Additive manufacturing of an object using freely movable slides

Abstract

In a method for producing an object (4) from at least one production material (6a-c) with the aid of an additive manufacturing process (8), a movement surface (10) and, fixed above said movement surface, at least one production station (12a-f) for the object (4) and at least one object carrier (14) are provided, which has a production surface (16) for the object (4), wherein the object carrier (14) can move freely in translation relative to the movement surface (10) in at least two degrees of freedom (x, y) and the production surface (16) can tilt in at least a third degree of freedom about at least one tilt axis (18) running parallel to the movement surface (10). A system (2) contains the movement area (10), the production stations (12a-f), and the object carriers (14) with the production areas (16).

Description

State of the art

[0001] The invention relates to a method and a system for manufacturing an object from at least one production material using an additive manufacturing process.

[0002] From DE 10 2022 200 357 A1 a connecting element is known for electrically contacting circuit carriers, in particular printed circuit boards, with a base body produced by an additive process, with first electrically conductive regions arranged on a surface of the base body, in particular in the form of conductor tracks, which are designed to come into contact with second electrically conductive regions of the circuit carrier, and with an opening for receiving an edge section of the circuit carrier, wherein the first electrically conductive regions are arranged on the base body in the region of the opening and form contact sections for the second electrically conductive regions of the circuit carrier.

[0003] From DE 10 2022 201 974 A1 a method is known for producing a carrier substrate on a semiconductor wafer, which has a front side and a back side, wherein the front side is opposite the back side, wherein the front side represents a structured semiconductor wafer side with contact regions, comprising the steps of applying at least one first layer to the front side by means of printing technology, wherein the at least one first layer comprises a first material which is insoluble in water, and curing the at least one first layer by means of UV radiation, thermally or by means of sintering. Disclosure of the invention

[0004] The invention relates to a method according to patent claim 1. Preferred or advantageous embodiments of the invention and other categories of invention emerge from the further claims, the following description and the attached figures.

[0005] The process is designed or used to manufacture an object. The object is manufactured from the production material using an additive manufacturing process.

[0006] In the method, a movement surface is provided. The movement surface is, in particular, flat, runs horizontally, thus forming a floor, and / or vertically, thus forming a wall, and / or horizontally overhead, thus forming a ceiling.

[0007] In addition, the method provides at least one production station fixed above the movement area. The production stations are used or are set up to produce the object. “Above the movement area” refers to the area and the surface normal pointing away from the area. If the area is a vertical floor, “above” actually means “vertically above.” If the area is a vertical wall, “above” means “horizontally next to” the area; if the movement area is overhead, “above the area” means, in absolute terms, “below the ceiling.” “Production by the production stations” means that each of the production stations takes over at least part of the production of the object. In the case of a single production station, this station takes over the entire production of the object.

[0008] At least one of the manufacturing stations must therefore contain at least one manufacturing tool for the object to additively add material to the object. This could be, for example, a print head for depositing manufacturing material, a laser for solidifying manufacturing material in a material bed, etc., depending on the type and nature of the additive manufacturing process used. Additional manufacturing stations can also be used for curing, laser processing, material removal, inspection of the object, etc.

[0009] The method also provides at least one object slide. Each object slide contains a production area. The production area can be a single, contiguous area or a multi-part production area. The production area serves or is configured to manufacture the object using the production process or production stations.

[0010] In the method, the specimen slide is configured to move freely in translation relative to the movement surface in at least two degrees of freedom, in particular in orthogonal x and y spatial directions. In other words, the specimen slide can move freely in translation over the entire surface of the movement surface. “Freely” is to be understood in this case as meaning that no mechanical guides such as rails, guard rails, etc. are provided that would guide or limit the movement of the specimen slide. Exceptions to this are, for example, limitations that prevent a specimen slide from leaving the movement surface or entering a certain area thereof. In the remaining area, however, free movement is always possible. The translational movement therefore takes place along or parallel to the movement surface.

[0011] The specimen slide is also configured to have at least a third degree of freedom. According to this third degree of freedom, the production surface can be tilted about a tilt axis, or the specimen slide can perform the corresponding tilt. The tilt axis runs parallel to the movement surface.

[0012] In the method, the production surface of at least one of the object slides is preferably tilted at least once around the tilt axis during the creation of the object. “During creation” means that the tilting occurs after the start of the creation of the object and before the end of the creation of the object. The “creation” can be divided into at least two production phases and a pause in between. During the production phases, additive production material is actually added to the object or the object is otherwise actively manufactured / processed / inspected, etc. During the pauses, no production material is added to the object and no other active production step takes place on the object. The tilting can also occur during such a pause. Alternatively, the tilting actually occurs during an active production phase. This will be explained in more detail below.

[0013] The creation of the object on the production surface particularly involves the production of the object on a substrate, which in turn is arranged on the production surface. Such a substrate could be, for example, a semiconductor wafer, a carrier plate, etc. Alternatively, the object can also be created directly on the production surface or with only a release film interposed, etc., to avoid, for example, direct contact between the object and the production surface and to be able to easily detach it from the production surface.

