is adapted (120) such that the treatment and / or dewatering product produced or the element (12) of the treatment and / or dewatering product produced (10) is free from post-processing. [6] Method (100) according to any one of the preceding claims characterized by , that during the application (110) of the additive material (20) at least one electronic component (34) and / or at least one sensor element (34) is integrated (130) into the treatment and / or dehydration product (10) to be produced or of the element (12) of the treatment and / or dehydration product (10) to be produced. [7] Method (100) according to any one of the preceding claims characterized by , that the at least one application unit (18) applies several additive materials (20) simultaneously, the additive materials (20) differing in their properties. [8] Method (100) according to any one of the preceding claims characterized by , that at least one further application unit (38) is provided, wherein the at least one application unit (18) and the at least one further application unit (38) are controlled separately from each other (140). [9] Method (100) according to any one of the preceding claims characterized by that at least one of the following additive materials is used: - Polylactide (PLA) - Acrylonitrile butadiene styrene copolymer (ABS) - Acrylonitrile-styrene-acrylate copolymer (ASA) - Polyamide (PA) - Polycarbonate (PC) - Polypropylene (PP) - Glycol-modified polyethylene terephthalate (PETG) - Thermoplastic elastomers based on urethane (TPU) [10] Method (200) for producing the treatment and / or dewatering product (10), wherein at least one first element (12) for a treatment and / or dewatering product (10) is produced by a method (100) according to any one of claims 1 to 9, and wherein at least one second element (12) for a treatment and / or dewatering product (10) is produced by a method (100) according to any one of claims 1 to 9, wherein a first additive material (2β) for the at least one first element (12) is applied from a first to an nth layer level (22, 23, 24) by means of the at least one application unit (18), and wherein a second additive material (20) for the at least one second element (12) is applied at least sectionally in at least one layer level (23), preferably in several successive layer levels, of the first additive material (20) in addition to the first additive material (20) by means of the at least one The application unit (18) is applied. [11] Method (200) according to claim 10 characterized by , that the first additive material (20) differs from the second additive material (20) in at least one material property. [12] Element (12) for a rinsing and / or drainage product (10) produced by a method according to any one of claims 1 to 9. [13] Irrigation and / or drainage product (10) produced by a method according to any one of claims 1 to 9 or claim 10. [14] A rinsing and / or drainage product (10) comprising at least one first element (12) according to claim 11. [15] a hydration and / or drainage product (10) comprising at least one element (12) with n layers (22, 23, 24) of at least one additive material (20) in n layer planes, wherein at least one layer transition (26) between two successive layer planes includes a ramp (28) with a slope. [16] Irrigation and / or drainage product (10) according to claim 14 or claim 15, characterized by , that at least a second element (12) according to claim 12 is provided from at least a second additive material (20) or that at least a second element (12) is provided with several layers (22, 23, 24) of at least a second additive material (20) in several layer planes, wherein the at least one second element (12) is integrated at least sectionally in at least several successive layer planes of the first additive material (20) in addition to the first additive material (20) into the at least one first element (12).

Images