Manufacturing device for manufacturing objects in layers

Abstract

The invention relates to a manufacturing device (1) for manufacturing objects (7) in layers, having at least one transfer platform (2) with a transfer platform surface (2Ä); at least one application unit (3) which is designed to apply at least one treatment layer (8A) and at least one material layer (8B), in particular comprising a granular and / or pulverulent material, onto the transfer platform surface (2A), said treatment layer and material layer together forming a pre-material layer of the object (7), wherein the pre-material layer extends in particular in a first direction (x) and in a second direction (y); and a construction platform (4) which is designed to receive at least the material layer (8Ä) of the pre-material layer from the transfer platform (2) so that the object (7) is produced in layers on the construction platform (4) in a third direction (z) in particular. The invention additionally relates to a method for manufacturing objects (7) in layers.

Description

[0001] Manufacturing device for layer-by-layer production of objects

[0002] Description

[0003] The invention relates to a manufacturing device. The manufacturing device serves for the layer-by-layer production of objects. The invention also relates to a method for the layer-by-layer production of objects. This manufacturing method is also called additive manufacturing or 3D printing.

[0004] Manufacturing devices that additively apply material to create a desired spatial geometry are known from the state of the art. Powder bed processes, in particular, have found their way into industry for the production of metallic components. All powder bed processes have in common that the build-up material is in powder form and is selectively bonded within a powder bed. This can conventionally be achieved through the use of beam sources (electron or laser beam) and the selective melting of the powder. Binder jetting processes play a special role in powder bed processes. In these processes, a green compact is first created within the powder bed by applying a binding liquid, the so-called binder. This green compact is then conventionally refined into the final metal component through heat treatment (so-called debinding and sintering).A key disadvantage of binder jetting is the fact that during debinding and sintering, residues of the binder or its decomposition products often remain in the component. These can act as foreign substances within the metal matrix and thus cause negative material properties. Furthermore, conventional binder jetting processes reach their limits with massive structures, as debinding is difficult due to large wall thicknesses and results in reduced strength. Another disadvantage of these conventional processes is the shrinkage of the green compacts during sintering, which can amount to up to 20% of the originally printed volume. This is accompanied by the formation of residual stresses and cracks, which in many cases equates to scrap.

[0005] It is therefore an object of the invention to provide a manufacturing device and a method for the layer-by-layer production of objects which, with a simple structure, enable reliable, cost-effective and time-saving, layer-by-layer production of objects which can also be manufactured with large wall thicknesses and with low shrinkage by means of the method according to the invention.

[0006] This problem is solved by the features of the independent claims. The subclaims contain preferred developments of the invention.

[0007] Where physical states of materials, substances, bodies or objects are described herein, such as "in liquid form", and no corresponding temperature specifications are given, a temperature of 20°C shall be assumed, unless a different temperature or temperature range can be derived from the context or the state of the art.

[0008] When "bottom" and "top" are mentioned here, this describes spatial arrangements, for example, of a device and / or a figure. "Bottom" is closer to the Earth's center than "top." A "bottom" is closer to the Earth's center than a "top."

[0009] When a "transfer platform" is mentioned herein, this refers to a structural element that preferably has at least one flat surface suitable for receiving or temporarily depositing at least one chemical element (layers explained below), in particular a starting material of the object to be manufactured. The surface can be smooth, rough, structured, or of another design.

[0010] When a "transfer platform surface" is mentioned herein, this means the surface of a "transfer platform" which has properties suitable for absorbing and / or releasing the at least one chemical element, in particular the starting material of the object to be manufactured. A "transfer platform surface" can have a special material or a special material matrix, i.e. the material of the transfer platform surface can differ from the material of the other parts of the transfer platform, can be formed in a special surface structure, can have at least one special coating and / or be equipped with further properties which are advantageous for the method and the device.

[0011] According to the invention, a "dispensing unit" can be any type of arrangement designed to transfer or transfer the at least one chemical element, in particular the starting material of the object to be manufactured, from a first position to another position, in particular from a starting material supply to a transfer platform or to a transfer platform surface. A "treatment layer" can be a chemical element or a medium that is suitable for exhibiting and / or exerting special properties relative to other elements or media.Such properties can be brought about, for example, by fixing and / or storing elements or materials, by physically and / or chemically influencing elements or materials, by electrically influencing elements or materials, and / or by other interactions between at least two elements and / or materials that are advantageous for the method and the device. Preferably, a chemical element or a medium of a “treatment layer” is at least partially in liquid form at temperatures from 0°C to 180°C, particularly preferably at temperatures between 10°C and 120°C, or, for example, at temperatures up to 200°C, 250°C, or 300°C. A “treatment layer” or parts of a “treatment layer” preferably have a boiling temperature or a boiling range. A “treatment layer” can comprise at least one solvent.A "treatment layer" can comprise at least one solid in powder form, in fiber form, in platelet form, or as nanoparticles. A "treatment layer" can comprise at least one polymer, which is preferably present in dissolved form. A "treatment layer" can also be referred to as a "treatment agent," especially before application to a transfer platform surface. A "treatment layer" can be created by applying several identical or different "treatment agents" to a transfer platform surface simultaneously or sequentially. "Treatment agents" can be heated before application to a transfer platform surface, preferably to a temperature of up to 250°C, particularly preferably to a temperature of up to 130°C, such as, for example, to a temperature of up to 110°C.

[0012] A “material layer” is preferably formed from at least one solid, i.e. from a material in the solid state, or comprises at least one such. A “material layer” is preferably in the form of a granular medium. Such granular media can be powdered, rod-shaped, sheet-shaped or in other forms. They can have a size in the nanometer range or a size up to one millimeter or more. Granular media of a “material layer” can comprise different materials, have a different size and shape and / or be provided with a surface coating. A “material layer” is particularly preferably in powder form and is formed from at least one metal, at least one polymer, at least one glass and / or at least one ceramic.

[0013] A "precursor material layer" describes a combination of at least one "treatment layer" and at least one "material layer." According to the invention, a combination of a "material layer" and a "treatment layer" that has already partially evaporated and / or physically and / or chemically modified also constitutes a "precursor material layer." If, after the material layer has been bonded to the treatment layer (precursor material layer), the treatment layer is completely evaporated, for example, before its transfer, the remaining material layer continues to be referred to as the "precursor material layer."

[0014] An "object" can be a part or structure of any shape and made of any material that can be manufactured using the method and / or device of this invention. Parts or regions of an entire component or assembly are also to be understood as an "object" according to the invention. Alternatively, such a part of an "object" can also be referred to as an "object part." In particular, an "object" is preferably formed at least in large part from a metal or a polymer material or preferably comprises larger amounts of one of these.

[0015] When a "build platform" is mentioned herein, this refers to a structural element that preferably has at least one flat surface. A "build platform" is suitable for receiving or accommodating material, in particular a layer of material, which can collectively be referred to as an object. The surface of a "build platform" can be smooth, rough, structured, or have a different design. A "build platform" can be made of metal, ceramic, plastic, glass, and / or combinations / mixtures thereof.

[0016] The problem is solved by a manufacturing device for the layer-by-layer production of objects. The manufacturing device has at least one transfer platform with a transfer platform surface and at least one application unit. The application unit is designed to apply at least one treatment layer and at least one material layer, which together form a pre-material layer of the object, to the transfer platform surface. The material layer comprises, in particular, granular and / or powdery material. The pre-material layer applied to the transfer platform surface by the application unit extends, in particular, in a first direction and in a second direction. The treatment layer and / or the material layer can, in particular, be applied linearly or over a surface area.In particular, it is provided that the system comprising the dispensing unit and the transfer platform has at least two degrees of freedom, which allow a relative movement of the transfer platform and the dispensing unit along the said two directions. A conventional additive manufacturing process can thus be carried out particularly advantageously in order to produce the treatment layer and / or the material layer on the transfer platform surface. The manufacturing device further comprises a build platform. This is designed to receive at least the material layer of the pre-material layer from the transfer platform, such that the object is produced layer by layer on the build platform, in particular in a third direction. The build platform can in particular be designed to receive the treatment layer and the material layer of the pre-material layer.

[0017] Advantageously, the first direction, the second direction and the third direction are perpendicular to each other.

[0018] In particular, the pre-material layer is applied to the transfer platform surface by means of the at least one application unit by applying at least one treatment layer and at least one material layer by means of a binder jetting process.

[0019] The application unit is particularly configured to apply the treatment layer to the transfer platform surface according to a predeterminable pattern. This pattern essentially corresponds to the geometry or shape of the layer to be transferred, in particular the resulting layer of the object or a part of the object on the build platform. After the material layer has been applied by the application unit, the material layer is bonded to the treatment layer (on the transfer platform surface), whereby the pre-material layer has the predefined geometry and shape of the layer to be transferred. As explained below with reference to the manufacturing process, the treatment layer can be applied before or after the material layer is applied.

[0020] Preferably, the material layer is applied to substantially the entire surface of the transfer platform. The material layer adheres only to those locations on the transfer platform surface that correspond to parts of the applied pattern of the treatment layer. In other words, portions of the material layer that are not bonded to the treatment layer do not adhere to the transfer platform surface. In the case where the material layer is applied before the treatment layer is applied, the material layer only adheres to the transfer platform surface when it is bonded to the treatment layer or when the pre-material layer is formed, i.e., after the treatment layer is applied.

[0021] Advantageously, the transfer platform is heated to transfer the layer (treatment layer and / or material layer) from the transfer platform to the build platform. According to a further embodiment, the transfer platform and the build platform and / or the object parts located on the build platform are heated to transfer the layer (treatment layer and / or material layer) from the transfer platform to the build platform, wherein the transfer platform is preferably heated more intensely (i.e., to a higher temperature) than the build platform and / or the object parts located on the build platform.

[0022] In some embodiments, at least the transfer platform and / or the construction platform can be designed to be movable at least in a third direction, preferably for transferring the pre-material layer or at least the material layer.

[0023] Advantageously, the construction platform is movable along the third direction, whereby movement of the transfer platform and / or the dispensing unit along the third direction is preferably not provided. This simplifies the construction of the production device.

[0024] In some embodiments, at least one transfer platform and / or at least one dispensing unit can be movable along the third direction, preferably movable relative to one another. As a result, for example, a plurality of pre-material layers can be applied one above the other to the transfer platform surface, and thus an object part formed from these multiple pre-material layers can be produced on the transfer platform surface. In this case, the degree of freedom in the third direction is preferably relatively small or short (particularly compared to the degree of freedom in the first and / or second direction), so that in particular only a few pre-material layers, preferably no more than ten pre-material layers, particularly preferably no more than five pre-material layers can be applied one above the other to the transfer platform surface.In other words, according to this embodiment, it is not intended to produce the object as a whole on the transfer platform, but only an object part. Advantageously, two pre-material layers are formed on the transfer platform surface, more preferably three pre-material layers. Two or more pre-material layers can be designed in particular to generate better material bonding in a third direction (Z-direction) on the component, i.e., to achieve greater strength, tensile strength, compressive strength, flexural strength, and / or stiffness of the finished object. In some embodiments, the ductility and / or damping capacity with respect to vibrations can be reduced, for example, by using different metals, plastics, and / or ceramics.In some embodiments, when forming two or more pre-material layers, the temperature and / or energy required for transfer to the build platform surface and / or to objects already located on the build platform surface can be reduced, for example, by using different materials for the pre-material layers. For example, at least one pre-material layer can be formed, at least in part, from an alloy that melts at a lower temperature than another, such as from at least one material that can be used for soldering or brazing.

[0025] Regardless of whether movement of the transfer platform and / or the dispensing unit along the third direction is not intended or whether movement of the transfer platform and / or the dispensing unit along the third direction is intended to a preferably limited extent - as just described - according to the invention, the object is not assembled on the transfer platform in the sense of conventional additive manufacturing processes, but rather new pre-material layers are produced on the transfer platform and at least the material layers of the pre-material layers are assembled to form the object in a subsequent step on the build platform. This makes it possible, in particular, to dispense with support structures. Furthermore, production can be operated in parallel by producing several pre-material layers simultaneously or at staggered times on separate transfer platforms.This can significantly shorten the production time for the object.

[0026] Furthermore, the possibility of targeted temperature and process control is provided. For example, a temperature at least close to or equal to the melting temperature of the material used for production can be easily and reliably reached and maintained. This allows for the strength and / or bonding between the individual layers to be optimized in a simple and reliable manner. The cooling of the material layer(s) and / or the object can also be very precisely controlled or regulated, for example, to specifically influence or modify crystallization behavior.

[0027] In principle, one application unit can be used for one or more transfer platforms. In particular, two application units can be used for one or more transfer platforms.

[0028] In some embodiments, two, three, four, five, or six transfer platforms and / or dispensing units may be used. In some embodiments, the manufacturing device may have more than two dispensing units for each transfer platform, for example, three, four, five, or six dispensing units.

[0029] The production device preferably has a dispensing unit for each transfer platform. Thus, in particular, a number of transfer platforms and dispensing units are identical. In other words, each transfer platform is preferably assigned exactly one dispensing unit. The dispensing unit is configured to apply both at least one treatment layer and at least one material layer of the material, in particular granular and / or powdery material, to the transfer platform surface of the transfer platform assigned to it.

[0030] The dispensing unit preferably has a piezo print head and / or a so-called recoater.

[0031] It is particularly advantageous if the production device has at least two dispensing units for each transfer platform. In other words, at least two dispensing units are preferably assigned to each transfer platform. It is particularly preferred if exactly two dispensing units are assigned to each transfer platform. In other words, the number of dispensing units is preferably twice the number of transfer platforms. Preferably, a first dispensing unit per transfer platform has a piezo print head for applying the at least one treatment layer. More preferably, a second dispensing unit per transfer platform has a recoater for applying the at least one material layer.

[0032] Preferably, the build platform has a build platform surface. The build platform is further configured to transfer at least the material layer of the pre-material layer from the transfer platform to the build platform surface or to object parts of the object already present on the build platform surface. The object parts of the object on the build platform surface represent, in particular, already transferred and interconnected object layers that were previously applied to the transfer platform and transferred from the build platform surface. Thus, the steps of producing the pre-material layer and connecting the pre-material layer with other layers to form an object part are separated from one another. This simplifies the execution of the respective steps, as they can always be optimized to specific requirements, whereby interactions no longer play a major role and can therefore be virtually disregarded.

[0033] The transfer platform and the construction platform are particularly advantageously each designed such that the adhesion of the layer to be transferred (ie the pre-material layer or the treatment layer or the material layer) and / or already existing object parts of the object to the construction platform is higher than to the transfer platform.

[0034] This can preferably be achieved by a respective surface finish and / or by a respective coating and / or by a respective material selection for the respective platforms. The coating can be, for example, polytetrafluoroethylene (PTFE) and / or perfluoro(ethylene-propylene) (PFEP). The transfer platform can preferably comprise ceramic or be formed from ceramic. The build platform can preferably comprise a metal or be formed from metal. These material examples can be used in particular when metals are used as components of the pre-material layer or the treatment layer or the material layer.

[0035] Different levels of adhesion can also be achieved by varying the temperature of the platforms. These different adhesion levels allow for quick and easy transfer of the layer from the transfer platform to the build platform.

[0036] In some embodiments, at the moment of transfer of the pre-material layer from the transfer platform to the construction platform or at least at the moment of detachment of at least the material layer of the pre-material layer from the transfer platform by a relative movement of the construction platform, the temperature of the construction platform and / or at least within the regions of an object located on the construction platform surface closest to a transfer platform surface is at least in places and / or partially higher than that of the transfer platform, preferably by at least 10°C higher, particularly preferably by at least 30°C higher and most particularly preferably by at least 50°C higher, such as by at least 80°C higher.