[0014] By tilting the production area around the tilt axis, a particularly varied and advantageous production of the object is possible and / or a simplification of the production stations, as explained in detail below.

[0015] With the additive manufacturing process, objects can be produced from any material.

[0016] In a preferred embodiment, the additive manufacturing process is one for producing metallic objects and / or objects made of plastic and / or ceramic and / or a 3D printing process and / or an inkjet-based printing process and / or a LIFT (laser-induced forward transfer) process and / or a STEP (Selective Thermoplastic Electrophotographic Process) process and / or an electrostatic multi-nozzle printing process and / or selective laser beam melting. The inkjet-based printing process used is, in particular, inkjet printing on wafers, as is known, for example, from DE 10 2022 201 974 A1.

[0017] Thus, the method according to the invention can be used in conjunction with most common additive manufacturing processes and its advantages can be transferred to the corresponding manufacturing process or used within its framework.

[0018] In a preferred embodiment, the specimen slide is configured to move with a further degree of freedom, namely to rotate about an axis of rotation perpendicular to the movement surface. In other words, the specimen slide can not only be translated across the movement surface, but can also rotate or turn on it. Alternatively or additionally, the specimen slide is configured to move the production surface translationally perpendicular to the movement surface according to a further degree of freedom. In other words, the production surface can then not only be tilted relative to the movement surface, but its (height) distance from the movement surface can also be changed. This also enables further simplifications in the production stations and, in particular, opens up a wide variety of possibilities for implementing the additive manufacturing process.

[0019] Both the tilting of the production surface and its height offset can be achieved as follows: The production surface can be fixed relative to the rest of the slide, e.g., the slide can be rigidly constructed. The movement of the production surface is then achieved by moving the entire slide. This is achieved, in particular, with a slide in the form of a floating substrate stage (SST), see below.

[0020] In a preferred embodiment, the production surface is tilted at least once around the tilt axis while the object is being manufactured at one of the production stations. In other words, the tilting actually occurs during the active production of the object (production phase, not pause, see above), for example, during the continuous deposition of production material to form the object, during a hardening step on the object, or while another production step is being performed, such as an inspection, measurement of the object, etc. This allows the respective production or the currently executed production step to be carried out with a particularly wide variety of options.

[0021] In a preferred embodiment, the production surface is also tilted before the start of creation of the object and / or tilted at least once around the tilt axis during (after the start of) creation of the object, but while no production is taking place on the object slide by any of the production stations. In other words, the tilting then takes place during an above-mentioned pause and not during a production phase. Although the tilting is also carried out during production (i.e. after the start of production and before the end of production), in contrast to the above, it does not take place during an active production step, but rather in a pause between two production phases, i.e. when no further material is being deposited on the object, no consolidation, measurement, testing or other process is taking place.

[0022] In particular, tilting occurs when the slide is located far away from all production stations, so that a production phase is excluded anyway.

[0023] In particular, tilting occurs between two production phases at at least one production station. Alternatively, the slide is tilted before the creation of the object begins, i.e., before the actual deposition of production material on the slide begins.

[0024] In a preferred embodiment, the specimen slide or the production area or the (if manufactured) object passes through one of the production stations, in particular the same one, at least twice during the creation of the object (after the start and before the end), in different production directions. These can therefore be the same or different production stations. The decisive factor is the creation of anisotropy in the object through different production directions on the object. The anisotropy / production direction is therefore related to the object. To achieve this, for example, the specimen slide can pass through a production station in the same absolute direction, but rotated around the rotation axis by an angle (not equal to n * 360° for successive passes). Or the slide moves - in particular unrotated around the rotation axis - in different absolute directions through the production stations.The “different manufacturing directions” therefore refer solely to the relative relationship between the object itself and the direction in which a manufacturing step is carried out on the object.

[0025] The anisotropy created in this way can improve the properties of the object.

[0026] In a preferred embodiment, at least one production head is fixed in place in at least one of the production stations, or at most is mounted so that it can be moved exclusively perpendicular to the movement surface. The production head is used to produce the object. Such a production head is, for example, the print head described above or a laser for solidifying material from a material bed, etc. "Fixed" here refers to the position relative to the movement surface. The production head can also be, for example, a curing unit, a loading and unloading device for object slides, a measuring station for objects, etc. The production stations can thus be designed particularly simply. Any positioning of the object relative to the production head is then taken over by the object slide or the production surface, which can move according to the degrees of freedom mentioned above.

[0027] In a preferred embodiment, they are provided at least two production stations (in the planar extension direction of the movement surface, i.e., at different surface locations) at a distance from one another, stationary above the movement surface. At least one of the slides then passes successively through at least two of the production stations, with the object being (partially) manufactured by each of the production stations. Both stations therefore contribute to the production of the object; the object is not manufactured by one of the production stations alone. "Production" is to be understood broadly here and refers to both the additive deposition or addition of production material to the object as well as other processing steps on the object, for example, hardening, measuring, further processing, intermediate processing, etc.This enables a division of labor between production stations and, in particular, a production cycle along a circular track, as will be explained in more detail below.

