Method and device for additively manufacturing an object

Abstract

The invention relates to a method for additively manufacturing an object (10), comprising the steps of: supplying a strand-shaped starting material (11) to a friction assembly (2) and accelerating the starting material (11) in an output direction (100) through the friction assembly (2) in order to apply the starting material (11), in particular in layers, to a building platform (12) and / or to already-manufactured regions of the object (10) in order to manufacture the object (10), wherein the strand-shaped starting material (11) is at least partly liquefied and / or at least partly plasticised and / or at least partially broken down into particles by the friction assembly (2). The invention also relates to a manufacturing device (1) for additively manufacturing an object (10), comprising a friction assembly (2) to which a strand-shaped starting material (11) can be supplied, wherein the friction assembly (2) is designed to accelerate the starting material (11) in an output direction (100) in order to apply the starting material (11), in particular in layers, to a building platform (12) and / or to already-manufactured regions of the object (10) in order to manufacture the object (10), wherein the friction assembly (2) is designed to at least partly liquefy and / or at least partly plasticise the strand-shaped starting material (11) and / or to at least partly break the starting material down into particles.

Description

[0001] Method and device for additive manufacturing of an object

[0002] Description

[0003] The invention relates to a method for the additive manufacturing of an object. Furthermore, the invention relates to a manufacturing device for the additive manufacturing of an object. In additive manufacturing, the object is constructed layer by layer from a starting material. This is also referred to as 3D printing.

[0004] 3D printing applications are known from the state of the art. In particular, such techniques are also being tested in the production of concrete components. For example, concrete is applied layer by layer to a surface to create a desired structure. However, concrete components require reinforcement when subjected to bending loads, which must be incorporated into the concrete component. For the additive production of reinforcement, for example, the Wire Arc Additive Manufacturing (WAAM) process is known, in which the reinforcement is produced layer by layer using arc welding. According to the current state of the art, the reinforcement is produced layer by layer in advance, in several layers, before the concrete is applied layer by layer.

[0005] However, arc welding requires electrical contact, for example, to an electrical ground connection outside the component or to the already manufactured reinforcement as a ground connection. This represents an additional manufacturing step and thus increases the complexity and costs. Furthermore, during the welding process, a significant amount of heat is introduced into the reinforcement and thus into the concrete layers, which are usually not yet fully cured. This poses the risk of negatively affecting the concrete. Furthermore, the layer-by-layer application of the weld layers to create the reinforcement often leads to adverse material properties of the reinforcement.

[0006] WO 2020 / 193150 A1 discloses a method for producing a reinforced concrete component. For this method, concrete is extruded in the form of a strand, with a yarn impregnated with a mineral suspension being inserted into the concrete strand as reinforcement. CN 104 014 793 A discloses an extruder designed for 3D printing of metal.

[0007] It is an object of the invention to provide an additive manufacturing method and an additive manufacturing device which enable a reliable, in particular layer-by-layer, construction of an object without a significant impairment of already existing areas of the object.

[0008] This problem is solved by the features of the independent claims. The subclaims contain preferred developments of the invention.

[0009] When "bottom" and "top" are mentioned herein, this describes the spatial arrangements within the manufacturing device, the method, and / or the figures according to the invention. "Bottom" is closer to the Earth's center than "top." A "bottom" is closer to the Earth's center than a "top."

[0010] The Cartesian coordinate system is preferably used, with the x- and y-directions preferably extending within the plane of the build platform and the z-axis pointing vertically upwards. When reference is made to an angle α, this refers to a rotation around the z-axis, β to a rotation around the x-axis, and y to a rotation around the y-axis.