[0037] In some embodiments, at the moment of transfer of the pre-material layer from the transfer platform to the construction platform or at least at the moment of detachment of at least the material layer of the pre-material layer from the transfer platform by a relative movement away of the construction platform and / or at least within the areas of an object located on the construction platform surface that are closest to a transfer platform surface, the temperature of the construction platform is at least partially and / or lower than that of the transfer platform, preferably by at least 25°C lower, particularly preferably by at least 50°C lower and very particularly preferably by at least 100°C lower, such as by at least 150°C lower.

[0038] Advantageously, the build platform surface is aligned substantially parallel to the transfer platform surface during the transfer of at least the material layer of the pre-material layer from the transfer platform. This enables easy transfer of the layer. In particular, the two platform surfaces can be arranged directly opposite each other, so that the layer to be transferred can have contact with both the transfer platform surface and the build platform surface or with object parts arranged on the build platform surface.

[0039] The production device preferably comprises at least one rotating device. The rotating device is designed to rotate the at least one transfer platform. In particular, one rotating device is provided per transfer platform. In some embodiments, all transfer platforms are connected together to a single rotating device which rotates all transfer platforms simultaneously. In particular, the rotating device is designed to rotate the respective or all transfer platforms preferably about an axis substantially parallel to the first direction and / or about an axis substantially parallel to the second direction and / or about an axis substantially parallel to the third direction. By rotating the transfer platform by means of the rotating device, excess material of the material layer which is not connected to the treatment layer can be removed from the transfer platform surface.

[0040] By rotating the transfer platform by means of the rotating device, in particular those sections of the material layer are removed which are not connected to the treatment layer and / or are bound by it and / or are not in contact with it. It is particularly preferred that the transfer platform is rotated about an axis substantially parallel to the first and / or the second direction. In this case, the transfer platform can in particular be rotated by an angle greater than 90°, preferably by 100°, particularly preferably by 100° to 180°. In other words, the transfer platform can particularly preferably be turned over so that the transfer platform surface pointing in a first spatial direction (for example upwards) points in a second spatial direction opposite to the first spatial direction (for example downwards) after rotation.After the excess material from the material layer has fallen off, the rotating device rotates the transfer platform(s) back to their original position. In a particular embodiment, the transfer platform can be rotated 360° using the rotating device. In some embodiments, the rotating device can be rotated several times through specific angles, for example, back and forth, preferably in short periods of time and / or at high speeds, in order to shake or shake off excess material from the material layer.

[0041] The rotating device is particularly configured to rotate the transfer platform(s) during the application of the treatment layer and / or the material layer. In particular, a movement of the application unit(s) is combined with a rotation of the transfer platform(s) in order to produce or apply at least one material layer and / or the predetermined pattern (of the treatment layer). The at least one transfer platform is preferably rotated about the axis parallel to the third direction. Alternatively or additionally, the at least one transfer platform can preferably be rotated or tilted about the axis parallel to the first direction and / or about the axis parallel to the second direction.

[0042] The manufacturing device preferably comprises at least one cleaning device configured to remove excess material of the material layer from the at least one transfer platform and / or the build platform by sucking in and / or blowing off a fluid. The cleaning device is preferably a blower device that sucks in and / or blows off gas and / or mist and / or steam. Alternatively or additionally, the fluid can be or comprise a solvent, which in particular does not correspond to the material of the treatment layer.

[0043] In some embodiments, the cleaning device can be equipped with at least one device for extracting excess material from the precursor layer and / or vapor and / or mist from the treatment layer. Such a device can, for example, be a suction nozzle that is in fluid communication with a suction device, such as a turbine or a vacuum cleaner. In some embodiments, suction nozzles can be designed as flat nozzles, preferably with a wider basic shape, in order to extract as much excess material and / or treatment agent as possible from the transfer platform.

[0044] Additionally or alternatively, the cleaning device can be equipped with at least one device for blowing off excess material from the precursor layer and / or steam and / or mist from the treatment layer. In some embodiments, a device for applying a gas or protective gas stream and / or another fluid stream, such as a mist or particle stream or jet consisting of a (protective) gas and / or a liquid and / or solid particles or powders, can be provided as a cleaning device, optionally as a pre-cleaning device, or as the first process step of a multi-stage cleaning device. Such a device can, for example, comprise a nozzle, preferably a plurality of nozzles. Such nozzles can be designed as round nozzles with preferably relatively small nozzle outlets, for example less than 2 mm or less than 1 mm, or as flat nozzles.Even partially formed annular nozzles, preferably with the option of combining an internal suction device, can be used according to the invention. In some embodiments, a (protective) gas stream and / or a fluid stream can be tempered, preferably heated, for example to a temperature above 70°C, preferably above 100°C, and particularly preferably above 150°C, such as above 200°C.

[0045] In some embodiments, a combination of at least one device for blowing off and / or accelerating excess material and / or treatment agent from a precursor material layer can be combined with at least one device for suctioning off and / or collecting at least one such device. The production device particularly preferably comprises a plurality of cleaning devices. In particular, the production device has a number of cleaning devices corresponding to the number of transfer platforms. Furthermore, the production device preferably has a single cleaning device which has a number of inlet and / or outlet nozzles corresponding to the number of transfer platforms. The production device particularly preferably comprises two cleaning devices, wherein in particular each of the two cleaning devices has a number of nozzles corresponding to the number of transfer platforms.One of the two cleaning devices is configured to blow off a fluid, and the second of the two cleaning devices is configured to suck in a fluid. In particular, the first cleaning device or the outlet nozzles of the first cleaning device can be arranged along the third direction above the respective transfer platform. In particular, the second cleaning device or the inlet nozzles of the second cleaning device can be arranged along the third direction below the respective transfer platform.

[0046] The manufacturing device preferably comprises at least one vibration-generating device. The vibration-generating device is configured to remove excess material of the material layer from the at least one transfer platform and / or the construction platform using sound, in particular ultrasound, and / or vibrations.

[0047] The manufacturing device, in particular, has one vibration-generating device per transfer platform. Preferably, the manufacturing device has a single vibration-generating device configured to remove excess material from the material layer from all transfer platforms. Preferably, the manufacturing device has a further vibration-generating device configured to remove excess material from the build platform.

[0048] Preferably, the vibration generating device is an ultrasonic generating device and the ultrasonic generating device is configured to heat the construction platform and / or the transfer platform by means of ultrasound.

[0049] In certain embodiments, the material layer or a portion of the material layer is processed prior to application using a fluidized bed process. In such an embodiment, the preferably granular, rod-shaped, and / or powdered material is stored in a storage container connected to the application unit, in which the material is exposed to a gas, a protective gas, or air from below (i.e., starting from a base of the storage container). Due to the fluidization of the material mediated by said exposure, granular, rod-shaped, and / or powdered media behave similarly to liquids. The fluidized material is then applied to the transfer platform by means of the application unit(s).

[0050] The manufacturing device preferably comprises at least one fiber application device. The fiber application device is configured to at least partially apply fibers to the pre-material layer, in particular the material layer of the pre-material layer, on the transfer platform and / or to object parts of the object on the build platform. The manufacturing device preferably comprises one fiber application device per transfer platform. The manufacturing device preferably comprises a further fiber application device for the build platform. In some embodiments, the manufacturing device comprises two or more fiber application devices per transfer platform and / or within the manufacturing device.

[0051] The fiber application device is preferably, for example, a recoater with rotatably mounted rollers. The rollers rotating in the operating state of the fiber application device accelerate fibers, in particular short fibers, towards the transfer platform in order to at least partially apply fibers to the precursor material layer, in particular the material layer, and / or towards the build platform in order to at least partially apply fibers to parts of the object on the build platform. In some embodiments, at least one roller can be smooth or predominantly or at least partially smooth on its surface and / or at least one roller can be equipped with predetermined surface profiles, such as in the form of threads and / or worm gears and / or at least approximately in the form of splined shafts.

[0052] The fibers or short fibers are preferably carbon fibers, glass fibers, aramid fibers, or natural fibers. The fibers preferably have a length of up to a few millimeters, such as up to 10 mm, preferably up to 7 mm, particularly preferably up to 4 mm, such as between 0.5 mm and 4 mm or between 0.8 mm and 2 mm. According to an alternative embodiment, the fibers preferably have a length of less than 1 mm, such as less than 0.8 mm, preferably less than 0.5 mm, such as between 0.05 mm and 0.4 mm.

[0053] The aforementioned fibers have the advantage that they can advantageously increase the bonding of the object parts, in particular the layer(s) to be transferred, with the already existing object parts on the build platform surface in the first, second, and / or third direction, particularly preferably in the third direction, thus increasing the material bond across layers. Using the fiber application device, short fibers can be introduced in addition to fibers already present in the material layer prior to the introduction of the short fibers.

[0054] Alternatively or in addition to the rollers of the fiber application device explained above, the fiber application device is preferably configured to accelerate the short fibers by means of a material flow in the direction of the transfer platform and / or the construction platform. The material flow can be, for example, a fluid flow, in particular a gas, protective gas, and / or air flow. In some embodiments, the fibers can be aligned along the material flow by the accelerating material flow. Thus, an impact angle between a longitudinal axis of the fibers and the surface of the pre-material layer on the transfer platform and / or the object parts of the object on the construction platform can be set, for example, to 10° to 90°, preferably approximately 90°. Here and in the following, "approximately" means, in particular, a deviation within an angular range of + / -10 0, preferably + / -5°. For example, "approximately 90°" means an angle range between and including 80° and 110°, preferably between and including 85° and 95°. This ensures the deepest possible penetration of the fibers into the respective material.

[0055] Particularly preferably, the first fiber ends facing the corresponding material (the precursor material layer or the object parts of the object) and / or at least parts of the long side of the fibers penetrate at least 10 pm to 100 pm into the corresponding material or into its surface, depending on their acceleration, speed, orientation and / or on the basis of material parameters, and very particularly preferably at least 150 pm. For example, the fibers penetrate between 20 pm and 400 pm or between 100 pm and 500 pm. In some embodiments, fibers can penetrate into a surface up to 300 pm, up to 600 pm, up to 1 mm, 2 mm or several millimeters, depending on their acceleration and / or other parameters. Preferably, the second fiber ends facing away from the first fiber ends and / or at least parts of the exposed long sides of the fibers and / or other regions or geometries of these, which emerge from the precursor material layer orprotruding from the material layer on the transfer platform are introduced into the object parts already present on the construction platform surface when the pre-material layer or the material layer is transferred to the construction platform. The aforementioned fiber ends are preferably introduced into the object parts by interacting with predetermined set parameters such as temperature, concentration of the treatment agent residues, pressure and / or speed. The penetration behavior of the fibers into the pre-material layer or into the material layer as well as into the object parts of the object can be adjusted by temperature control of the respective material (into which the fibers penetrate). Thus, a higher temperature of the pre-material layer, the material layer and / or the object parts of the object preferably leads to deeper penetration of the fibers with otherwise identical or essentially identical process parameters.Alternatively or additionally, the fibers and / or a material stream can also be tempered to accelerate the fibers. This can also affect the penetration behavior of the fibers. Depending on the material used for the material layer, the fibers and / or a said material stream preferably have a temperature above 150°C, particularly preferably above 200°C, and most preferably above 250°C, such as between 250°C and 450°C, at least within the fiber application device.

[0056] Fibers that impinge at a shallow angle, for example, between and including 0° and 45°, to the surface of the pre-material layer on the transfer platform and / or the object parts of the object on the build platform, largely adhere to the corresponding surface, depending on the temperature, or barely penetrate. These fibers can then be removed from the corresponding surface using the cleaning device and / or the vibration generation device.

[0057] In some embodiments, other particles or granular media can be used alternatively or in addition to the fibers or short fibers, such as powder, grains, platelets, nanoparticles, or tubes such as carbon nanotubes (CNTs). In an alternative embodiment, a manufacturing device has at least one fiber application device, at least one transfer platform, at least one application unit for applying at least one layer of the object, and at least one build platform. The application unit applies the at least one layer of the object, in particular line by line, to a transfer platform surface of the transfer platform, wherein the layer extends in a first direction and in a second direction. The build platform is designed to receive the layer from the transfer platform, so that the object is produced layer by layer in a third direction.The at least one fiber application device is designed to apply fibers to the layer on the transfer platform surface and / or to parts of the object already present on the construction platform surface.

[0058] In this case, the at least one dispensing unit is preferably an extruder, which is particularly designed for extruding a thermoplastic material. In some embodiments, the dispensing unit operates according to a so-called "Fused Filament Fabrication (FFF)" process (FFF process) and / or a so-called "Fused Granular Fabrication (FGF)" process.

[0059] In a particularly advantageous variant, the application unit can apply different materials to the transfer platform.

[0060] Advantageously, the manufacturing device according to the above embodiments has a plurality of transfer platforms, wherein preferably each transfer platform is assigned at least one separate dispensing unit.

[0061] This enables parallel production of the object by manufacturing multiple pre-material layers independently of one another. In this case, the build platform is configured to receive at least the material layer of the pre-material layer from the transfer platforms in a predeterminable sequence in order to produce the object. This means that even large and / or complex objects can be manufactured quickly. Furthermore, it is preferably provided that different application units are available so that individual transfer platforms can be printed / loaded with different materials. This means that layers made of different materials can be applied to the transfer platforms, for example using different material layers and / or different treatment layers. In this way, mechanical properties of the object to be manufactured, such as a targeted mass distribution or a defined local stiffness, can be influenced.This also allows for the adjustment of specific thermal conductivity or electrical conductivity. Sensor and / or actuator functions can also be integrated easily and with minimal effort.

[0062] It is particularly advantageous if at least one application unit is set up to produce the layer on the transfer platform by means of the binder jetting process and at least one further application unit is set up to produce the layer on the same or another transfer platform by means of the FFF process (extruder or filament extruder) and / or FGF process (granulate extruder).

[0063] The ability to move the build platform to pick up layers from the transfer platform(s) also creates the option of picking up additional components. In particular, a stiffening element can be inserted, for example pressed, into an already manufactured object part. The inserted stiffening element can be concealed by subsequently picking up further layers. Advantageously, the production device can also have a plurality of build platforms. In this way, for example, two or more objects and / or object parts can be manufactured in parallel or simultaneously. In particular in the case of a multi-material arrangement or hybrid material arrangement, it is possible to start, for example, with the application of a layer of a first object part made of a first material to a first build platform.If a further layer of a different material is then to be applied to the first object part, a layer of the first material can be applied to a second object part on a second build platform in parallel. This allows two or more objects or object parts to be manufactured quickly and efficiently, especially in multi-material or hybrid material arrangements.

[0064] Advantageously, the manufacturing device comprises at least one energy application device. The energy application device is configured to supply energy to the treatment layer and / or the material layer and / or the object parts of the object. Preferably, the energy application device is configured to supply energy to the transfer platform(s) and / or the build platform.

[0065] The energy application device is configured, in particular, to heat the treatment layer and / or the material layer and / or the object parts of the object. The energy application device can heat the aforementioned layers and / or object parts of the object directly and / or indirectly by heating the transfer platform(s) and / or the build platform. The treatment layer and / or the material layer can be heated, in particular, before and / or after their application. For this purpose, the energy application device preferably comprises or includes at least one heating device.

[0066] The energy application device is particularly configured to heat the treatment layer of the precursor material layer and, in particular, to evaporate and / or vaporize it. After evaporation and / or vaporization, essentially only the material layer remains on the transfer platform. This makes it possible to transfer only the material layer to the build platform.