[0028] In a preferred embodiment, at least two specimen slides are provided. The at least two specimen slides pass one after the other through at least one of the production stations. The objects on the respective specimen slides can thus be produced in particular continuously / quasi-continuously by the production station, for example if a type of "chain" of specimen slides passes through the production station without a break. Short breaks are only necessary between the departure of one specimen slide and the arrival of the next. Longer breaks during production, for example to move a specimen slide back and forth under the production station (to slow down, to accelerate) can be omitted. The production station can thus be operated continuously / (quasi-)continuously by specimen slides repeatedly passing through the production station in one throughput direction and the respective objects being produced on each of the specimen slides.For example, a ring-shaped arrangement is possible, or a loop that runs through at least one production station, with several slides circulating or moving within the loop. This allows for particularly efficient production of the slides and operation of the production stations.

[0029] In a preferred embodiment, a tool associated with at least one of the production stations is provided on at least one of the slides. The production station is then processed using the tool. Such a tool can, for example, be a repair, cleaning, or maintenance tool for the respective production station. Thus, slides can be used multifunctionally, both for producing objects on them and for maintenance / processing, etc., of the production stations. "Associated" means that the tool is capable of performing an activity at the production station.

[0030] In a preferred embodiment, at least one of the slides is configured to move contactlessly relative to the movement surface. In particular, the slide is designed as a so-called floating substrate table (SST). Such slides are available, for example, from the product "ctrlX FLOW 6D “ of the company Bosch Rexroth, see e.g. “https: / / apps.boschrexroth.com / microsites / ctrlx-automation / de / portfolio / ctrlx-flow / , accessed on February 16, 2024”.

[0031] In particular, the relative position between the production surface and the rest of the slide is fixed. The production surface is thus moved relative to the movement surface by moving the entire slide accordingly. In particular, the production surface is a fixed and immobile component of a completely rigid slide. The tilting of the production surface relative to the movement surface, as well as the movement of the production surface in the normal direction to the movement surface, is then achieved solely by moving the entire slide, in particular its tilting and raising or lowering relative to the movement surface.

[0032] In a preferred embodiment, a track is provided on the movement surface, and at least one of the specimen slides is moved along the track to pass at least one of the production stations. Since the specimen slides are freely movable on the movement surface, the track is not a mechanical guide but rather a virtual track or a movement instruction for the specimen slides on the movement surface. In other words, a specific path is prescribed for how the specimen slide, in particular several specimen slides in a row, move along the movement surface. This enables coordinated movement of the specimen slides on the movement surface. The track can be a single linear track, but alternatively it can also contain branches, loops, etc., i.e. it can have circular tracks.

[0033] In a preferred variant of this embodiment, the track is provided with at least one first ring section. The first ring section serves at least for the partial, in particular complete, additive construction of the object using the additive manufacturing process. The first ring section therefore contains at least one production station. It contains, in particular, for example, one or more print heads for one or more production materials, a unit for laser beam melting, an NIR module (near infrared), a curing module for the object / production material, etc. The track is also provided with at least one second ring section branching off from the first ring section. The second ring section serves for the other production of the object, i.e. either for part of the additive construction or, for example,Only or also for measuring, inspecting, or loading the slides with additional elements of the object, such as prefabricated elements to be integrated into the object, such as a pick-and-place module. The second ring section can alternatively or additionally be used for loading and / or unloading the slide.

[0034] This allows for different ring sections to be used for different tasks in the production / processing of the object, which enables particularly efficient process execution.

[0035] A further subject matter of the invention is a system according to patent claim 14. This system serves or is preferably configured to carry out the method according to the invention, i.e. it is a manufacturing system for manufacturing the object from the at least one manufacturing material with the aid of the additive manufacturing process(es).

[0036] The system contains the movement surface. The system contains at least one production station for at least partially producing the object, which is provided in a fixed position above the movement surface. The system contains at least one object carrier, which has the production surface on which the object is manufactured with the aid of the production stations. The object carrier is configured to move freely in translation relative to the movement surface in at least two degrees of freedom, and is configured to tilt the production surface (at least once during the creation of the object) about the at least one tilt axis running parallel to the movement surface in at least one third degree of freedom.

[0037] The system has already been described in connection with the method. In particular, the system has the embodiments mentioned above in connection with the method, for example, multiple slides, multiple production stations, corresponding tracks, slides with additional degrees of freedom, etc.

[0038] The invention is based on the following findings, observations, and considerations and also includes the following preferred embodiments. These embodiments are sometimes referred to as "the invention" for simplicity. The embodiments may also contain parts or combinations of the above-mentioned embodiments or correspond to them and / or may also include previously unmentioned embodiments.

[0039] According to the invention, a flexible delivery of an object / substrate (on which an object is to be built) / production area for an additive manufacturing process, in particular inkjet printing, in particular continuous inkjet printing, results.