[0011] When "friction discs" are mentioned herein, this refers in particular to any type of machine element that has an at least largely rotationally symmetrical design. The "friction discs" are designed in particular to convert kinetic energy into frictional heat through friction against one another and / or against another body, such as, for example, against a supplied starting material for additive manufacturing. Preferably, one "friction disc" or at least two "friction discs" are designed to place supplied starting material into a state that enables acceleration of the material upon leaving the friction arrangement. One or at least two "friction discs" can be designed with any possible diameter and / or effective diameter. Friction discs can be cylindrical, conical, spherical and / or with other rotationally symmetrical geometries.

[0012] When "conical friction discs" are mentioned herein, this refers in particular to any type of at least largely rotationally symmetrical machine element which is not cylindrical in its geometry. "Conical friction discs" can be designed at any angle or angle combination and at any diameter which is appropriate for the method and device of the present invention. Angles of the friction surfaces between 0° and 90° in relation to the axis of rotation of the "conical friction discs" can be represented. "Conical friction discs" also include friction discs which have an at least partially convex or concave contour at least in the region of the friction surface. Alternatively or additionally, "conical friction discs" can also be referred to herein as "conically designed friction discs" or "friction discs with a conical design" or a similar wording and are to be understood accordingly.

[0013] A "friction surface" is to be understood herein in particular as that area of ​​a friction disc in which a deliberately induced frictional contact is accompanied by heat development or in which a significant interaction between a strand-like starting material and the friction disc takes place at least predominantly. A "friction surface" can be smooth or relatively smooth, such as a polished surface, or can have a deliberate roughness. A "friction surface" can have at least locally arranged surface structures that can promote frictional contact. Such surface structures can, for example, be designed as elevations, such as small pyramids. A "friction surface" can be a surface coating of a friction disc or an interchangeable element for application, in particular for segmented application, to a friction disc.

[0014] A “friction arrangement” has one, two or more rotatable / rotating friction disc(s) which come or are in contact with the strand-like starting material.

[0015] An “effective diameter” is the diameter or diameter range of at least one friction disc at which at least one friction surface is formed, i.e. at which the friction disc comes into frictional contact with the starting material.

[0016] The term "starting material" refers, in particular, to any material in a solid initial state that can be converted into a plastic and / or molten state and / or broken down into particles according to the invention through the application of friction energy. A starting material can be a metal, an alloy, a polymer, or a material compound, such as a combination of a polymer and fibers. A "starting material" can, in principle, consist of any material and any material combination that is suitable for being formed into a strand, at least within certain sections, and for use with at least one, two, or more friction discs.

[0017] A “strand-shaped starting material” is preferably round in cross-section with preferred diameters between 0.25 mm and 50 mm, or for example between 0.5 mm and 15 mm. In some embodiments, the strand-shaped starting material has an outer diameter between 1 mm and 10 mm, preferably between 1.5 mm and 8 mm and particularly preferably between 2 mm and 6 mm. The cross-section can also have other shapes such as an oval, a triangle, a square, a polygon or a star shape, wherein the circumference is preferably between 0.25 mm and 50 mm or for example between 0.5 mm and 15 mm. A “strand-shaped starting material” can also be designed as a tube, for example as a round tube or as a rectangular tube, i.e. it can have a recess / cutout that extends along the longitudinal direction of the “strand-shaped starting material”.A "stranded starting material" can range in length from a few centimeters to several kilometers, provided it can be stored on or in appropriate facilities or otherwise processed. A "stranded starting material" can be produced from any starting material or from a combination of starting materials using various processes. For example, it can be produced from two or more materials by coextrusion and / or it can be modified with nanoparticles. A "stranded starting material" can also have a coating.

[0018] The “build area” is at least one area within the manufacturing device in which heated or hot, accelerated particles are decelerated upon impact with a surface and preferably form a positive and / or material bond with the surface material.

[0019] A "process zone" is the area within a friction arrangement in which the strand-like starting material is in direct contact with at least one friction disc and / or is in the immediate or (near) vicinity of at least one friction disc and is heated and / or accelerated in the process. An immediate or (near) vicinity of a friction disc can include radial distances and / or material-free distances from the effective diameter of a few hundredths of a millimeter up to a few millimeters, for example, up to 4 mm or, in some embodiments, up to 8 mm. "Immediate" in this context can also be understood as minimal or very short spatial and / or temporal distances.