[0067] The energy application device is particularly designed to plasticize and / or melt the material layer.

[0068] The manufacturing device comprises, in particular, at least one energy application device for the build platform and at least one energy application device for all transfer platforms or for each transfer platform. Advantageously, the energy application device, in particular each energy application device, is configured to apply energy to, in particular heat, the transfer platform and / or the build platform by means of induction and / or microwaves. The energy application device for the build platform is preferably configured to directly apply energy to, in particular heat, the object parts already present on the build platform surface, for example by means of induction or microwaves. Alternatively or additionally, the energy application device for the build platform can heat the build platform directly, for example by means of induction.

[0069] Advantageously, the energy application device, in particular any energy application device, is configured to apply energy to the transfer platform and / or the build platform, in particular the layer(s) and / or the object parts of the object, through a direct current flow (direct current or alternating current), in particular to heat and / or weld them. This can be combined, in particular, with the aforementioned induction option.

[0070] The energy application device is particularly designed to heat the entire production device (global warming).

[0071] For high-melting powders or granules as the material layer, the transfer platform, in certain embodiments, exhibits high heat dissipation and is, for example, formed at least partially from copper. Ceramics, such as aluminum oxide, aluminum titanate, aluminum nitride, silicon carbide, dispersion ceramics, or silicon-aluminum oxide-nitride, or a combination of at least two of the above, can also be used as the material for the transfer platform or for parts of the transfer platform.

[0072] Particularly preferably, the manufacturing device comprises a cooling device with which the transfer platform and / or the construction platform can be cooled. The cooling device can, in particular, be a gas cooling device and / or a coolant cooling device. The transfer platform can, in particular, comprise at least one heat sink, preferably on an underside opposite the transfer platform surface.

[0073] The manufacturing device preferably has at least one machining unit designed to machine parts of the object applied to the build platform and / or of an entire object and / or for at least one (pre-)material layer formed on the transfer platform surface. The machining unit is preferably a milling unit, a grinding unit, or a drilling unit. The machining unit enables the object or parts thereof to be machined in a partially finished state, so that even those areas on the finished object that are difficult or impossible to access can be machined. Particularly advantageously, machining using the machining unit can also be carried out during periods in which the transfer platform is waiting for the completion of another layer to be transferred.

[0074] In some embodiments, instead of or in addition to a machining unit, at least one cutting and / or punching unit can be used, such as an (oscillating) tangential knife, to process at least parts of layers such as a (pre-)material layer and / or at least parts of objects and / or, for example, continuous fibers and / or fiber mats on at least one transfer platform and / or on at least one build platform.

[0075] The machining unit is particularly designed to machine fibers protruding from the object parts of the object, which fibers were introduced into the layers and / or directly into the object parts by means of the fiber application device.

[0076] The transfer platform has a film element and a holding plate receiving the film element. The film element preferably forms the transfer platform surface. Instead of a film element, a thin plate can also be used, such as a carbon plate or another, preferably fiber-reinforced plate with a thickness of less than or equal to 5 mm, preferably none or equal to 2 mm, more preferably less than or equal to 1 mm, and most preferably less than or equal to 0.5 mm, such as between 0.1 mm and 0.3 mm. It is also preferably provided that the film element or the thin plate can be lifted off the holding plate, at least in some areas, to release a layer applied thereto. This allows the layer to be peeled off the film element or the thin plate, thereby minimizing stress on the layer when it is released from the transfer platform.This minimizes the risk of damage to the layer and thus reduces the scrap rate. Particularly advantageously, the film element or the thin plate lies directly against the holding plate during application of the material layer and the treatment layer to the transfer platform surface, so that the film element or the thin plate acts like a transfer platform surface. To detach the pre-material layer from the transfer platform surface, in particular after excess material of the material layer has been removed, the film element or the thin plate can be lifted off the holding plate in certain areas, so that the pre-material layer is peeled off from the film element or the thin plate, for example starting from an edge of the pre-material layer. The film element is preferably made of polyimide and can have different surface roughnesses and / or surface structures.The thin plate is preferably formed from at least one polymer, is preferably reinforced with fibers or other materials and / or preferably has different surface roughnesses and / or surface structures.

[0077] In some embodiments, the transfer platform surface and / or the build platform surface can be cleaned after at least one process step or after at least one transfer of at least one (pre-)material layer, for example, by at least one washing device, at least one grinding device, at least one polishing device, and / or at least one blasting device. The at least one cleaning device can advantageously be used for this purpose.

[0078] Advantageously, the transfer platform and / or at least one removable film or at least one removable (thin) plate has surface structures for the preferential enlargement of the transfer platform surface. These surface structures can in particular be pyramids, webs, grooves or similar structures protruding from the surface and / or introduced into the surface. If a layer is applied to these surface structures, the contours of the surface structures are also visible on the side of the layer facing away from them (opposite them). Such a layer or layer provided with predetermined surface structures, for example as a result of a previous process step already located on the build platform surface or on an object part on the build platform surface (i.e. already transferred).This allows the (pre-)material layer to be bonded particularly reliably to the next layer, (pre-)material layer, and / or intermediate layer (to the build platform or to the object parts) when transferring it. This, in turn, ensures optimal adhesion between successive layers and thus improved object integrity, especially in the direction of the layer thickness.

[0079] The invention also relates to a method for manufacturing objects layer by layer. The method comprises the following steps:

[0080] Applying at least one treatment layer to at least one transfer platform by means of at least one application unit. The treatment layer extends in particular in a first direction and in a second direction. Before or after the application of the at least one treatment layer, at least one material layer is applied to the transfer platform. The material layer comprises in particular granular and / or powdery and / or fibrous and / or lamellar material. By connecting the treatment layer to the material layer, these form a pre-material layer of the object. Next, at least the material layer of the pre-material layer is transferred from the transfer platform to a construction platform, in particular along a third direction. In some embodiments, the treatment layer or at least parts and / or regions of the treatment layer can also be transferred to the construction platform.The steps of applying the at least one treatment layer and the at least one material layer and transferring them can be repeated, so that the object is produced layer by layer on the build platform, particularly in the third direction. When repeating the transfer, the layer to be transferred during this repetition can be transferred to a build platform surface of the build platform (locations where no layer is yet present) and / or to parts of the object that are already present or have been formed by the previous transfer of layer(s) on the build platform.

[0081] The first applied layer, either the treatment layer or the material layer, is applied to a transfer platform surface of the corresponding transfer platform. The subsequently applied layer is applied to the first applied layer and, if applicable, to any uncovered sections of the transfer platform surface.

[0082] Preferably, the treatment layer, regardless of whether it is applied to the transfer platform before or after the material layer, is applied to the transfer platform according to a predeterminable pattern. This predeterminable pattern of the treatment layer corresponds and / or at least substantially corresponds to the dimensions and geometry of the layer of the object to be produced and is preferably provided and / or processed by at least one controller. The layer of the object to be produced is particularly preferably provided according to at least one parameter of the pre-material layer to be produced, as explained below.

[0083] Preferably, substantially the entire surface of the transfer platform and / or a removable surface element is exposed to the or at least one material layer.

[0084] In some embodiments, at least large parts of the transfer platform or optionally of a removable surface element are exposed to the material layer, for example in a linear or planar manner, in particular not according to a predetermined pattern, at least partially corresponding to the geometry of the current layer pattern (for example the associated treatment layer).

[0085] In some embodiments, only areas and / or structures of the transfer platform or optionally of a detachable surface element are, for example, linearly and / or punctually coated with at least one material layer, in particular according to a predetermined pattern and / or at least largely according to the templates and / or geometries of the current layer pattern (for example the associated

[0086] Treatment layer). The material of the material layer preferably comprises polymers and / or metals. In further embodiments of the invention, the material of the material layer can consist of or comprise ceramic or glass. In some embodiments, the material for the material layer can consist of mixtures and / or combinations of the materials mentioned herein, in any conceivable mixture, combination, and / or order.

[0087] Preferably, after the treatment layer and the material layer have been applied to the transfer platform, the excess material of the material layer that is not connected to the treatment layer is removed. For this purpose, the method preferably comprises a cleaning step after the treatment layer and after the material layer have been applied, in which cleaning step excess material of the material layer is removed from the transfer platform. The cleaning step preferably comprises rotating the at least one transfer platform by means of the at least one rotating device and / or sucking in and / or blowing off a fluid by means of the at least one cleaning device and / or removing excess material of the material layer by means of sound and / or by means of vibration by means of the at least one vibration generating device.

[0088] In the case where the cleaning step comprises the suction and / or blowing off of a fluid, gases and / or vapors of the treatment layer, in particular of the evaporating and / or vaporizing treatment layer, are preferably sucked in and / or blown off, in particular in addition to or alternatively to the sucked in and / or blown off material of the material layer.

[0089] In particular, the cleaning step is carried out after the application of the treatment layer and the material layer (regardless of the order of application of these two layers) and before the transfer of the material layer or the pre-material layer to the build platform.

[0090] A "post-treatment step" is preferably understood as the finishing and / or temporary fixation of at least parts of at least one pre-treatment layer or at least one material layer. During a post-treatment step, for example, a pre-material layer or a material layer can be treated with at least one additional agent or treatment agent in order to, for example, effect a material refinement on the subsequent object, such as the incorporation or application of alloys, plasticizers, fibers, dyes, and / or nanomaterials. A post-treatment step can be the application of at least one agent or (additional) treatment agent which is suitable, alone or in conjunction with other elements, media, and / or materials, for temporarily increasing the bonding of at least the material layer.A temporary increase in bonding preferably means that the bonding energy is increased and remains so at least until the pre-material layer or at least the material layer is completely transferred and solidified onto the transfer platform or onto a part of an object present on the transfer platform surface. Such a post-treatment step is preferably performed before the material layer is transferred.

[0091] The transfer of the material layer and the treatment layer or only the material layer (hereinafter "the layer to be transferred" or "the layer") from the transfer platform to the build platform preferably comprises the following sub-steps: First, the transfer platform and the build platform are brought relatively close together. In particular, this ensures that the layer is in contact with both the transfer platform and the build platform, in particular with parts of the object already present on the build platform. The layer to be transferred can then be pressed on the transfer platform surface against the build platform surface of the build platform or against parts of the object already present on the build platform surface. The pressing force is preferably exerted by the build platform on the layer.Pressing improves the adhesion of the layer to the build platform surface and / or to the respective parts of the object. Finally, the layer is detached from the transfer platform surface. The transfer platform surface is then available for the application of another layer of pre-material.

[0092] When transferring the layer to be transferred to the build platform, no pressing force, especially not high ones, is required. As an alternative to pressing, the transfer can be achieved by simply bringing the layer to be transferred into contact with the build platform surface or with the parts of the object on the build platform.

[0093] Particularly preferably, the method comprises a first energy application step before and / or during and / or after the application of the treatment layer and / or before and / or during and / or after the application of the material layer.

[0094] The first energy application step and / or the subsequent energy application steps mentioned below can preferably be carried out using a heating device for applying thermal energy. Alternatively or additionally, the energy application can be carried out, for example, by means of radiation and / or induction and / or vibration and / or sound and / or by means of an electric current.

[0095] In this case, the precursor layer is preferably heated, in particular to a temperature close to or equal to the evaporation temperature of the treatment agent of the treatment layer. Preferably, the precursor layer is heated to a temperature within a temperature range of ± 20°C of the evaporation temperature of the treatment agent of the treatment layer. Such a heating step can be carried out continuously or at discontinuous time intervals. "Continuously" means that the energy application steps or heating steps are carried out with a temporal overlap.

[0096] The treatment layer preferably comprises a solvent as a treatment agent, such as water, in particular deionized or demineralized water (DI water). The precursor material layer is preferably heated to a temperature between 80°C and 120°C, preferably between 90°C and 110°C, particularly preferably to 100°C. In this way, the treatment layer evaporates or vaporizes essentially residue-free, so that only the material layer with the pattern of the treatment layer remains on the transfer platform surface.

[0097] In some embodiments, the first energy application step can at least largely impart / generate temperatures below 100°C, preferably below 80°C, for example in the case of treatment layers with at least portions of esters, ketones and / or simple alcohols such as ethanol or isopropanol, with or without the addition of water, such as, in various embodiments, azeotropic mixtures of at least two media or treatment agents, and / or in the processing of material layers with at least portions or completely formed from at least one polymer.

[0098] In some embodiments, for example in the processing of metals, ceramics, glass, silicates and / or regolith, a treatment layer may preferably consist at least in part of at least one glycerol, a glycol such as triethylene glycol and / or a glycol ether such as butyl triglycol, wherein the first energy application step achieves, for example, temperatures between 80°C and 220°C, or between 140°C and 320°C.

[0099] In some embodiments, in a first energy application step, preferably at least 50 mass% of the entire treatment layer or at least of a component or a medium of the treatment layer is evaporated and / or vaporized, particularly preferably at least 70 mass% and very particularly preferably at least 90 mass%, such as for example at least 97 mass% or (almost) 100 mass%.

[0100] The method preferably comprises a second energy application step, in particular after the first energy application step, in which the precursor material layer is brought to a further elevated temperature, which should in particular be lower than, equal to, or higher than the melting temperature or the melting range of the material of the material layer.

[0101] In the second energy application step, the precursor material layer is preferably brought to a temperature which is equal to or greater than the melting temperature or melting range of the material of the material layer.

[0102] For example, alloys or certain polymers have a melting range between solidus and liquidus temperatures.

[0103] The second energy application step is preferably performed continuously, i.e., overlapping in time, with the first energy application step. In other words, the first energy application step does not have to be completed before the second energy application step is initiated or performed. Alternatively, the second energy application step can be initiated or performed only after the first energy application step has been completed, i.e., it can be performed discontinuously with the first energy application step.

[0104] The aforementioned second energy application step can preferably be carried out in various ways and depends largely on the material selection for the material layer and / or the material selection for the transfer platform. For example, if a high-performance polymer such as PEEK (polyetheretherketone), PEI (polyethyleneimine), and / or PPSII (polyphenylenesulfone) is used as the material layer, the precursor material layer can be heated in the second energy application step, in particular, to a temperature range between and including 150°C and 350°C.

[0105] In some embodiments, preferably in the processing of polymers, the temperature achieved in the second energy application step is preferably below 500°C and particularly preferably below 400°C, such as between 80°C and 350°C or between 140°C and 300°C.

[0106] When using metals such as stainless steel as the material layer, in particular in granular and / or powder form, the pre-material layer is preferably heated to a temperature of approximately 1,500°C or higher during the second energy application step.

[0107] In some embodiments, preferably when processing metals, ceramics, and / or glass, the precursor material layer is preferably heated to a temperature of at least 400°C, preferably at least 500°C, and particularly preferably at least 600°C or higher during the second energy application step. It is particularly preferred if only the precursor material layer or the material layer is (actively) heated, and not, for example, the transfer platform.

[0108] In some embodiments, at least during the second energy application step, not only the precursor material layer or the material layer is heated, but additionally at least parts or regions of the transfer platform and / or the transfer platform surface and / or a detachable surface element, preferably only at the locations or closer regions of the (precursor) material layer, very particularly preferably more pronounced or with more heat output as the temperature of the (precursor) material layer increases, and very particularly preferably starting from a temperature of the (precursor) material layer of approximately 500°C.

[0109] The first and / or second energy application step can be achieved, for example, by introducing heat energy using microwave radiation. The microwave radiation can preferably be generated either via a vacuum time-of-flight tube, a so-called magnetron, or via a laser in the microwave range, a MASER (microwave amplification by simulated emission of radiation). With the help of the magnetron, the radiation is emitted over a large area or in a directed manner onto the pre-material layer. When using a MASER, the microwave radiation can be introduced into the pre-material layer in a directed manner.