[0040] The invention is based on the following practical observation: In order to print an object onto a substrate using inkjet printing or to produce a 3D-printed component (object), the substrate must move in the x and y directions to the print head (production station). If the substrate has a varying height, movement in the z direction is also required. Movement in the x or y direction is usually achieved by either the print head or the substrate being on linear axes and moving accordingly in the xy direction. Alternatively, the print head can move in the x direction, for example, and the substrate in the y direction. In the z direction, the print head, for example, is moved in the z direction. The printing distance in inkjet printing is typically in the range of 1 mm and can be increased by a few millimeters with a reasonable reduction in print quality.

[0041] For example, a substrate on the printing table (movement area / relative to the production station) always moves from front to back and back again.

[0042] Printing often occurs only during movement in one direction, and no printing occurs during the return movement, as this can reduce reproducibility and accuracy. Furthermore, the speed should be as constant as possible during printing. During acceleration and deceleration, or at the turning point, no printing occurs at all. This means that, overall, only a small portion of the time is actually printed, and a significant portion is spent accelerating and reversing the substrate table (slide / production area).

[0043] Further time is lost for example • Curing the ink e.g. with UV light etc. • Loading and unloading the substrate table

[0044] The invention is based on the idea that a production surface, in particular the substrate to be printed, is delivered to the print head (production station) by means of a floating substrate table (SST, object carrier, e.g., the ctrlX FLOW6D from Bosch Rexroth) and executes the necessary movement beneath the print head. The floating substrate table can change its z-position, tilt, rotate freely, and move freely in the x- and y-directions. Multiple SSTs can be controlled individually, thus essentially moving independently of one another.

[0045] According to previous practice, the rigid alignment of the substrate table meant that the substrate or 3D-printed component could only be printed in one direction, which could result in anisotopic properties (e.g. different tensile strength in the x- and y-direction).

[0046] The invention enables: When printing multiple layers, the substrate / production surface moves under the printing table (production station) at different angles. This reduces anisotropy.

[0047] Previous practice for printing on curved surfaces included the following: The substrate table (production area) could not be tilted relative to the print table (production station), so printing could only be done vertically from above. The print head could not be positioned closer to the substrate than the highest point of the substrate / production area.

[0048] The invention enables: The substrate table / production area can be tilted during printing. • Tilting occurs before the substrate passes under the print head / production station. This allows, for example, deeper spots on the substrate to be reached or steeper surfaces to be printed. • Tilting occurs as the substrate passes under the print head. This allows, for example, the interior of convex surfaces to be printed. • The print table / production area changes its z-position: This allows an optimal distance between the print head and the substrate / object / production area to be achieved.

[0049] In summary, the floating substrate table allows printing on surfaces that are currently impossible or difficult to print. When 3D printing objects, better / more homogeneous (keyword: anisotropy) component properties can be achieved.

[0050] According to previous practice, the pure printing time for inkjet is usually less than 50% of the total process time, since no printing takes place during the deceleration and acceleration of the printing table (slide / production area) or print head (production head) as well as, for example, during loading and unloading or curing of the ink.

[0051] The invention enables: continuous printing by SST: Multiple SSTs run through the process one after the other, e.g., in a ring-shaped arrangement. While printing is already underway on a (second) SST2, (a first) SST1 can accelerate or change its direction, and (a third) SST3 can decelerate or change its direction. This allows for continuous printing and significantly increases throughput.

[0052] According to previous practice, when printing multiple materials, the print heads are arranged one after the other. The curing unit (e.g., UV lamp) is also located before or after the print heads. In order to print and expose the entire substrate table (slide), the required travel distance (back and forth) of the substrate table / slide is extended. This reduces throughput because the time during which printing is not taking place is increased.

[0053] The invention enables: Continuous tracking of the SST does not reduce throughput, even if the process path is increased. Previous practice has been: The printing process is stopped for loading (loading the substrate table / production area with substrates or placing a slide) or unloading (removing the printed substrate, the 3D-printed object, or the slide).

[0054] The invention enables: For loading and unloading, the corresponding SST moves to the loading / unloading station. All other SSTs can continue printing, so the printing process is not interrupted and throughput is not reduced.

[0055] In summary, SST enables a continuous inkjet printing process. Furthermore, throughput is not reduced when, for example, multiple materials are to be printed in parallel or the printed materials are to be cured in parallel. These advantages are particularly evident in 3D printing, as an object is generated by printing many layers, and thus the printing process of one layer must be repeated frequently (up to several thousand times, depending on the object height).

[0056] In inkjet-based 3D printing, the invention could increase throughput by a factor of 2-10 compared to solutions known from practice, using the same number of print heads.

[0057] In particular, the invention leads to a much more flexible substrate delivery in inkjet printing through the use of a levitating substrate carrier for delivering the substrate under the print head.

[0058] According to the invention, the substrate in inkjet printing is supported by a levitating substrate carrier (object slide / production surface). This can rotate, tilt, and change its z-position during the printing process. This allows the z-distance to the surface to be printed to be kept as small as possible. Furthermore, printing on the substrate from different directions is possible. • Rotation of the substrate when printing different layers. • Tilting the substrate to improve accessibility at certain points on the substrate.