[0020] A “build platform” is, in particular, any type of subsurface and / or any type of surface suitable for receiving starting material according to the inventive embodiments mentioned herein. In certain embodiments, a “build platform” can be flat or nearly flat. In other embodiments, it can have an uneven surface design. In some embodiments, a “build platform” can have locally different properties and / or be made of different materials. A “build platform” can be formed from solid or predominantly solid material, as well as from soft and / or loose components, such as granular fill. A “build platform” can also comprise or be a liquid. In certain embodiments, a “build platform” can have a smooth or a rough surface. In certain embodiments, it can also be formed in different planes.In some embodiments, a “build platform” may have a coating and / or be subjected to a pretreatment.

[0021] An "object" is, in particular, 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. In particular, an "object" is preferably formed largely from a metal or a polymer material or contains at least larger portions of one of these.

[0022] A "component" is, in particular, any physical structure that can be manufactured at least in part using the method and / or the device according to the invention. A "component" is preferably a combination of concrete and at least one metal. In some embodiments, a "component" can be a combination of at least one metal and at least one polymer. For example, an object and / or a semi-finished product made of at least one metal can be further processed using the device and / or the method according to the invention with at least one polymer.In some embodiments, an object and / or a semi-finished product made of metal, such as a steel or a nickel-based alloy, can be processed by the device according to the invention and / or the method according to the invention with at least one further metal, such as by the application of a further metal such as copper or a copper alloy, e.g. for the production of heat exchangers or for rocket combustion chambers.

[0023] According to the invention, a "semi-finished product" can be any type of raw material that does not yet correspond to the final object and / or the final component, preferably not yet corresponding to the final geometry or shape. For example, mechanically worn components or machine elements can be processed according to the invention and are understood herein as "semi-finished products."

[0024] A "material jet" describes the material of a starting material and its state in a region between the friction surface or the process zone and the build platform or an object or semi-finished product. A "material jet" preferably consists of very fast, hot particles formed from the material of the starting material. These particles can have different shapes and sizes, ranging from a few micrometers to the millimeter range. In some embodiments, a "material jet" corresponds in its shape at least partially or predominantly to a continuous (closed) material complex, comparable to a water jet, rather than to isolated particles, which would be comparable to water droplets in this context.In other words, the fast and hot particles can be so dense or close to one another at corresponding, usually very high, feed speeds of the strand-like starting material that, when viewed optically, they have at least a partially closed shape or contour, preferably over the entire length of the "material jet", with the major difference to the strand-like starting material that the speed can be orders of magnitude faster, for example at least 50 times, or even at least 250 times as fast as the feed speed of the starting material.

[0025] A "discharge direction" describes the movement trajectory of a starting material, particularly in the area between the friction surface or friction arrangement and the build platform, or in the area between the friction surface and the object. The geometric configuration of a "discharge direction" can be at least approximately linear, or it can be more or less planar or three-dimensional. The projected material jet of a "discharge direction" can be at least predominantly a point or a circular area, or at least partially elliptical, or it can take on any other geometric shape. The projected material jet of a "discharge direction" can also have the cross-sectional shape of a tube. The projected material jet of a "discharge direction" can be more or less geometrically undefined, making it more comparable to the impact behavior of shotgun pellets.The movement trajectory of a "dispensing direction" can also exhibit a twist and thus at least partially correspond to a helix. The direction vectors of a "dispensing direction," starting from the friction surfaces, preferably intersect the surface of the build platform and / or parts of the object. A "dispensing direction" is oriented in particular toward the build platform and / or a semi-finished product to be processed and can preferably assume an angle of 0° to 90° relative to a perpendicular to the build platform or a semi-finished product.