[0110] Alternatively or in addition to the use of microwave radiation, the energy can be introduced by induction. For this purpose, the transfer platform is, in particular, electrically conductive. When energy is applied or heated by induction, an induction coil, in particular a flat coil, is preferably arranged near the transfer platform. Alternatively or additionally, the induction coil can be arranged such that the transfer platform is located within it. Furthermore, the production device, in particular the energy application device, can have additional switched active and passive coils to enable a targeted design of the inductive alternating field for the energy introduction by induction. This ensures, in particular, an optimized energy introduction into the pre-material layer.

[0111] Alternatively or additionally, the aforementioned energy, in particular thermal energy, can be introduced by means of high-frequency alternating electrical fields as dielectric or capacitive heating. Alternatively or additionally, the aforementioned energy can be introduced by means of galvanic coupling through ohmic heating. It is particularly preferred if the entire heating and, in particular, melting process of the material layer takes place in a protective gas atmosphere in order to avoid oxidation or interactions with atmospheric gases. Alternatively or additionally, the aforementioned energy for heating and / or welding the layer(s) can be induced or promoted by a redox reaction within itself and / or with the object parts already present on the build platform.

[0112] The aforementioned energy application steps can be performed either or both after the application of the treatment layer and the material layer and before transferring at least the material layer of the pre-material layer to the build platform. Alternatively or additionally, the energy application steps can be performed either or both after the transfer of the material layer and the treatment layer (pre-material layer) to the build platform. In other words, for example, the treatment layer and the material layer can first be applied to the transfer platform, excess material of the material layer can be removed, the remaining pre-material layer can be transferred to the build platform, and then, by applying energy, the treatment layer can be at least partially removed from the pre-material layer transferred to the build platform.Furthermore, the transferred (pre-)material layer can then be heated to a melting temperature as explained above.

[0113] The treatment layer does not need to be completely removed from the pre-material layer. Rather, a quantity of the treatment agent from the treatment layer can remain in the pre-material layer after the first energy application step, particularly to keep the melting point of the material layer low. This is preferably used when polymers are used as the material layer. This ensures, in particular, better adhesion of the material layer to the object parts of the object and / or the build platform surface.

[0114] The method preferably comprises a fiber application step, particularly after the cleaning step, in which the pre-material layer and / or the material layer is at least partially coated with fibers, preferably short fibers. The fiber application step is carried out, in particular, by means of the at least one fiber application device.

[0115] The fiber application step is preferably carried out during or after the first and / or second energy application step. In this case, the fiber application step is carried out in particular during and / or after heating the precursor material layer in a temperature range of the melting temperature of the material of the material layer, for example 50°C below a melting point to 50°C above such a melting point or 30°C below to 30°C above, so that the precursor material layer has a reduced viscosity. As a result, the fibers are accelerated as described above by means of, for example, a recoater with rotating rollers and / or by means of a material stream in the direction of the precursor material layer on the transfer platform surface and / or the already existing object parts of the object on the build platform surface. The orientation of the fibers is largely arbitrary.This means that a certain number of fibers are more likely to impinge on the pre-material layer and / or the existing parts of the object at a steep angle (particularly between 45° and 90°) and, depending on the fiber speed, penetrate at a steep angle. Fibers that impinge at an increasingly shallow angle will not, or hardly, penetrate the pre-material layer or the said parts of the object, but will essentially remain by lightly adhering to the surface of the pre-material layer and / or the said parts of the object. The rotating rollers of the recoater, the material flow, and / or the fibers can be heated using methods and devices known to those skilled in the art.

[0116] Such a fiber reinforcement process can, in particular, achieve a nearly isotropic alignment of fibers bound in polymer.

[0117] Preferably, after the fiber application step, the aforementioned cleaning step can be carried out again so that fibers that are not bonded or are only insufficiently bonded are removed from the surface of the pre-material layer and / or the object parts of the object.

[0118] It is particularly preferred if both the last transferred layer (object part of the object) on the build platform and the pre-material layer on the transfer platform surface are coated with fibers. This creates fiber reinforcement between the boundaries of the individual layers of the object being produced. The fiber coating ratio between the object part of the object and the layer to be transferred can be approximately 1:1. This means that approximately half of the fibers present in one layer of the object are incorporated into the surface of the object part of the object on the build platform, and approximately the other half of these fibers are incorporated into the layer to be transferred.

[0119] The method preferably comprises a third energy application step before and / or during the fiber application step, in which energy is supplied to the pre-material layer on the transfer platform and / or the object parts of the object on the build platform before and / or during the application of fibers. This preferably heats the pre-material layer on the transfer platform and / or the object parts of the object on the build platform. The energy application or heating of the pre-material layer on the transfer platform and / or the object parts of the object on the build platform preferably reduces the viscosity of the pre-material layer or of said object parts of the object, so that the fibers can penetrate deeper into them.

[0120] Alternatively or in addition to the application of energy, the viscosity of the pre-material layer and / or the object parts of the object can be reduced using solvents and / or pressure changes and / or other physical and / or chemical measures, or a combination thereof. By heating the pre-material layer and the object parts of the object, which in particular both contain fibers, the fibers can be introduced from one of the two into the other while the pre-material layer and the object parts of the object are in contact with each other.

[0121] For example, if PEEK is used as the material of the material layer and heated to the temperature range of the melting temperature or to the melting temperature, the viscosity of this polymer material in the material layer decreases.

[0122] When processing PEI as the material for the material layer, however, a comparable effect can be achieved using the solvent DOM (dichloromethane). In some embodiments, such a solvent is preferably a component of the treatment layer and / or is additionally applied to the precursor layer and / or to the object parts of the object prior to the fiber application step. Preferably, the proportion of the DOM solvent in the treatment layer is at least 10% of the treatment layer. When using a solvent to reduce the viscosity of the precursor layer and / or the object parts of the object, the method can comprise an additional (virtually fourth) heating step after the fiber application step to evaporate the solvent.

[0123] When using a solvent to reduce the viscosity, the fibers can be mixed with this solvent or dissolved in it, whereby the corresponding surface of the layer and / or the object parts of the object are then exposed to the mixture of solvent and fibers.

[0124] In a particular embodiment, the fibers can preferably be heated immediately before and / or during the fiber exposure step, for example by means of radiant energy such as microwave radiation or infrared radiation, and / or by means of induction and / or sound waves. A corresponding radiation source can also be used to align the fibers. This can eliminate the need for an accelerating material flow. Furthermore, the radiation can also be used after exposure and penetration into the respective surface to readjust the alignment of the fibers. If thermal energy is also introduced into the fibers and thus into the polymer material in this way, the temperature or solvent concentration can be adjusted for further processing.

[0125] Particularly advantageously, the temperature of the pre-material layer before and / or during pressing corresponds at least to the plasticizing temperature and / or the melting temperature of the material of the material layer. In this way, optimal adhesion / bonding between successive layers is achieved. Advantageously, the temperature of the pre-material layer corresponds at least to the plasticizing temperature or the melting temperature of the material of the material layer, preferably shortly before contacting or pressing, in particular at the beginning of pressing, whereby the temperature of the pre-material layer decreases during pressing, in particular due to contact with the build platform and / or the object parts of the object.

[0126] Advantageously, the transfer platform surface and / or the build platform surface are cooled during and / or after the step of removing the pre-material layer from the transfer platform. This can simplify the removal of the material from the transfer platform.

[0127] In a preferred embodiment, during the application steps, exactly one pre-material layer is produced on the transfer platform surface. Thus, each pre-material layer is produced individually and transferred to the build platform. This ensures optimal interconnection of all layers, since the individual layers are joined to form the finished object exclusively by transferring them from the transfer platform to the build platform. This avoids the direct production of a layer on top of an existing layer (on the transfer platform).

[0128] To transfer the pre-material layer from the transfer platform to the build platform, in particular to bring the transfer platform and the build platform closer together, the build platform is preferably moved along the first direction and the second direction and / or the third direction. The transfer platform advantageously remains in a predefined position. In particular, a movement of the transfer platform along the third direction is preferably not provided. The transfer platform can be moved either stationary or along the first direction or along the first and second directions, with a movement being carried out in particular only for applying the pre-material layer. The layer can be applied particularly advantageously in such a way that the transfer platform is moved along the first direction and the application unit(s) is moved along the second direction or vice versa.In any case, it is preferably provided that the transfer platform remains in a predefined position during the transfer of the layer to the construction platform. Advantageously, in a case in which a plurality of transfer platforms is provided, all transfer platforms can remain in the same predefined position, particularly with respect to the second direction, for transferring the respective layers.

[0129] Preferably, the treatment layer comprises a solvent according to the above explanations. Particularly preferably, the treatment layer comprises a solvent mixture, for example, a solvent with further additives such as dissolved polymers and / or nanoparticles and / or fibers.

[0130] The treatment layer preferably comprises a medium that is in liquid form at room temperature, in particular at 20°C. The treatment layer can be or comprise water. Alternatively or additionally, the treatment layer comprises an alcohol and / or glycols such as ethylene glycol, diethylene glycol, triethylene glycol, propylene glycol, or polyethylene glycol and / or an ester and / or an ether and / or an acetal and / or an acid and / or a base and / or a buffer, or is formed from at least one of these.

[0131] In a preferred embodiment, the treatment layer is made of at least one solvent from the group of halogen-free and non-polar hydrocarbons and their derivatives and / or a solvent from the group of bio-based solvents or comprises at least one of them.

[0132] In some embodiments, the treatment layer is made of or comprises at least one material that can activate or promote a chemical reaction, which can be a component of a chemical reaction, or which comprises a combination thereof, in particular for a chemical reaction with the material layer.

[0133] In some embodiments, the treatment layer is or comprises an adhesive or at least one component of an adhesive. In preferred embodiments, the adhesive is formed from an epoxy resin, a polyester resin, a phenolic resin, or an acrylic resin, or comprises at least one of these. In this case, the treatment layer can be transferred, in particular, together with the material layer, to the build platform or to the existing parts of the object.

[0134] In some embodiments, the treatment layer is formed from at least one solvent and at least one dissolved polymer. In certain embodiments, further substances can be dispersed in the treatment layer, which can preferably be embodied as solids. In some embodiments, dispersed or dissolved substances can be embodied as or comprise nanoparticles. In certain embodiments, substances introduced into the treatment layer can comprise or be embodied from at least one of the following: boron nitride nanotubes (BNNTs), carbon-containing nanoparticles, metal and semimetal oxides, semiconductors, metals, metal sulfides. Nanoparticles can preferably be brought into contact with at least one electric field before the treatment layer is applied.In this way, nanoparticles can be directed after application to the transfer platform surface by applying an electric field, preferably in the immediate area of ​​the transfer platform.

[0135] In some embodiments, the treatment layer can comprise water or an aqueous solution. For example, a mixture of water and glycol can be used as the treatment layer. Such a treatment layer can be exposed to microwaves after application to the transfer platform. Microwaves are readily absorbed by water and can thus at least promote rapid heating. In this way, accelerated melting can be achieved, particularly in polymers.

[0136] In a particularly preferred embodiment, the object or parts of the object on the build platform can be coated and / or infiltrated with the treatment layer before a new layer is applied. Such a treatment layer can perform additional functions in the object. In certain embodiments, substances dispersed in such a treatment layer, such as fibers or adhesion promoters, can be applied and / or incorporated onto the object, preferably onto the last layer created.

[0137] In some embodiments, by applying such a treatment layer to the last layer when using an aqueous-based treatment layer, an increase in temperature by means of microwaves or other forms of energy can be achieved, preferably immediately before and / or during the transfer of the newly applied layer.

[0138] In particular embodiments, such a treatment layer can use or comprise solvents that promote fusion of the layers, for example, by at least temporarily reducing the melting point of the polymers used in the contact area with such solvents. Contacting, exposure, and / or infiltration as described above can be carried out, for example, by dipping, spraying, printing, or vapor deposition, in particular by means of the application unit(s).

[0139] All or some of the aforementioned heating steps can be performed globally, i.e., heating the entire manufacturing device, or locally, i.e., heating only individual components of the manufacturing device. In addition to the melting temperature or melting range of a material or material layer, there are other process-relevant temperatures that may be of particular importance for the method and device. Thus, it may be particularly advantageous to heat at least one material or material layer to a temperature equal to or greater than the heat deflection temperature (HDT), the Vicat softening temperature, the glass transition temperature, the crystallization temperature, or the recrystallization temperature during one or more of the aforementioned energy application steps or during one or more of the aforementioned heating steps.

[0140] In some embodiments, at least residual amounts of at least one treatment layer within at least one precursor material layer can reduce the melting temperature of the material layer, usually specifically and predetermined for combinations of certain treatment agents of the treatment layer and the at least one polymer, preferably depending on the concentration ratios of the treatment agent to the polymer.In some embodiments, the mass ratios of the concentrations of the treatment agent of at least one treatment layer to the polymer of at least one material layer, which is referred to herein as the “BP ratio”, at a time point during the first energy application step, the second energy application step, an application of fibers or short fibers and / or during the transfer of the precursor material layer to the build platform surface or to object parts of an object present on the build platform surface are between 70 / 30 and 1 / 99, preferably between 50 / 50 and 5 / 95 and particularly preferably between 35 / 65 and 10 / 90, such as at least temporarily at 50 / 50, at 40 / 60, at 30 / 70, at 20 / 80, at 10 / 90, at 5 / 95 and / or at 3 / 97.

[0141] In addition to the aforementioned standard temperatures, there are other temperatures of materials and material layers that may be important at least for certain embodiments of the method and device. In particular, a solvent softening temperature is defined. A solvent softening temperature describes the temperature at which a material (of a material layer), in particular at least one polymer material, permeated or infiltrated with at least one specific solvent exhibits viscous or melt-viscous properties and / or other technical properties that are at least highly comparable to the heat distortion temperature (HDT) of the same material or the same material mixture, but are up to 150°C, preferably up to 100°C, and particularly preferably up to 30°C lower due to the solvent present.The properties of a temperature-dependent change in solvent softening and the associated melting behavior of a material depend in particular on the type of solvent and / or solvent mixture and its concentration and / or distribution in the material or material layer. In other words, by applying and / or introducing solvents into materials, their properties such as melting temperature, heat resistance, melt viscosity, and other properties can be changed or reduced. The change in these properties depends in particular on the type of solvent or solvent mixture, its concentration relative to the material or material quantity, and its homogeneous or inhomogeneous distribution in the material or material layer.

[0142] A "detachable surface element" is primarily used for supporting and / or attaching to transfer platforms and / or transfer platform surfaces and / or to build platforms and / or build platform surfaces, preferably for temporary attachment. A "detachable surface element" can be designed in the form and shape of at least one film, a thin, for example, flexible plate and / or a (solid) plate, a mat or fiber mat such as a glass fiber or carbon fiber mat, and / or a three-dimensional (more complex) structure such as a semi-finished product, an at least prefabricated component, and / or an at least partially manufactured object.A detachable surface element can be formed from any material mentioned herein, particularly with reference to the transfer platform and / or the build platform, or any combination of elements and materials, and / or can have at least any surface design, surface shaping, and / or surface coating disclosed herein. A detachable surface element should, in particular, withstand the process-related temperatures at least temporarily or permanently, and preferably exhibit low wear properties and / or preferably exhibit low thermal expansion coefficients or at least exhibit thermal material expansion similar to that of the underlying platform.Preferably, a detachable surface element is equipped with provisions to be able to be connected to the corresponding platform (surface) in a predetermined manner, as reproducibly and / or automatably as possible, such as by locking, plugging, snapping, pivoting, rotating and / or sliding.