[0059] According to the invention, the substrate delivery (on the production area: this can be, for example, a component to be printed (e.g., a film) or a slide / printing plate on which 3D objects are printed) is carried out by an SST (e.g., based on ctrlX FLOW6D technology from Bosch Rexroth). The SST can move freely in the x- and y-directions within the limits of the base platform (movement area). In the z-direction, movements in the range of, for example, + / -10mm are possible. As is usual with inkjet printing, the SST moves at a constant speed under a print head (production station), so that the print image is deposited on the substrate (film, 3D-printed object, etc.).

[0060] To print multiple layers, the SST returns to its starting point (especially along a ring section), and the process repeats until, for example, the 3D object(s) are completely printed. In the z-direction, the print head (production head) moves upwards as the substrate height increases. At lower heights, the SST can also be moved downwards. • Variant 1: Multiple SSTs are used. Each SST can move independently in the x and y directions within the boundaries of the base platform (movement area) or can be controlled individually. The substrates on the SST are printed one layer at a time. After printing, the SSTs move in a loop back to the starting point, allowing multiple layers or one or more 3D objects to be printed on one SST. • Option 2: Like Option 1, except that a curing unit (e.g., UV lamp or NIR (near-field infrared)) is used to cure the ink. After printing, the SSTs move beneath a curing unit. They can do this at the same speed as during printing, or at a slower or faster speed. The SSTs then return to their starting point. • Variant 3: Like Variant 1 or like Variants 1+2, except that multiple print heads with different inks are used. The SSTs can pass through print heads with different inks / materials (e.g., different hardness, colors, etc.) to produce multi-material or multi-color components. • Variant 4: As in variants 1, 2, and 3, except that individual SSTs can be removed from a first loop 1 (ring section) in order to, for example, load or unload the SST (particularly in further ring sections), or to perform a separate curing process (e.g., NIR), a pick-and-place process into a cavity, a dispensing process, a component / height measurement, etc., or an alignment of the substrates / components on the SST. The SST can then be reinserted into the further printing process. The printing process itself does not need to be interrupted, so throughput is not reduced. • Option 5: A tool, e.g., a cleaning station (wiping, vacuuming) for printhead cleaning (processing the production station), can also be located on an SST. This tool can be moved under the printhead as needed to clean the printhead (advantage: faster cleaning than with conventional solutions). Furthermore, a nozzle inspection device could also be moved under the printhead as a tool to inspect the condition of the nozzles.

[0061] In addition to inkjet technology, the invention, in particular an SST as described here, can also be used in other printing technologies, such as Laser Induced Forward Transfer (LIFT), Selective Thermoplastic Electrophotographic Process (STEP), Electrostatic Multi-Nozzle Printing, ...) Inkjet structures (objects) produced according to the method show certain characteristics as a result, based on which it can be recognized in which direction printing was carried out.

[0062] The process significantly reduces the costs of inkjet-printed 3D components through significantly increased speed. Furthermore, the flexible use of additional processes (multi-material, pick & place) enables more complex components.

[0063] The invention can be used for: • Systems for inkjet-based additive manufacturing. • The process can be used, for example, to produce a printed wafer carrier to improve the layer properties. • For printing curved covers / housings etc. • The invention can be used for many plastic-based components or assemblies such as covers, sensor carriers, housings.

[0064] Further features, effects, and advantages of the invention will become apparent from the following description of a preferred embodiment of the invention and the accompanying figures. Each of these figures shows a schematic diagram: Fig. 1 a plant for manufacturing an object from at least one production material in a plan view with a slide, Fig. 2a a side view of a part of the system from Fig. 1 in the production of the object to a specific and Fig. 2b at a subsequent time, and Fig. 2c of an alternative object to a specific and Fig. 2d at a subsequent time, whereby the slide passes through the production station again in its entirety, Fig. 3a in a representation according to Fig. 2 the production of an alternative object to a specific, Fig. 3b a subsequent, Fig. 3c and another subsequent time point, while the slide passes through the production station once, Fig. 4a in plan view, how a slide enters a production station for the first time, Fig. 4b rotated a second time by 45°, Fig. 4c rotated a third time by 90°, Fig. 4b a fourth time twisted by 135°, Fig. 5 an alternative investment in a representation according to Fig. 1 with four production stations and eight slides, Fig. 6 an alternative investment in a representation according to Fig. 1 with six production stations and thirteen slides as well as a track with five ring sections.

[0065] Fig. 1 shows a system 2. This system serves to carry out or is set up to carry out a process. The process serves to manufacture an object 4 from a production material 6 using an additive manufacturing process 8. The object 4 is only shown symbolically here, and the additive manufacturing process 8 is also only symbolically indicated by an arrow. System 2 contains a movement area 10. In the example, this is flat and horizontally aligned. System 2 also contains a production station 12. System 2 is therefore a production system for objects 4 from the production material 6 using the additive manufacturing process 8 in the production station 12.