[0143] A "material layer manipulation device" is preferably designed to remove excess powder or material from a material layer that does not correspond to the precursor material layer, i.e., is not bonded, fixed, and / or glued within a treatment agent layer. Any device suitable for performing or at least supporting such removal is to be understood as a "material layer manipulation device."In some embodiments, a "device for material layer manipulation" can consist at least in part of a cleaning device or contain at least one such device and / or execute and / or assume predetermined movements and / or orientations of at least regions, parts, and / or machine elements of the production device to ensure and / or effect the removal of excess material from a material layer that does not belong to and / or correspond to the precursor material layer. In some embodiments, a "device for material layer manipulation" can be alternatively or additionally designed or equipped with an additional energy input, such as sound waves, vibrations, and / or oscillations.

[0144] In some embodiments, at least parts of the device are not moved within map-stable coordinates and / or trajectories for predetermined distances. For example, delta, tripod, or hexapod systems and / or rotary, pan, arc, and / or tilt mechanisms can be used as the movement device, at least in part or in sections, and / or in combination with each other and / or with Cartesian systems.

[0145] If method steps are mentioned herein, the device according to the invention or the control device according to the invention is configured in some embodiments to carry out one, several or all of these method steps, in particular if these are automatically performable steps, or to control corresponding devices, which are preferably based on the name of the respective method step (e.g. "determining" as a method step and "device for determining" for the device, etc.) and which can also be part of the device(s) according to the invention or can be connected thereto in a signal connection.

[0146] When reference is made herein to programmed or configured, these terms may be interchangeable in some embodiments.

[0147] The control device can initiate the execution of all or substantially all method steps. The method according to the invention can be executed substantially or entirely by the control device. It can be executed partially by the control device; in particular, those steps that do not require or involve human intervention and / or provision can be executed by the control device. The control device can serve as a pure control device or also as a regulating device.

[0148] The control device can be programmed to execute or cause the method according to the invention in any embodiment disclosed herein, for example by issuing control commands to the components and / or actuators required for this purpose, in particular as disclosed herein. For this purpose, the control device can be in signal communication with the required components or be prepared for this purpose.

[0149] In some embodiments, a controller is configured to use the measurement data of at least one infrared camera and / or at least one infrared thermometer with the 3D data of a 3D scanner in programmable combinations in order to determine the most accurate temperature data possible of at least one (pre-)material layer and to control the energy application devices according to the measured values.

[0150] In some embodiments, a controller is designed to utilize artificial intelligence (AI) in closed-loop control, particularly through the use of machine learning algorithms, to model the processes of material heating, preferably metal heating and / or melting of metals, polymers, ceramics, and / or glass. The model is trained using sensor data and historical data and can predict the temperature of the material at a specific time. The controller uses this prediction to adjust the heating system, thus improving the accuracy and efficiency of the device and / or process.

[0151] In some embodiments, a powder or granular media for forming a material layer is preferably formed at least in large part or entirely from at least one polymer, such as at least one semi-crystalline polymer such as PEEK, polyethylene, polybutylene, polyisobutylene, or PLA, and / or from at least one amorphous polymer such as ABS, ASA, PMMA, and / or SAN. Standard plastics, quality plastics, and / or high-performance plastics can be used as polymers. In some embodiments, thermosetting plastics or elastomers can be used as powder or granular media; in others, PTFE or silicone.

[0152] In some embodiments, a powder or granular media for forming a material layer is preferably formed at least in large parts or entirely from at least one metal, an amorphous metal, a noble metal, a refractory metal, a light metal, a heavy metal, a non-ferrous metal, a shape memory metal, a rare earth metal, or a metal alloy, such as aluminum, AlMg3, Al99.5, AlMgSilO, Al-AW7075, Ti6Al4V, an aluminum casting alloy, magnesium, a magnesium alloy, tin, zinc, bismuth, a bismuth-tin alloy, copper, a copper alloy, copper-tin, copper-zinc, brass, bronze, iron, steel, structural steel, tempering steel, quality steel, case-hardening steel, low-carbon steel, tool steel, hardenable steel, austenitic stainless steel, ferritic stainless steel, martensitic stainless steel, stainless steel 316L, titanium, nickel, titanium / nickel alloy (Nitinol), nickel-based alloys, chromium, palladium, molybdenum,Worlfram, gold, silver and / or other metals or alloys containing at least one such metal.

[0153] In some embodiments, a powder or granular media for forming a material layer is preferably formed at least in large parts or entirely from at least one ceramic, such as aluminum oxide, aluminum nitride, silicon carbide, silicon nitride, zirconium oxide, mixed ceramic, boron carbide or sapphire glass.

[0154] In some embodiments, a powder or granular media for forming a material layer is preferably formed at least in large part or entirely from at least one glass, such as silicate glass, quartz glass, borosilicate glass, crown glass, and / or flint glass. In some embodiments, glass or glasses can be produced with predetermined optical, thermal, and / or strength values, for example, with relatively uniform or homogeneous properties or with gradients, for example, layer by layer. The combination of glass and polymers, for example, laminated glass, can also be produced using the manufacturing device and the method.In some embodiments, glass or glasses can be produced with predetermined optical, thermal, and / or strength values, for example, with relatively uniform or homogeneous properties or with gradients, for example, layered. A combination of glass and polymers, for example, laminated glass, can also be produced using the manufacturing device and method.

[0155] In some embodiments, a powder or granular media for forming a material layer is preferably formed at least in large part or entirely from regolith.

[0156] In some embodiments, a powder or granular media for forming a material layer is preferably formed at least in large part or entirely from at least one polymer, a metal, a ceramic, a glass and / or a regolith, which may be mixed with one another in any possible combination that is technically reasonable.

[0157] Mixing and / or joining and / or fusing of materials for a material layer, for example as a compound, blend or mixed material, can take place both before powder production or before processing into granular media, for example by means of a powder mill and / or by mixing powders or granular media from different starting materials after pulverization and / or after processing into granular media, either outside and / or inside the production device and in some embodiments as part of the method according to the invention.

[0158] In some embodiments, a transfer platform and / or a transfer platform surface and / or a construction platform and / or a construction platform surface and / or a detachable surface element is designed at least substantially as a flat plate, preferably formed at least partially and / or in portions from at least one ceramic and / or at least one refractory metal, in order in this way to be able to withstand preferably process-related temperatures and conditions above 500°C, particularly preferably above 800°C and very particularly preferably above 1200°C, in particular over a longer period of time and / or over several or many thermal cycles and without or at least without significant signs of wear.

[0159] In some embodiments, at least one material, a ceramic, a metal, a refractory metal and / or a glass of a transfer platform and / or a transfer platform surface and / or a build platform and / or a build platform surface and / or a detachable surface element can be made of aluminum oxide, aluminum nitride, aluminum titanate, silicon carbide, silicon nitride, zirconium oxide, mixed ceramic, boron carbide, sapphire glass, boron nitride, yttrium oxide, borosilicate glass, quartz glass, natural stone, granite, tungsten, molybdenum, platinum, nickel, chromium, steel, spring steel, stainless steel, fiber matrix, CFRP, GFRP, high-temperature polymer, duoplastic resin and / or other materials.

[0160] In some embodiments, the at least one construction platform or construction platform surface and at least one transfer platform or transfer platform surface are at least approximately equal in their size, area, length, shape and / or geometric configuration at least within a first direction and / or within a second direction and / or these platform(s) form at least partially such comparable or at least approximately identical properties and / or sizes in the shape when viewed from at least one perspective third direction, preferably from opposite sides.

[0161] In some embodiments, a transfer platform and / or a build platform comprises a heating device and / or an energy application device with at least 3000 watts of power, preferably with at least 5000 watts and particularly preferably with at least 10000 watts, such as with at least 15000 watts or with at least 20000 watts.

[0162] In some embodiments, the at least one energy application device of a transfer platform and / or a construction platform consists of a resistance heating device, which preferably consists of at least one graphite and one boron nitride, and particularly preferably is designed as a resistance heater from a graphite core that is at least largely coated and / or encased with pyrolytic boron nitride (PBN).

[0163] In some embodiments, the at least one energy application device is designed as an induction heater, preferably by means of a high-frequency generator, in order to be able to heat powder or granular media directly on the transfer platform in this way, i.e. at least primarily without or at least without a significant and / or additional energy input into the transfer platform and / or into the transfer platform surface carried out by this.

[0164] In some embodiments, the material thickness of a transfer platform is at least somewhat comparable to that of a build platform.

[0165] In some embodiments, the material thickness of a transfer platform and / or a construction platform is predominantly or at least over large areas at least 8 mm, preferably at least 14 mm and most preferably at least 18 mm.

[0166] In some embodiments, a transfer platform and / or a construction platform is at least initially round in shape and / or designed as a disc or ring, for example with a diameter and / or circumference of at least 100 mm, of at least 400 mm or of at least 800 mm.

[0167] In some embodiments, a transfer platform is preferably designed, at least partially, as a disk or ring, with a dispensing unit arranged such that it can only treat segments of the circle or ring within each process step of applying the treatment layer and / or the material layer. With a manufacturing device having at least one at least partially circular or ring-shaped transfer platform, at least the process steps of treatment agent layer and material layer dispensing, material layer manipulation, energy application to the (pre-)material layer, and transfer to at least one build platform can be performed in a circular manner, preferably within one revolution of the transfer platform.In other words, with each rotation of such an at least partially circular and / or annular transfer platform, at least one pre-material layer can be created and transferred to the build platform, preferably in conjunction with at least a first and a second heat input. A transfer platform, which is at least partially designed as a disk or ring, rotates about an at least largely central axis of rotation, which is at least approximately perpendicular to the transfer platform surface, preferably at least predominantly in only one direction of rotation, particularly preferably not continuously, but with pauses and / or at least significant changes in angular speeds, and preferably requires at least 20 seconds, preferably at least 40 seconds, and particularly preferably at least 60 seconds for a complete rotation.

[0168] In some embodiments, a transfer platform and / or a construction platform has length dimensions in a first direction and in a second direction of at most 400 mm each.

[0169] In some embodiments, a device for guiding the protective gas is preferably configured and / or designed to at least largely prevent oxidation of at least one material layer, such as metals or metal powders, on at least one transfer platform or at least one construction platform.

[0170] In some embodiments, a device for guiding the protective gas is arranged at least in the immediate vicinity of at least one transfer platform and / or a transfer platform surface and / or is movable (equally) together with the latter at least within a movement device and / or is configured to carry out at least one or recurring relative movement(s) during the various method steps and / or during the progressive layer build-up of the object.

[0171] In some embodiments, a device for guiding the protective gas is arranged at least in the immediate vicinity of at least one construction platform and / or construction platform surface and / or is movable (equally) therewith within a movement device and / or is configured to carry out at least one relative movement during the various method steps and / or during the progressive layer build-up of the object, preferably depending on the progressive layer build-up of the object, in order in this way to preferably ensure a protective gas flow that is at least partially comparable across the layers on or around the at least one object part of an object, particularly preferably approximately at the level of the object parts currently closest to the construction platform (viewed within a third direction).

[0172] In some embodiments, a device for guiding protective gas is designed, at least in part, as an elongated, preferably at least partially straight and / or tubular machine element, and is configured to deliver a fluid flow onto at least one transfer platform (surface) and / or at least one construction platform (surface) using several or many bores or holes arranged laterally to the longitudinal direction, preferably with as uniform a flow and / or effect as possible at least within a first and / or second direction and particularly preferably with an at least predominantly laminar protective gas flow. A protective gas can also be designed as a process gas, so that a device for guiding protective gas then represents a device for process gas guidance.

[0173] In some embodiments, the manufacturing device is equipped with a condensation device and / or an extraction device for collecting and / or recovering evaporated and / or vaporized treatment agent layers.

[0174] In some embodiments, in particular by a first heating step, at least 25 mass% of a treatment layer or at least the volatile solvent components of a treatment layer are evaporated and / or vaporized, preferably at least 50 mass%, particularly preferably at least 75 mass% and very particularly preferably at least 90 mass%, such as for example at least 95 mass% or at least 99 mass%.

[0175] In some embodiments, the at least one energy application device for a transfer platform is designed such that the entire or at least almost the entire transfer platform is heated as evenly as possible.

[0176] In some embodiments, the at least one energy application device for a transfer platform is designed such that all pre-material layers or at least all material layers on a transfer platform are heated simultaneously, preferably as evenly as possible.

[0177] In some embodiments, a first and a second heating step and / or energy input are carried out within two directly successive method steps, in particular without an intermediate cleaning step of a cleaning device and / or a device for material layer manipulation.

[0178] In some embodiments, a movement device is designed to move at least one transfer platform and / or a construction platform and / or a dispensing unit in at least one direction of movement.

[0179] In some embodiments, a controller is configured to controllably execute at least one movement of the at least one transfer platform and / or the at least one construction platform and / or the at least one dispensing unit in response to at least one parameter associated with the precursor material layer and / or at least one material layer in terms of speed and / or movement sequences. Preferably, the at least one parameter comprises a material of the precursor material layer, a desired surface quality of the precursor material layer, and / or a geometric property of the precursor material layer, including particle size, particle distribution, density, volume, dimensions, and / or complexity of the precursor material layer.

[0180] Preferably, the at least one parameter is at least one temperature of the transfer platform surface, the material layer, the pre-material layer, the construction platform surface and / or the surface of an object located on the construction platform.

[0181] Preferably, the at least one parameter is measured by an infrared thermometer and / or by an infrared camera.

[0182] Preferably, the at least one parameter is at least one comparison value of the construction height of the object located on the construction platform with the target height of the digital twin.

[0183] In some embodiments, the device is equipped with a compaction module, wherein a compaction module is preferably arranged downstream of at least one device for printing at least one treatment layer and / or downstream of at least one binder printer.

[0184] In some embodiments, a dispensing unit for at least one material layer within the same device can include at least one compaction device and / or a compaction module, in order to dispense at least one material for a material layer onto a transfer platform at least almost simultaneously and / or preferably as a unit or device and / or within one method step and to compact it (simultaneously), either to predetermined values ​​and / or ranges for a compaction specified by the controller or alternatively to non-predetermined and / or non-predeterminable values ​​and / or ranges,wherein the at least one application unit for at least one material layer and the at least one compaction device or the at least one compaction module are not separated from each other, in particular by any direction of movement of a transfer plate and / or a carrier substrate, and / or, according to the invention, they do not have any clearly definable spatial / temporal relationships to each other, e.g., no relative specifications such as "upstream" or "downstream." Preferably, a device with the combination of an application unit for at least one material layer and a compaction device for at least one material layer can be designed such that at least one roller-shaped machine element is arranged in the immediate or at least close area of ​​the transfer platform surface and / or a detachable surface element.which is responsible for the conveyance and thus the application of at least one material of a material layer and at the same time can ensure compaction of at least the material layer.

[0185] In some embodiments, a first energy application step is performed only after a material layer manipulation step

[0186] In some embodiments, a printer or print head for a treatment agent layer and / or a binder printer is not arranged or at least not substantially arranged in a direction of movement of a compaction unit and / or a device for compacting at least one material layer.

[0187] In some embodiments, a treatment layer application unit is configured by a controller to apply predetermined patterns for the successive layers of an object or part of an object in the form of isolated fluid drops (drop on demand) or by a continuous fluid flow onto at least one transfer platform, for example by at least one piezo print head, by at least one electromagnetic print head, by at least one pneumatic print head, by at least one binder print head, by at least one eccentric screw extruder, by at least one piston extruder and / or by at least one volumetric material extruder with an elastic stator according to the operating principle of a linear hose pump.

[0188] In some embodiments, the manufacturing device or the at least one transfer platform and / or the at least one construction platform no longer performs any movement or at least almost no movement after heating, plasticizing, liquefying, melting and / or fixing at least parts of at least one material layer and / or after a first heating step and / or after a second heating step and / or after optionally further heating steps, preferably no linear and / or Cartesian movement and / or no rotational movement and / or at least no movement in a first and / or second direction, wherein small or very small movements, for example for fine adjustment and / or for correcting the alignment of the platforms, can be excluded from this.

[0189] In some embodiments, a detachable surface element can be used only once on at least one transfer platform and / or at least one build platform, in particular only for transferring at least one material layer and / or one treatment layer. In some embodiments, at least one intermediate layer can be transferred to the build platform or to the surface of an object part already present on the build platform surface, such as a polymer layer made of at least one polymer.

[0190] In some embodiments, only one intermediate layer is formed between at least two material layers or pre-material layers.

[0191] In some embodiments, several intermediate layers are formed between at least two material layers or pre-material layers.

[0192] In some embodiments, at least one intermediate layer is designed as a soldering or adhesive layer, preferably with at least one soft or hard solder or with at least one 1-component epoxy adhesive, a 2-component epoxy adhesive, a PU adhesive, an acrylate, a UV adhesive or a hot melt adhesive.

[0193] In some embodiments, a detachable surface element can be used multiple times on at least one transfer platform and / or at least one construction platform, in particular for the transfer of many material layers, pre-material layers and / or treatment layers, for example at least 10 times, preferably at least 100 times and particularly preferably at least 500 times, in order to be able to produce at least one entire object with a detachable surface element in this way.

[0194] In some embodiments, the temperature profiles of a transfer platform surface and / or a (pre-) material layer are recorded and / or measured with an infrared thermometer or with an infrared camera and forwarded to a controller.

[0195] In some embodiments, an infrared camera or an infrared thermometer is equipped with at least one optical filter such as an infrared filter in order to filter out, for example, cross-fading of the images, for example due to superimposed thermal radiation from a resistance heater, and in this way to be able to record and measure primarily and predominantly the temperatures and temperature profiles of the (pre-) material layer.

[0196] In some embodiments, the time during a first energy application step is up to 15 minutes, preferably up to 8 minutes, and more preferably less than 4 minutes, such as 3 seconds to 180 seconds or 30 seconds to 300 seconds.

[0197] In some embodiments, the time during a second energy application step is up to 15 minutes, preferably up to 5 minutes, and more preferably less than 3 minutes, such as 3 seconds to 120 seconds or 15 seconds to 300 seconds.

[0198] In some embodiments, the (temperature) holding time during which the (pre-) material layer is in contact with the transfer platform surface or a detachable surface element and simultaneously with the construction platform surface or with object parts of an object already located on the construction platform surface or at least is not more than 0.5 mm away from it, is up to 5 minutes, preferably up to 2 minutes and particularly preferably up to 30 seconds, such as 0.1 seconds to 5 seconds or 1 second to 20 seconds.

[0199] In some embodiments, the cooling time during which the (pre-)material layer is in contact with the transfer platform surface or a detachable surface element and simultaneously with the build platform surface or with object parts of an object already located on the build platform surface, or at least is at a distance of no more than 0.5 mm from each other, is up to 10 minutes, preferably up to 5 minutes, and particularly preferably up to 3 minutes, such as 5 seconds to 120 seconds or 30 seconds to 180 seconds. A cooling phase with a cooling time is started or initiated after either the energy application device remains switched off (for at least 10 seconds) and / or when the temperature falls below the uppermost target temperature of a second energy application step by more than the target-actual deviation defined within the temperature control.

[0200] In some embodiments, a transfer platform, a transfer platform surface, a build platform, and / or a build platform surface is manufactured at least in part from ceramics such as silicon carbide or from ceramics that contain at least silicon carbide, in order to be able to directly absorb the radiation or energy of microwaves or a device for generating microwave radiation, at least in large quantities, and to heat up quickly in this way. Such ceramics are preferably designed to be rather thin, for example between 0.2 mm and 2 mm or between 0.5 mm and 5 mm, in order to form little thermal mass, to heat up quickly to very quickly in this way, and later (if necessary) to cool down quickly again. Such thinner versions of these microwave-absorbing ceramics are preferably formed in thin plates, which preferably rest on or are supported on thicker carrier plates or support plates.enter into a material bond with them or are otherwise firmly and / or permanently connected to one another. In some embodiments, microwave-absorbing ceramics can preferably be designed as plates or disks with material thicknesses of, for example, 1 mm to 4 mm, with or without special surface geometries, and can thus be used as detachable surface elements, for example lying on a (solid) transfer and / or build platform made of a ceramic such as aluminum oxide or aluminum nitride. In some embodiments, microwave-absorbing ceramics are preferably applied as a surface coating, for example pyrolytically, at least part of a transfer platform surface and / or build platform surface and / or are applied at least to parts or within regions of a detachable surface element.

[0201] Preferably, instead of the treatment layer and the material layer, a layer can be applied by an extrusion process using an extruder as the application unit.

[0202] Further details, advantages, and features of the present invention will become apparent from the following description of exemplary embodiments with reference to the drawings. It shows:

[0203] Fig. 1 is a schematic illustration of a manufacturing device according to an embodiment of the invention,

[0204] Fig. 2 is a detailed view of a discharge unit of the production device according to an embodiment of the invention,

[0205] Fig. 3 is a schematic detailed view of the manufacturing device according to a

[0206] Embodiment of the invention,

[0207] Fig. 4 is a schematic flow diagram of a method according to a

[0208] Embodiment of the invention,

[0209] Fig. 5 is a schematic detailed view of a sequence of method steps of the method according to an embodiment of the invention,

[0210] Fig. 6 is a schematic detailed view of an embodiment of the manufacturing device according to an embodiment of the invention,

[0211] Fig. 7 is a schematic detailed view of a sequence of a method step of the method according to an embodiment of the invention,

[0212] Fig. 8 is a schematic detailed view of an embodiment of the manufacturing device according to an embodiment of the invention,

[0213] Fig. 9 is a schematic detailed view of an embodiment of the manufacturing device according to an embodiment of the invention,

[0214] Fig. 10 is a schematic detailed view of an embodiment of the manufacturing device according to an embodiment of the invention, Fig. 11, 12 are schematic detailed views of an embodiment of the manufacturing device according to an embodiment of the invention,

[0215] Fig. 13 is a schematic detailed view of an embodiment of the manufacturing device according to an embodiment of the invention,

[0216] Fig. 14 is a schematic detailed view of an embodiment of the manufacturing device according to an embodiment of the invention, and

[0217] Fig. 15 is a schematic diagram of a manufacturing device according to an embodiment of the invention.

[0218] Figure 1 schematically shows a manufacturing device 1 for the layer-by-layer production of an object 7. In the illustrated embodiment, four identical objects 7 are manufactured simultaneously. For this purpose, a build platform 4 with a build platform surface 4A and six transfer platforms 2, each with a transfer platform surface 2A, are provided. Each transfer platform 2 is assigned a dispensing unit 3. Thus, several layers 8 of the objects 7 can be manufactured essentially simultaneously (in parallel) (the production of the layers 8 is explained below). “Essentially simultaneously (in parallel) production” means that the production of the several layers 8 using the transfer platforms 2 and the dispensing units 3 assigned to them at least partially overlaps in time, preferably largely or completely overlaps in time. This achieves parallelization in production.As soon as the individual layers 8 are completed, these layers 8 are transferred to the build platform 4. On the build platform surface 4A, the layers 8 are thus assembled layer by layer to form the objects 7.

[0219] In this example, the production device 1 has two application units 3A, 3B for each transfer platform 2 (see Figure 2). These application units 3A, 3B are each, in particular, a printing unit 3A and a recoater 3B, which together apply the layers 8 using the so-called binder jetting process.

[0220] These application units 3A, 3B are shown in more detail in Figure 2. In the following explanation, the application units 3A, 3B are collectively referred to as an application unit 3, which comprises the printing unit 3A and the recoater 3B.

[0221] The application unit 3 has a printing unit 3A. The printing unit 3A is, for example, a piezo print head. The printing unit 3A is particularly configured to apply a treatment layer (explained below with reference to Figure 5) to the transfer platform 2. The treatment layer consists, for example, of a solvent. Furthermore, the application unit 3 has the recoater 3B. The recoater 3B contains rotatable rollers 27 and is configured to apply a granulate and / or powdered material to the transfer platform 2 and form a material layer. According to the binder jetting method (explained in detail below), the layers 8 are formed by combining and bonding the treatment layer with the material layer.

[0222] In Figures 1 and 2, the printing units 3A and the recoaters 3B are shown as one-piece pairs. However, they can also be arranged in pairs spatially separated from each other. In this case, the printing unit 3A and the recoater 3B can, in particular, be movable independently of each other.

[0223] Each application unit 3 can have one or more printing units 3A and / or one or more recoaters 3B. Furthermore, the production device 1 can have several such application units 3 for each transfer platform 2.

[0224] With reference again to Figure 1, the transfer platforms 2 according to the embodiment shown here have mobility along the y-direction. Movement in another spatial direction is preferably not provided here. According to the embodiment shown here, the dispensing units 3, in particular the printing units 3A and the recoaters 3B, have mobility along the x-direction. Thus, a contour / layer 8 can be generated on the transfer platform surfaces 2A in the xy plane (the layer thickness in the z-direction is neglected here). This allows layers 8 of any design to be generated on the transfer platform surfaces 2A. In some applications, a layer 8 can have a recess. If several layers 8 have a corresponding recess, a cavity can be formed within the object 7 to be manufactured by serially transferring these layers 8 to the build platform 4.This also makes it possible to create completely closed cavities without powder inclusions, as is the case with other state-of-the-art powder bed processes, such as selective laser melting (SLM).

[0225] Once the application of a layer 8 is complete, the transfer platform 2 remains in a reference position, i.e., in a predefined position for transferring the layer 8 to the build platform 4. In particular, all transfer platforms 2 can remain in the same reference position in the y-direction after each application of a layer 8. According to the exemplary embodiment shown here, the build platform 4 preferably has mobility in all three spatial directions, i.e., in the x-direction, the y-direction, and the z-direction. This also means that the build platform 4 can be moved in the opposite direction to the respective spatial directions, i.e., in the x-direction, the y-direction, and the z-direction. Thus, the build platform 4 can be placed above the transfer platforms 2 in order to subsequently apply a pressing force in the z-direction to the transfer platforms 2. At the same time, the transfer platforms 2 are heated to a greater degree than the build platform 4.Thus, the layers 8 are transferred from the transfer platforms 2. The layers 8 are applied either to the build platform surface 4A itself or to object parts 9 of the objects 7 already present on the build platform surface 4A. The object parts 9 are previously manufactured layers that have already been transferred to the build platform 4 and connected to one another in the z-direction.

[0226] This is shown in more detail in the detailed view in Figure 3.

[0227] Due to the possibility of pressing the individually produced layers 8, optimal strength of the objects 7 is achieved in the layer thickness direction, i.e., in the z-direction. In particular, notch effects are also avoided or reduced. Thus, in addition to faster production due to parallelization, manufacturing quality is also increased.

[0228] The manufacturing device 1 preferably has a machining unit 11, in the embodiment shown in Figure 3 in the form of a milling tool. The machining unit 11 enables machining of the object parts 9, especially before the objects 7 are completed. This allows, in particular, those areas to be machined that are difficult or impossible to access after the respective object 7 has been completed. For machining, the build platform 4 must be moved to the machining unit 11, wherein the machining unit 11 is preferably arranged stationary. Alternatively or additionally, the machining unit 11 can be movably mounted.

[0229] In order to efficiently manufacture the objects 7, the adhesion of the layers 8 to the transfer platform surfaces 2A is lower than to the build platform surface 4A or to the object parts 9 already present on the build platform surface 4A. This is achieved in particular by a suitable selection of materials for the transfer platform surfaces 2 and the build platform surface 4A or by appropriate coatings. The respective surface properties can also be different. Particularly advantageously, the transfer platforms 2 have surface structures to enlarge the transfer platform surfaces 2A. These surface structures can be, for example, fine webs or pyramids, with the surface structures becoming apparent on the side of the layers 8 facing away from them.As a result, the layers 8 are applied with a correspondingly enlarged surface area to the layers 8 immediately previously transferred to the build platform 4 upon transfer to the build platform 4, thereby increasing the adhesion of the layers 8 to one another, i.e., the adhesion of the newly produced layers 8 to the already existing object parts 9. At the moment of transfer of the produced layers 8, appropriate temperature management can also be carried out. This temperature management can be carried out in particular in addition to the heating steps (energy application steps) explained below for producing the layers 8. Thus, by appropriately heating the transfer platforms 2 and / or the build platform 4, an optimal, material-dependent temperature gradient can be set for the transfer.Likewise, targeted temperature control can be achieved by additionally introducing heat energy, for example, by means of ultrasound and / or thermal radiation (e.g., infrared radiation) and / or microwave radiation. Cooling can also be carried out in a targeted manner, for example, by means of compressed air, to achieve optimal transfer of the layers 8. Particularly advantageously, the temperature of the layers 8 during transfer corresponds at least to the plasticizing temperature or the melting temperature of the material of the layers 8.

[0230] In the following, the method for layer-by-layer production of objects 7, including the production of the layers 8 by means of the binder jetting method, is explained.

[0231] Figure 4 schematically shows an overview of a manufacturing process that can preferably be carried out with the previously described manufacturing device 1. The process is initially divided into two steps, wherein in a first step, at least one layer 8 is produced 100 on the transfer platform 2, and in a second step, the layer(s) 8 are transferred 200 to the build platform 4.

[0232] The step of producing 100 a layer 8 can preferably be carried out in parallel, ie this step is carried out multiple times and essentially simultaneously on different transfer platforms 2.

[0233] Figure 5 shows detailed views of steps 110 - 130 of manufacturing 100 of layer 8.

[0234] First, at least one treatment layer 8A is applied 110 to the transfer platform 2 by means of the application unit 3, in particular by means of the printing unit 3A of the application unit 3. The treatment layer 8A, which comprises, for example, a solvent, is applied to the transfer platform 2, in particular to the transfer platform surface 2A, according to a predeterminable pattern. The pattern according to which the treatment layer 8A is applied to the transfer platform surface 2A essentially corresponds to the shape of the layer 8 to be produced, which is transferred to the construction platform 4 for the production of the object 7 (step 200).

[0235] Subsequently, at least one material layer 8B is applied 120 to the transfer platform surface 2A or to the transfer platform surface 2A and to the treatment layer 8A. The material layer 8B is formed from a granulate or powdered material. In particular, the material layer 8B is applied to the entire transfer platform surface 2A. In this case, the material layer 8B comes into contact with the treatment layer 8A at least in sections, whereby the material layer 8B is bonded to the transfer platform surface 2A at the locations where the treatment layer 8A is present on the transfer platform surface 2A.

[0236] The layer resulting from the combination of the treatment layer 8A with the material layer 8B is also referred to as the “pre-material layer”.

[0237] The order of application 110 of treatment layer 8A and application 120 of material layer 8B can be reversed. In other words, material layer 8B can be applied first, followed by treatment layer 8A. Preferably, treatment layer 8A is also applied to transfer platform 2 according to the predeterminable pattern of layer 8 to be produced.