[0066] Fig. 2 shows a side view of the system 2 in the direction of arrow II in Fig. 1 in a highly symbolic representation. Here it can be seen that the production station 12 in a spatial direction z (in Fig. 1 perpendicular to the plane of the page) above the movement area 10. “Stationary” means that this is in relation to the spatial directions x and y (in Fig. 2 perpendicular to the plane of the page) and the spatial direction z rests at a fixed position relative to the movement surface 10. The spatial directions x, y, z are those of a Cartesian coordinate system.

[0067] Annex 2 also contains a slide 14. This is in Fig. 1 several times at different times to illustrate how it moves over time. The object carrier 14 has a production surface 16. The object carrier 14 is configured to move in two degrees of freedom, namely the degrees of freedom or spatial directions x and y, translationally and freely relative to the movement surface 10. Furthermore, the object carrier 14 is configured to tilt the production surface 16 in a third degree of freedom about a tilt axis 18 (which thus represents the corresponding degree of freedom), which in Fig. 2 runs perpendicular to the plane of the page and parallel to the spatial direction y. In any case, the tilt axis 18 always runs parallel to the movement surface 10.

[0068] Plant 2 is designed to carry out the following process in the form of a manufacturing process for objects 4: In the process, the objects 4 are manufactured from the production material 6 using the additive manufacturing process 8. Specifically, the production station 12 is used to manufacture the objects 4 from the production material 6. The objects 4 are manufactured on the production area 16 using the production station 12.

[0069] In order to complete the production of the object 4, the object carrier 14 is moved translationally on the production area on the movement area 10 along a path 24 in the direction of the arrows 22. In doing so, the object carrier 14 passes the production station 12 many times or passes under it in the direction of the arrow 22. With each pass, a layer of production material 6 is deposited in the respective areas 20a,b ( Fig. 2) deposited or additively manufactured on the successively growing object 4. The additive manufacturing process 8 here is an inkjet-based printing process.

[0070] The track 24 here forms a first ring section 34a in which the object carrier 14 circulates several times.

[0071] The object carrier 14 is thus moved on the path 24 along the movement surface 10 in order to pass the production station 12.

[0072] In the method, the production surface 16 of the object carrier is tilted at least once around the tilt axis 18 during the creation of the object 4. This is in Fig. 2 to see:

[0073] Fig. Figure 2a shows a partial step in the production of object 4, in which a layer of production material 6 is applied to the partially produced object 4 in an area 20a indicated by lines in the figure. The object carrier 14 or the production surface 16 is in a first tilted position about the tilt axis 18. The lines are intended to represent the application of production material 6 to the object 4. The object carrier 14 with the object 4 is moved through the production station 12 in the direction of arrow 22.

[0074] Fig. Figure 2b shows how, at a later point in time, the same object 4 is moved again through the production station 12 in the direction of arrow 22. In the meantime, however, the production surface 16 has been tilted about the tilt axis 18 to a second, different tilt position, so that a second area 20b of the object 4 is now covered with a layer of production material 6.

[0075] Fig. 2c and d point directly to the Fig. 2a,b the production of an alternative object 4. Here too, in a first tilt position ( Fig. 2c) a first area 20a of the object 4 is manufactured or covered with production material 6. Before the object carrier 14 passes through the production station 12 again ( Fig. 2d) In the meantime, the production area 16 was tilted about the tilting axis 18, so that the area 20b is now covered with another layer of production material 6 on the object 4.

[0076] The tilting around the tilting axis 18 always takes place when no production step is carried out on the object 4, i.e. when it is located away from the production station 12. The location at which the tilting takes place is in Fig. 1 is marked by arrow 23.

[0077] According to Fig. 2, the object carrier 14 is tilted from its horizontal position both before the start of the creation of the object 4 and also tilted about the tilt axis 18 during the creation of the object, but at the position of the arrow 23, namely while no production is taking place on the object 4 by the production station 12.

[0078] In Fig. 2b also shows, by way of example, that a production head 30 is arranged in a fixed position in the production station 12. The production head 30 serves for the actual production of the object 30, in this case for the dispensing / deposition of production material 6. The production head 30 is an inkjet print head, and the production material 6 is ink.

[0079] In an alternative embodiment, indicated here by dashed lines, the production head 30 is mounted in the production station 12 so as to be movable exclusively perpendicular to the movement surface, namely in the z-direction. Thus, height adjustment to objects 4 or slides 14 can be performed without having to move the slide 14 itself translationally perpendicular to the movement surface 10, i.e., in the z-direction.

[0080] The object carrier 14 is configured here to move contactlessly relative to the movement surface 10. The production surface 16 is arranged fixedly or rigidly on or relative to the rest of the object carrier 14. Thus, the entire object carrier 14 is moved to move the production surface 16, in particular to tilt the latter about the tilt axis 18 and to raise it in the spatial direction z from the movement surface 10 or to lower it toward it.

[0081] Fig. 3 shows in a view according to Fig. 2, the production of an alternative object 4 in system 2. Here, the production area 16 is tilted around the tilt axis 18 while the production of object 4 takes place at the production station 12. The tilting thus occurs during the single pass and at the location of the production station 12.

[0082] Fig. Figure 3a shows how the slide 14 with the object 4 begins to pass the production station 12. The production area 16 is in a first tilted position. This tilted position is now continuously changed during the movement of the slide 14.

[0083] Fig. Figure 3b shows how the slide 14, or rather its center, passes the production station 12. The production surface 16 has now reached a different tilt position. During the movement along arrow 22 and the ongoing production, i.e., the application of production material 6 to the object 4, the gradual tilting of the slide 14 and thus of the object 4 continues around the tilt axis 18. Fig. 3c shows that the production surface 16 was tilted further around the tilt axis 18, i.e. the further the slide 14 passed the production station 12.

[0084] Fig. Figure 3 also shows that the object carrier 14 is configured to move in a further degree of freedom, namely, it can move the production surface 16 translationally perpendicular to the movement surface 10, in this case in the spatial direction z. The spatial direction z therefore represents the corresponding degree of freedom. The movement in this degree of freedom is for the Fig. 3b,c are indicated by dashed lines and arrows, which are each related to the geometric center of the object carrier 14 and thus indicate the elevation of the production area 16 from Fig. 3b to Fig. 3c (lowering of Fig. 3a to Fig. 3b).

[0085] According to Fig. 3, the object carrier 14 is tilted about the tilt axis 18, while the object 4 is manufactured on it by the production station 12.

[0086] Fig. 4 shows a simplified representation according to Fig. 1 the top view of the system 2 or the movement area 10. Here an alternative slide 14 is present.

[0087] The Fig. 4a-d show how the object carrier 14 passes the production station 12 four times in a total of four passes along the track 24. The object carrier 14 is configured to rotate in a further degree of freedom about an axis of rotation 26 (this represents the degree of freedom) relative to the movement surface 10. The axis of rotation 26 runs in the spatial direction z and thus perpendicular to the movement surface 10 and in Fig. 4 perpendicular to the drawing plane.

[0088] The dashed lines indicate an earlier and later point in time during the respective passage of the production station 12. In this case, a purely translational displacement of the object carriers 14 relative to the production station 12 always takes place. Between the individual passages, a 45° rotation takes place around the rotation axis 26. This again takes place at the point indicated by the arrow 23 in Fig. 1 marked location outside the production station 12.

[0089] Thus, viewed from the object 4, the respective printing direction 28 in which production material 6 is printed onto the object 4 changes between each of the four passes according to the Fig. 4a-d by 45° to each other. This creates an object 4 whose individual layers are anisotopically oriented. In other words, object 4 is oriented in each of the passes according to the Fig. 4a-d is moved through the production station 12 at a different approach angle and thus each layer of production material 6 - seen from the object 4 - is successively stacked onto the object 4 in a different pressure direction 28.

[0090] Fig. 4 thus illustrates how the object carrier 14 passes through the production station 12 several times during the creation of the object 4, each time in different production directions 28. The object carrier 14 passes through the production station 12 in the same absolute direction (arrow 22), but is rotated around the rotation axis 26 by an angle of n* 45°.

[0091] Fig. 5 shows an alternative system 2 in which a total of four production stations 12a-d are included in system 2. The production stations 12a-c are each production stations for different production materials 6a-c in order to be able to manufacture objects 4 from the different production materials 6a-c (each alone or in combination). The production station 12d is a curing unit for curing the production material 6 of the objects 4. The four production stations 12a-d are each provided at a distance from one another and are each stationary with respect to the movement area 10. The object carriers 14 pass through all four production stations 12a-d in the direction of movement along the arrows 22 on the track 24. The object 4 is manufactured in each of the production stations 12, i.e., each contributes to its production.

[0092] Fig. Figure 5 also shows that the system 2 contains a total of eight slides 14, which are numbered "1" to "8" in the figure. Each slide 14 serves to support a respective object 4, or an object 4 is manufactured on each of the slides 14. The eight slides 14 pass consecutively through the production stations 12a-d in the direction of arrow 22 on the track 24. Each of the production stations 12a-d can therefore continuously produce the respective objects 4.

[0093] Fig. 6 shows a further alternative system 2, in which a total of thirteen object slides 14 are present, which are also numbered "1" to "13." A total of six production stations 12a-f are also provided here. Station 12a contains a production head 30 for the single production material 6. Production station 12b is a curing unit, and production station 12c is a pick-and-place station for placing additional components (not shown) on the objects 4, which are integrated into the objects 4 by refining them with production material 6. Station 12 is an NIR (near infrared) station, in which the objects 4 are irradiated with infrared radiation.Station 12e is a measuring station to check whether the objects 4 have been manufactured correctly and station 12f is a loading and unloading station to load the object carriers 14 with substrates (not shown) on which the objects 4 are to be manufactured and then to unload the finished objects 4 built on them with the corresponding substrates from the object carriers 14 or production areas 16.