[0238] After the application steps 110, 120, a cleaning step 130 follows, in which the excess material of the material layer 8B is removed from the transfer platform 2. For this purpose, the manufacturing device 1 has, for example, a rotating device 21, which rotates the transfer platform 2 to remove the excess material of the material layer 8B. As shown in Figure 5, the transfer platform 2 is rotated about an axis Y, which runs parallel to the y-direction (also referred to as the "second direction").

[0239] Alternatively, the transfer platform 2 can also be rotated along an axis parallel to the x-direction or the z-direction in order to remove the excess material of the material layer 8B from the transfer platform 2. During the possible rotation about the axis parallel to the z-direction, a centrifugal force resulting from this rotation causes the excess material of the material layer to be removed from the transfer platform 2. However, a rotational speed of the transfer platform 2 is selected such that the predetermined pattern of the pre-material layer is maintained. In this case, it is particularly possible for the rotating device 21 to rotate the transfer platform 2 about an axis which lies in a plane spanned by the x-direction and / or the y-direction and / or the z-direction.

[0240] The transfer platform 2 is preferably rotated 180° around the Y axis, so that the transfer platform 2, as shown in Figure 5, is oriented upside down after rotation, so that the transfer platform surface 2A points in the -z direction. After the excess material of the material layer 8B has fallen from the transfer platform surface 2A due to gravity, the transfer platform 2 is either rotated again by -180° or rotated by a further 180° (a total of 360°) to return to the initial position (before rotation).

[0241] In an alternative embodiment of the manufacturing device 1, the dispensing unit 3 can be arranged along the z-direction below the transfer platform 2. The transfer platform surface 2A points in the -z-direction. In this embodiment, the cleaning step 130 can be at least partially, in particular completely, omitted, since the excess material of the material layer 8B, which is not bonded to the treatment layer 8A, falls downwards due to gravity and does not remain on the transfer platform surface 2A.

[0242] The rotating device 21 can then rotate the transfer platform 2 by 180° so that a transfer 200 of the produced layer(s) 8 to the construction platform 4 can take place.

[0243] In a further exemplary embodiment of the manufacturing method or the manufacturing device 1, the cleaning step 130, as shown in Figure 6, can be carried out by means of a cleaning device 23.

[0244] Here, the cleaning device 23 is configured to suck in and / or blow off a fluid 24, in particular air and / or inert gas. The cleaning device 23 is mounted, for example, on a frame 22 of the production device 1 shown in Figure 1, in particular movably mounted. An outlet or inlet nozzle of the cleaning device 23 and / or the entire cleaning device 23 is preferably movably mounted. In a further embodiment, the cleaning device 23 is mounted, in particular, on the discharge unit 3 in order to be movable therewith.

[0245] The cleaning step 130 by means of the rotating device 21 can be combined with the cleaning step 130 by means of the cleaning device 23, in particular carried out simultaneously or sequentially.

[0246] Referring again to Figure 4, after the application steps 110, 120, a first energy application step 140 is performed. This can generally be performed before or after the cleaning step 130. In this embodiment, the precursor layer is heated by the energy application step 140. This energy application step is referred to below as the "first heating step 140."

[0247] In the first heating step 140, the precursor material layer, consisting of the treatment layer 8A and the material layer 8B, is heated to a temperature close to the evaporation temperature of the treatment agent of the treatment layer 8A. Here, "close to the evaporation temperature" means a temperature range of approximately 20% around the evaporation temperature (i.e., above or below the evaporation temperature) of the treatment agent of the treatment layer 8A.

[0248] In one example, the treatment layer 8A comprises deionized or demineralized water (DI water) as the treatment agent. Thus, in the first heating step 140, the precursor layer is heated to approximately between 80°C and 120°C, in particular to 100°C.

[0249] Through this first heating step 140, the treatment layer 8A is largely removed from the pre-material layer, so that essentially only the material layer 8B remains on the transfer platform 2.

[0250] The first heating step 140 can also be started during the application steps 110, 120. In particular, the transfer platform 2 can be preheated before the application 110 of the treatment layer 8A, whereby the evaporation temperature of the treatment agent of the treatment layer 8A is only reached after the application 120 of the material layer 8B and either before or after the cleaning step 130.

[0251] If the production device 1 is arranged in a closed space and / or in a closed container, the air pressure in the space / container can be reduced by means of the cleaning device 23 by sucking in air in order to support or accelerate evaporation of the treatment layer 8A by means of the heating described above.

[0252] The manufacturing method further includes a second energy application step 150. The second energy application step 150 is performed after the first heating step 140. The second energy application step 150 is hereinafter referred to as the "second heating step 150."

[0253] During the second heating step 150, the remaining material layer 8B is heated to a temperature near or above the melting temperature of the material of the material layer 8B. Here, "near the melting temperature" means a temperature range of approximately 20% around the melting temperature (i.e., above or below the melting temperature) of the material of the material layer 8B.

[0254] If, for example, high-performance polymers such as PEEK, PEI, or PPSII are used as the material for the material layer 8B, the material layer 8B can be heated to a temperature of approximately 250° C to 350° C. If, alternatively or in addition to the aforementioned polymers, metals such as stainless steel are used as the material for the material layer 8B, the material layer 8B can be heated to a temperature of approximately 1,500° C or higher.

[0255] As can be seen from the dashed connecting lines in Figure 4, the manufacturing process comprises selective steps 310, 320, which can be performed before the transfer 200 of layer 8 to the build platform 4 according to an alternative embodiment of the manufacturing device or the manufacturing process. If these steps 310, 320 are not performed, the transfer 200 of the material layer 8B to the build platform 4 takes place after the second heating step 150.

[0256] The remaining material layer 8B, which was heated in the second heating step 150 and is preferably melted, is preferably cooled after the second heating step 150. If steps 310, 320 are not performed, the material layer 8B subsequently corresponds to layer 8, which is then transferred to the build platform 4.

[0257] In the following, the transfer 200 of layer 8 to the build platform 4 is first explained before the selective steps 310, 320 are explained.

[0258] The transfer step 200 has several substeps:

[0259] First, a relative approach 210 of transfer platform 2 and construction platform 4 takes place (see in particular Figures 1 and 3). Transfer platform 2 preferably remains stationary, while construction platform 4 is moved along the x-direction, y-direction, and z-direction.

[0260] Subsequently, the build platform 4 is pressed 220 onto the transfer platform 2 in the z-direction. This ensures a tight fit and optimal adhesion of the layer 8 to the object parts 9, as previously described.

[0261] Finally, layer 8 is removed 230 from transfer platform 2. Transfer platform 2 is then ready to receive another layer of pre-material, so that the application steps 110, 120 can be performed again. If multiple transfer platforms 2 are present, layers 8 are transferred from the individual transfer platforms 2 to build platform 4 in a predeterminable order.

[0262] During the transfer step 200, the build platform 4 and the transfer platform 2 can be arranged centered relative to one another, in particular—viewed in plan view—completely overlapping, wherein a positioning of the layers 8 on the object parts 9 is predetermined during the application steps 110, 120, in particular during the step 110 of applying the treatment layer 8A. Alternatively or additionally, the layers 8 can be produced centered on the transfer platform 2 during the application 110, 120, wherein the positioning of the layers 8 on the object parts 9 is achieved by a relative alignment of the build platform 4 and the transfer platform 2.

[0263] During the transfer step 200, the transfer platform(s) 2 and / or the build platform 4 can be heated in addition to the heating steps 140, 150 explained above in order to transfer the layers 8 to the build platform 4 with as little residue as possible. It is particularly advantageous if the build platform 4 or the object parts 9 of the object 7 already present on the build platform surface 4A is / are heated to a temperature close to, in particular below, the melting temperature of the material of the material layer 8B. For example, the temperature reached during this heating can be approximately 5%, preferably 10%, more preferably 15% below the melting temperature of the material of the material layer 8B.

[0264] Although the transfer 200 of layer 8, which results from the pre-material layer after the second heating step 150, was described above, the transfer 200 can also be carried out before the first heating step 140 and / or before the second heating step 150. In such a case, after the transfer 200, the first heating step 140 and / or the second heating step 150 are carried out on the pre-material layer that has just been transferred to the building board 4 and / or the object parts 9.

[0265] The steps of producing 100 and transferring 200 the layer(s) 8 explained above can be repeated as often as desired until the object 7 is completed.

[0266] Figure 7 shows a schematic detailed view of an embodiment of the manufacturing device 1 according to an embodiment of the invention. Figure 7 shows, in particular, a schematic representation of two transfer platforms 2 of the manufacturing device 1.

[0267] Here, for example, three first layers 8, in particular pre-material layers, are produced on top of one another on a first transfer platform 2 (left), while on the second transfer platform 2 (right) a second layer 8 is produced whose layer thickness / height in the z-direction essentially corresponds to the total height (in the z-direction) of the three first layers. The stacked layers 8 shown on the left in Figure 7 can be pre-material layers which at least partially (still) comprise the treatment layer, or can comprise only the material layer. For this purpose, the dispensing unit 3 is movable along the z-direction. Alternatively or additionally, the transfer platform 2 can also be movable along the z-direction. In this way, one or more levels of the object parts 9 can also be formed from a combination of individual or multiple layers 8 from multiple transfer platforms 2 after the layers 8 have been transferred to the build platform 4.

[0268] The height or total height of these different layers 8 does not have to be the same. Instead, they can also be deliberately formed in or with different heights, which can increase the strength of the object 7 in the z-direction, in particular, at predetermined locations.

[0269] As explained above, different materials of the layers 8 can also be combined to achieve a multi-material arrangement within a plane of the finished object 7, which is formed from different layers 8 of several transfer platforms 2. Specifically, the first three layers 8 (Figure 7, left) can advantageously be formed from different materials and the second layer 8 (Figure 7, right) from a single material.

[0270] During the production 100 of multiple layers 8, as shown in Figure 7, steps 110-150 are preferably performed for each layer 8 before a further layer 8 is produced. During the second heating step 150, the layers 8 can be fused together.

[0271] For adjusting or moving the dispensing unit 3 and / or the transfer platform 2, the production device 1 can have a solid-state joint and / or a short-stroke cylinder and / or a motor, in particular a model-making servo motor. These can particularly preferably move and position the dispensing unit 3 and / or the transfer platform 2 between predetermined end stops.

[0272] With reference to Figures 4 and 8, the selective steps 310, 320, which are collectively referred to as fiber reinforcement 300, will now be explained.

[0273] Figure 8 shows a schematic detailed view of an embodiment of the manufacturing device 1 according to an embodiment of the invention.

[0274] The production device 1 has at least one fiber application device 25. The production device 1 can have a fiber application device 25 for each transfer platform 2 and, in particular, an additional fiber application device 25 for the build platform 4. In the example shown in Figure 1, the production device 1 would thus have seven fiber application devices 25 (six for the six transfer platforms 2 and one for the build platform 4). Similar to the recoater 3B, the fiber application device 25 has rotatable rollers 27, by means of which the fiber application device 25 can apply fibers 26 to the transfer platform 2, in particular to layer 8, in a fiber application step 310.

[0275] The fibers 26 are preferably carbon fibers. The fibers 26 preferably have a length of up to a few millimeters (so-called "short fibers"). Alternatively, the short fibers can preferably have a length of less than 1 mm. Fibers of different lengths can also be combined.

[0276] By means of the rotating rollers 27, the fibers 26 are accelerated in the direction (-z direction) of the transfer platform 2. Due to their air resistance, the fibers 26 can largely align themselves such that they strike layer 8 at a steep angle (between 45° and 90° relative to layer 8 or the x direction). The fibers 26, which strike layer 8 at a steep angle, penetrate layer 8. They can penetrate layer 8 completely or only partially.

[0277] The fibers 26 that do not impinge on layer 8 at a steep angle, i.e., at a shallow angle between 0° and 45° relative to layer 8, penetrate little to not at all into layer 8. They largely remain on the surface of layer 8. These fibers 26 can then be removed from layer 8, for example, by means of the cleaning device 23 or by rotation by the rotating device 21. Alternatively or additionally, these fibers 26 can be detached from the surface of layer 8 using ultrasound.

[0278] Alternatively or in addition to the rotating rollers 27, the fibers 26 can be accelerated by means of a material stream, for example, a gas stream of air and / or inert gas (not shown). By using such a material stream, the orientation of the fibers 26 can advantageously be influenced, particularly on average, to a steep angle of approximately 90°.

[0279] The fiber application device 25 can also apply fibers 26 to the object parts 9 on the build platform 4. When the object parts 9 are connected to the layer 8, which has also been applied with fibers 26, the fibers 26 of the object parts 9 can penetrate into the layer 8 and vice versa. For this purpose, the object parts 9 and / or the layer 8 can advantageously be heated and / or exposed to solvent and / or excited by ultrasound in order to reduce the surface tension of the object parts 9 and / or the layer 8. In a further, third energy application step 320, the pre-material layer, consisting of the treatment layer 8A and the material layer 8B, or only the material layer 8B (after the first heating step 140), is heated before and / or during the application 310. The third energy application step 320 is hereinafter referred to as “third heating step 320”.

[0280] The third heating step 320 reduces the surface tension of the material layer 8B so that the fibers 26 can penetrate deeper into it.

[0281] After the third heating step 320, the material layer 8B is cooled (not shown).

[0282] Alternatively or in addition to the third heating step 320, the surface tension of the material layer 8B can be reduced by means of a solvent, which is applied, for example, by means of the cleaning device 23 and / or the printing unit 3A.

[0283] The fiber reinforcement 300 described above is performed in particular after the cleaning step 130. Preferably, the fiber reinforcement is performed after the first heating step 140 and during the second heating step 150. Alternatively or additionally, the fiber reinforcement 300 can be performed after the second heating step 150, wherein, in particular, in the third heating step 320, the temperature of the material layer 8B is kept close to the melting temperature of the material of the material layer 8B so that the fibers 26 can penetrate into it.

[0284] If the selective steps 310, 320 of fiber reinforcement 300 are performed, the resulting fiber-reinforced material layer 8B is referred to as the layer 8 to be transferred. After fiber reinforcement 300, the previously described transfer 200 of the (fiber-reinforced) layer 8 to the build platform 4, in particular to the object parts 9, then takes place.

[0285] If the selective steps 310, 320 of fiber reinforcement 300 are performed, the dispensing units 3 can, in particular, be extruders that do not produce the layer(s) 8 using the binder jetting process. The extruders can dispense the same material, or different materials can be provided, so that different materials can be applied to different transfer platforms 2. These extruders operate particularly advantageously using the FFF process.

[0286] Figure 9 shows a further embodiment of the production device 1 according to an embodiment of the present invention. Here, each transfer platform 2 is formed by a holding plate 6 and a film element 5. The film element 5, in turn, forms the transfer platform surface 2A. Thus, the layer 8 is applied to the film element 5 by means of the application unit 3 (and is therefore not in direct contact with the holding plate 6). The film element 5 rests against the holding plate 6, so that the transfer platform surface 2A acts like a plate surface (not shown in Figure 9). The holding plate 6 can be heatable. In order to enable the film element 5 to lie tightly against the holding plate 6, a tensioning device (not shown) is preferably provided for the film element 5.Additionally or alternatively, it is also conceivable that the space enclosed by the film element 6 and the retaining plate 5 can be subjected to a negative pressure in order to enable the film element 5 to fit tightly against the retaining plate 6. The film element 5 can be elastic.