[0094] The object carrier 14 numbered "7" is not used to produce an object 4, but rather contains a tool 32 associated with the production station 12a, specifically for cleaning the print head located there in the form of the production head 30. Therefore, the tool 32 is used to process the production station 12a as the object carrier 14 numbered "7" passes through, specifically to clean the print head.

[0095] Fig.6 shows that the track 24 here has a first ring section 34a, which, thanks to the production station 12a, serves for the additive construction of the object 4. A total of four further ring sections 34b-e branch off from the ring section 34a, which serve for the further production of the object 4. This takes place as explained above, namely for pick & place, NIR, measurement, and loading and unloading. QUOTES CONTAINED IN THE DESCRIPTION

[0000] This list of documents submitted by the applicant was generated automatically and is included solely for the convenience of the reader. This list is not part of the German patent or utility model application. The DPMA assumes no liability for any errors or omissions. Cited patent literature

[0000] DE 10 2022 200 357 A1

[0002] DE 10 2022 201 974 A1 [0003, 0016] Cited non-patent literature

[0000] https: / / apps.boschrexroth.com / microsites / ctrlx-automation / de / portfolio / ctrlx-flow / , Abruf am 16.02.2024

[0030]

Claims

[1] Method for manufacturing an object (4) from at least one production material (6a-c) using an additive manufacturing process (8), in which: - a movement area (10) is provided, - at least one production station (12a-f) for producing the object (4) is provided above the movement surface (10), preferably stationary above the movement surface (10), - at least one object carrier (14) is provided which has a production surface (16) on which the object (4) is manufactured with the aid of the production station (12a-f), - wherein the object carrier (14) is configured to move freely in translation relative to the movement surface (10) in at least two degrees of freedom (x, y) and to tilt the production surface (16) in at least a third degree of freedom about at least one tilt axis (18) running parallel to the movement surface (10). [2] Method according to claim 1, characterized bythat the additive manufacturing process (8) is one for producing metallic objects (4) and / or objects (4) made of plastic and / or ceramic and / or a 3D printing process and / or an inkjet-based printing process and / or a LIFT process and / or a STEP process and / or an electrostatic nozzle printing process and / or selective laser beam melting. [3] Method according to one of the preceding claims, characterized by that at least one of the object carriers (14) is configured to rotate in a further degree of freedom about an axis of rotation (26) perpendicular to the movement surface (10) and / or to move the production surface (16) translationally perpendicular to the movement surface (10) in a further degree of freedom (z). [4] Method according to one of the preceding claims, characterized bythat at least one of the production surfaces (16) is tilted at least once about the tilting axis (18), while the object (4) is being manufactured on the production surface (16) by one of the production stations (12a-f). [5] Method according to one of the preceding claims, characterized by that at least one of the production areas (16) is tilted at least once about the tilt axis (18) even before the start of the creation of the object (4) and / or during the creation of the object (4) and while no production of the object (4) is taking place on the production area (16) by one of the production stations (12a-f). [6] Method according to one of the preceding claims, characterized by that the object carrier (14) passes one of the production stations (12a-f) at least twice during the creation of the object (4) in different production directions (28). [7] Method according to one of the preceding claims, characterized bythat in at least one of the production stations (12a-f) at least one production head (30) for producing the object (4) is fixed in place or is mounted so as to be movable exclusively perpendicular to the movement surface (10). [8] Method according to one of the preceding claims, characterized by that at least two production stations (12a-f) are provided at a distance from one another in a fixed location, and at least one of the object carriers (14) passes at least two of the production stations (12a-f), with each of which the object (4) is manufactured. [9] Method according to one of the preceding claims, characterized by that at least two object carriers (14) are provided, which pass through at least one of the production stations (12a-f) one after the other. [10] Method according to one of the preceding claims, characterized bythat a tool (32) associated with at least one of the production stations (12a-f) is provided on at least one of the object carriers (14), and the production station (12a-f) is processed with the aid of the tool (32). [11] Method according to one of the preceding claims, characterized by that at least one of the object carriers (14) is arranged to move contactlessly relative to the movement surface (10). [12] Method according to one of the preceding claims, characterized by that a track (24) is provided on the movement surface (10) and at least one of the object carriers (14) is moved on the track (24) along the movement surface (10) in order to pass at least one of the production stations (12a-f). [13] Method according to claim 12, characterized bythat the track (24) is provided with at least one first ring section (34a) at least for the additive construction of the object (4) and with at least one second ring section (34b-e) branching off therefrom for the other production of the object (4) and / or for the loading and / or unloading of the object carrier (14). [14] Plant (2) for manufacturing an object (4) from at least one production material (6a-c) by means of an additive manufacturing process, wherein the plant (2) is preferably designed to carry out the process according to one of the preceding claims, - with a movement area (10), - with at least one production station (12a-f) provided in a fixed position above the movement surface (10), - with at least one object carrier (14) having the production surface (16), - wherein the object carrier (14) is configured to move freely in translation relative to the movement surface (10) in the at least two degrees of freedom (x,y) and to tilt the production surface (16) about the at least one tilt axis (18) running parallel to the movement surface (10) in the at least one third degree of freedom.

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