[0287] After the layer 8 has been produced on the film element 5 as explained above, the layer 8 is transferred to the construction platform 4, in Figure 9, for example, to an already manufactured object part 9. To detach the layer 8 from the film element 5, the film element 5 is lifted off the holding plate 6 in certain areas, so that the layer 8 is peeled off from its edges. This lifting of the film element 5 can be accomplished, for example, by a controllable supply of a fluid working medium into the space enclosed by the film element 6 and the holding plate 5. The detachment process can be carried out by flowing compressed air 10 to one of the said edges of the layer

[0288] 8, whereby the compressed air 10 additionally provides a cooling effect.

[0289] By using the foil element 5, a simple and reliable transfer of the layer 8 can be carried out, whereby damage to the layer 8 or the object part

[0290] 9 is avoided. The film element 5 is preferably made of polyimide.

[0291] Figure 10 shows a schematic detailed view of a further embodiment of the manufacturing device 1 according to an embodiment of the invention.

[0292] Here, the manufacturing device 1 has at least one vibration generating device 12. The vibration generating device 12 can comprise an ultrasonic probe, a sound wave generator, and / or a mechanical vibration generator such as an eccentric imbalance. In particular, the manufacturing device 1 has a vibration generating device 12 for each transfer platform 2. Alternatively, a single vibration generating device 12 can be arranged in the manufacturing device 1 such that, in the operating state, it applies vibrations to all transfer platforms 2 and / or the construction platform 4.

[0293] By means of the vibration generation device 12, vibrations can be introduced into the production device 1 (here in particular into the transfer platform 2) in order to increase the layer strengths, for example, during the transfer of the layers 8 from the transfer platform 2 to the build platform 4 by a targeted introduction of energy, in particular thermal energy and / or kinetic energy, at the contact surfaces. Kinetic energy can support the bonding of polymer chains in or between the layers 8.

[0294] The vibration generating device 12 can also be used to remove the excess material of the material layer 8B during the cleaning step 130 or to assist in the removal of the excess material, for example by the rotating device 21 and / or by the cleaning device 23.

[0295] The manufacturing device 1 can have at least one further vibration generating device 12 for the construction platform 4.

[0296] Figures 11 and 12 show schematic detailed views of a further embodiment of the manufacturing device 1 according to an embodiment of the invention. Figures 11 and 12 show, in particular, a preferred embodiment of the transfer platform 2 of the manufacturing device 1. Figure 11 shows a basic state of the transfer platform 2, and Figure 12 shows a curved state of the transfer platform 2, as explained below.

[0297] Here, the transfer platform 2 has a transfer plate 15, wherein the layers 8 are produced on the transfer plate 15 as explained above. The transfer platform 2 also has an active actuator 17, which can specifically curve the transfer plate 15. The transfer platform 2 also has spacers 13, which optimize the height of the transfer plate 15 during pressing.

[0298] Such a spacer 13 can in particular be formed from a hard or elastic material.

[0299] In addition, the transfer platform 2 has adjusting screws 16, which serve as counterbearings for the curvature. Depending on the arrangement of the adjusting screws 16, the transfer plate 15 is curved evenly or almost evenly in the x-direction and y-direction. If the adjusting screws 16 are arranged differently and / or the transfer plate 15 is stiffened on two opposite sides, for example by a strut (not shown), the transfer plate 15 can be specifically bent at least predominantly in one direction only. The adjusting screws 16 can also be used to adjust the parallelism of the transfer plate 15 to the plane of the dispensing unit 3. The adjusting screws 16 can, in particular, be electrically driven.

[0300] The actuator 17 is preferably moved by an electromagnet 18, as shown in Figures 11 and 12. Alternatively, the actuator 17 can also be a pneumatic cylinder. The actuator 17 is connected to a plunger 14, which transfers forces generated by the electromagnet 18 to the transfer plate 15.

[0301] The transfer plate 15 is preferably designed as a CFRP plate (carbon fiber reinforced plastic) or GFRP plate (glass fiber reinforced plastic).

[0302] Such active curvature of the transfer plate 15 can be used during the transfer of layer 8 from the transfer platform 2 to the build platform 4. This can occur particularly at the moment the actual pressing process begins. This allows force to be transmitted over a certain distance, which is defined by a curvature radius. In this way, the surface forces or the effective pressure can be increased without having to significantly increase the total force, since initially only areas near a curvature center are applied.

[0303] It is further advantageous that any air or protective gases present can escape more easily to the outside, especially in the area of ​​the center of the curvature, especially in the case of relatively large-area structures or layers 8.

[0304] Preferably, the electromagnet 18 can be switched in a pulsed manner, whereby dynamic oscillations can be generated by pulsating curvatures in the transfer plate 15.

[0305] Furthermore, the curvature allows the layers 8 to be more easily detached from the transfer plate 15, particularly after the aforementioned cooling after the second or third heating step 150, 320, and transferred to the build platform 4. In particular, this can reduce the tensile forces acting on the layers 8 during detachment.

[0306] This advantageous embodiment can be combined in particular with the film element 5 explained above.

[0307] Figure 13 shows a schematic detailed view of a further embodiment of the manufacturing device 1 according to an exemplary embodiment of the invention. The manufacturing device 1 comprises a heating device 19, preferably a heat radiator 19, particularly preferably an infrared light source 19, which applies heat / heat radiation 20 to the object parts 9. The heating device 19 can thus, as shown in Figure 13, temporarily and quickly heat, in particular, the layers 8 of the object parts 9 that were last transferred to the build platform 4, so that more heat energy is available for bonding the layer 8 currently to be transferred to the object part 9 during the transfer 200. The heating device 19 can also be used, in particular, for the heating steps 140, 150, and / or 320 explained above.

[0308] Alternatively or in addition to the heat radiator 19, the layers 8 can also be heated inductively by means of an electric field which is generated by a generator (not shown) as a heating device 19.

[0309] Figure 14 shows a schematic detailed view of a further embodiment of the manufacturing device 1 according to an exemplary embodiment of the invention. In particular, a detailed view of the machining unit 11 is shown.

[0310] As explained above, the machining unit 11 is designed in particular as a milling tool 11. The machining unit 11 can machine the object parts 9 after each transfer of a layer 8 and / or after the transfer of multiple layers 8 in order to achieve greater dimensional accuracy and a better surface quality. A lower flat surface of the object parts 9 can also be machined in this way, so that optimal flatness of the object parts 9 or the finished object 7 can be achieved.

[0311] This prevents, in particular, the occurrence of flatness errors in the transferred layers 8, which could otherwise accumulate or propagate in the object parts 9. This can improve the quality of the object 7.

[0312] The machining unit 11 can in particular machine fibers 26 protruding from the object parts 9.

[0313] Furthermore, the manufacturing device 1 can have a system for monitoring flatness (not shown). For this purpose, the manufacturing device 1 can have a tactile or non-contact system, such as a laser measuring system or other optical systems.

[0314] Based on such measurements, which can also monitor the entire construction height of the object part 9, it is also advantageously possible to actively control the amount of material used in the printing process on the transfer platforms 2. Furthermore, it is possible to control the alignment of the transfer platforms 2 via the adjusting screws 16, which are in particular electrically driven, so that the layer height can be varied slightly locally, thereby reacting to possible warping and thus allowing the component to continue to be built planar. This control can regulate the material flow, in particular the amount of material that the application units 3 transfer to the transfer platforms 2, based on the detected flatness and / or height of the object part 9. For this purpose, the production device 1 can have a control unit or a regulating unit, in particular in the form of a CPU (not shown).In particular, this can carry out or control / regulate the method steps explained above for manufacturing an object by means of the manufacturing device 1.

[0315] The above-described configurations of the manufacturing device 1 can be suitably combined with one another. As one example of several possible configurations, the manufacturing device 1 can comprise the machining unit 11 and the heating device 19.

[0316] Fig. 15 shows a schematic illustration of a manufacturing device 1 according to an embodiment of the invention.

[0317] In the present embodiment, the manufacturing device 1 has two transfer platforms 2 and a construction platform 4.

[0318] The production device 1 has printing units 3A designed as piezo print heads. Furthermore, the production device 1 has storage containers 28 for the material of the material layer. Openings and rollers are arranged at a lower end (in the Z direction) of the storage containers 28, which together function as a recoater 3B for applying the material and forming the material layer.

[0319] Furthermore, the production device 1 has two cleaning devices 23.

[0320] In the present embodiment, the cleaning devices 23 are configured to suck up excess material. The cleaning devices 23 are each connected to one of the storage containers 28 and return the sucked-up material, which is not connected to the treatment layer and is therefore excess, back to the storage container 28.

[0321] In the manufacturing apparatus 1 according to the present embodiment, a storage container 28, together with a recoater 3B, a printing unit 3A, and a cleaning device 23 are formed as a single module that is movable along the X direction. The printing unit 3A is also movable along the Y direction.

[0322] Fig. 15 shows a point in time immediately before the transfer of the pre-material layer 8. The pre-material layer 8 was previously applied and cleaned (removal of excess material) by the right-hand module in the X-direction. The right-hand module was then moved to the right edge so that the build platform 4 with the previously produced object parts 9 could be moved over the right-hand transfer platform 2. In a next step, the pre-material layer 8 is transferred to the object parts 9 by moving the build platform 4 in the Z-direction. Afterward or during this time, the left-hand module produces the next pre-material layer 8. In this way, several pre-material layers 8 can be produced as seamlessly as possible on the transfer platforms 2 and transferred one after the other to the build platform or the object parts 9.

[0323] In addition to the above written description of the invention, reference is hereby explicitly made to the graphic representation of the invention in Figures 1 to 15 for its supplementary disclosure.

[0324] List of reference symbols

[0325] 1 manufacturing device

[0326] 2 transfer platform

[0327] 2A transfer platform surface

[0328] 3 Application unit

[0329] 3A printing unit

[0330] 3B Recoater

[0331] 4 Construction platform

[0332] 4A Build platform surface

[0333] 5 slide element

[0334] 6 Holding plate

[0335] 7 Object

[0336] 8 layer

[0337] 8A treatment layer

[0338] 8B material layer

[0339] 9 object parts

[0340] 10 Compressed air

[0341] 11 Machining unit

[0342] 12 Vibration generator

[0343] 13 spacers

[0344] 14 tappets

[0345] 15 Transfer plate

[0346] 16 Adjusting screw

[0347] 17 Active actuator

[0348] 18 Electromagnet

[0349] 19 Heat source

[0350] 20 Heat

[0351] 21 Rotating device

[0352] 22 Frame of the manufacturing device

[0353] 23 Cleaning device

[0354] 24 Fluid

[0355] 25 Fiber application device

[0356] 26 fibers

[0357] 27 reels

[0358] 28 storage containers

[0359] 100 Creating a layer

[0360] 110 Application of the treatment layer 120 Application of the material layer

[0361] 130 cleaning steps

[0362] 140 first heating step

[0363] 150 second heating step 200 transfer of the layer

[0364] 210 Approach

[0365] 220 presses

[0366] 230 replacements

[0367] 300 Fiber reinforcement 310 Fiber loading

[0368] 320 third heating step

Claims

Claims 1. Manufacturing device (1) for manufacturing objects (7) layer by layer, comprising . at least one transfer platform (2) with a transfer platform surface (2A), . at least one application unit (3), configured for applying at least one treatment layer (8A) and at least one material layer (8B), in particular comprising granular and / or powdered material, which together form a pre-material layer of the object (7), onto the transfer platform surface (2A), wherein the pre-material layer extends in particular in a first direction (x) and in a second direction (y), and . a building platform (4), designed to take over at least the material layer (8B) of the pre-material layer from the transfer platform (2), so that the object (7) is produced layer by layer on the building platform (4) in particular in a third direction (z).

2. Manufacturing device (1) according to claim 1 , characterized in that the build platform (4) has a build platform surface (4A) and is designed to transfer at least the material layer (8B) of the pre-material layer from the transfer platform (2) onto the build platform surface (4A) or onto object parts (9) of the object (7) already present on the build platform surface (4A).

3. Manufacturing device (1) according to claim 2, characterized in that the build platform surface (4A) is aligned substantially parallel to the transfer platform surface (2A) during the transfer of at least the material layer (8B) of the pre-material layer from the transfer platform (2).

4. Manufacturing device (1) according to one of the preceding claims, comprising at least a rotary device (21) which is configured to rotate the at least one transfer platform (2), in particular about an axis substantially parallel to the first direction (x) and / or about an axis (Y) substantially parallel to the second direction (y) and / or about an axis substantially parallel to the third direction (z).

5. Manufacturing device (1) according to one of the preceding claims, comprising at least one cleaning device (23) which is configured to remove excess material of the material layer (8B) from the at least one transfer platform (2) and / or the build platform (4) by suction and / or blowing off a fluid (24).

6. Manufacturing device (1) according to one of the preceding claims, comprising at least one vibration generation device (12) which is configured to generate sound and / or to remove excess material of the material layer (8B) from the at least one transfer platform (2) and / or the build platform (4) by means of vibrations. Manufacturing device (1) according to one of the preceding claims, comprising at least one fiber application device (25) which is configured to apply fibers (26) at least partially to the pre-material layer, in particular the material layer (8B) of the pre-material layer, on the transfer platform (2) and / or object parts (9) of the object (7) on the build platform (4). Manufacturing device (1) according to one of the preceding claims, characterized by a plurality of transfer platforms (2), wherein preferably each transfer platform (2) is assigned at least one separate application unit (3).Manufacturing device (1) according to one of the preceding claims, comprising at least one energy supply device (19) configured to supply energy to the treatment layer (8A) and / or the material layer (8B) and / or the object parts (9) of the object (7), wherein the energy supply device (19) is configured in particular to evaporate or vaporize the treatment layer (8A) and / or to plasticize the material layer (8B) and / or to melt the material layer (8B) of the pre-material layer of the object (7). Method for manufacturing objects (7) layer by layer, comprising the steps of: . Applying (110) at least one treatment layer (8A) to at least one transfer platform (2) by means of an application unit (3), wherein the treatment layer (8A) extends in particular in a first direction (x) and in a second direction (y), . Applying (120) at least one material layer (8B), in particular comprising granular and / or powdered material, to the transfer platform (2) before or after applying (110) the treatment layer (8A), wherein the treatment layer (8A) and the material layer (8B) form a pre-material layer of the object (7), . Transfer (200) at least the material layer (8B) of the pre-material layer from the transfer platform (2) to a build platform (4) in particular along a third direction (z), and . Repeating the steps of applying (110, 120) the at least one treatment layer (8A) and the at least one material layer (8B) and transferring (200), so that the object (7) is produced layer by layer on the building platform (4), in particular in the third direction (z).

11. Method according to claim 10, characterized by a cleaning step (130) after the application (110) of the treatment layer (8A) and after the application (120) of the material layer (8B), in which excess material of the material layer (8B) is removed from the transfer platform (2).

12. Method according to claim 10 or 11, characterized by a first energy application step (140) before and / or during and / or after the application (110) of the treatment layer (8A) and / or before and / or during and / or after the application (120) of the material layer (8B).

13. Method according to one of claims 10 to 12, characterized by a second energy application step (150), in particular after the first energy application step (140), in which the pre-material layer is heated to a temperature in particular less than or equal to or greater than the melting temperature or the melting range of the material of the material layer (8B).

14. Method according to one of claims 10 to 13, characterized by a fiber impregnation step (310), in particular after the cleaning step (130), in which the pre-material layer is at least partially impregnated with fibers (26).

15. Method according to claim 14, characterized by a third energy application step (320) before and / or during the fiber application step (310), in which energy is supplied to the pre-material layer on the transfer platform (2) and / or the object parts (9) of the object (7) on the build platform (4) before and / or during the application of fibers (26).

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