[0026] "Concrete" refers, in particular, to material mixtures consisting of an aggregate (made from rocks such as sand, gravel, or aggregates made from other materials such as glass, clay, or wood), a binder such as cement, water, and possibly other additives. The binder is primarily inorganic and / or mineral, such as cement, geopolymer, or magnesia binder. Mortar or fine-grained concrete, which is technically usually defined as such by the choice of a maximum grain size of less than or equal to 4 mm, also falls under the term "concrete" according to the invention.

[0027] When reference is made herein to a “component made of concrete” or a similar term, this preferably refers to a component that can preferably be produced at least partially by additive manufacturing and comprises previously defined material mixtures corresponding to the term “concrete”. Additive manufacturing processes can include: concrete extrusion, additive application by concrete dispensing, other depositing or spraying processes and, in particular, selectively binding particle bed processes such as SCA or SPI. SCA stands for “Selective Cement Activation” and means that a binder is provided in a particle bed, with selective binding taking place through an activator such as water. In this way, a concrete layer of any shape can be produced. SPI stands for “Selective Paste Intrusion” and means that the particle bed is selectively bound with a liquid binder.In both cases, a particle bed is initially provided, with uncured areas of the particle bed being removed after curing.

[0028] “Reinforcement” or “armoring” refers in particular to the strengthening of components (e.g., components made of concrete) to increase their load-bearing capacity. Reinforcement can be used to specifically influence the load-bearing capacity of a component in an anisotropic manner. Reinforcement primarily absorbs tensile stresses within the component. Reinforcement can be made of metal, steel, plastic, glass, or carbon. Reinforcement can be rod-shaped, wire-shaped, fiber-shaped, mat-shaped, or textile / knitted. Rod-shaped or wire-shaped reinforcement can be straight, curved, or follow a direction of force. Rod-shaped or wire-shaped reinforcement can also include additional fibers.

[0029] 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, in any combination 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.

[0030] When reference is made herein to programmed or configured, these terms may be interchangeable in some embodiments.

[0031] Whenever reference is made here to a signal or communication connection between two components, this may be understood as a connection that is already in use. It may also be understood as preparation for such a signal connection (wired, wireless, or implemented in another way), for example, by coupling the two components, such as by pairing, etc.

[0032] Pairing is a process that occurs in the context of computer networks to establish an initial connection between computer units for the purpose of communication. The most common example of this is establishing a Bluetooth connection, which connects various devices (e.g., smartphones, headphones) to each other. Pairing is sometimes also referred to as bonding.

[0033] The problem is solved by a method for the additive manufacturing of an object, comprising the following steps: First, a strand-shaped starting material is fed to a friction arrangement. The feeding is carried out in particular by the friction arrangement and / or by an (additional) feed device. The friction (between the fed starting material and the friction arrangement or parts thereof) within the friction arrangement preferably causes the starting material to heat up, as a result of which it preferably loses its strand shape. Finally, the starting material is accelerated along an output direction by the friction arrangement. This allows the starting material to be applied, in particular layer by layer, to a build platform and / or to already manufactured areas of the object for production of the object.

[0034] The strand-like starting material is at least partially liquefied and / or at least partially plasticized and / or at least partially broken down into particles by the friction arrangement. The kinetic energy imparted by the acceleration of the starting material is preferably used to create a connection between the starting material and already manufactured areas of the object. The starting material is preferably applied by means of a positive connection, in particular mechanical interlocking, due to the kinetic energy of the accelerated starting material and a deformation when it impacts the build platform or the already manufactured areas of the object and / or by means of a material-to-material connection with already manufactured areas of the object, in particular due to melting of the starting material and / or the already manufactured areas of the object.The structure, in particular the layer structure and / or the material composite, is preferably achieved through a combination of melting heat and kinetic energy and / or a combination of thermal and kinetic energy. In some embodiments, the kinetic energy is the energy that dominates the process. In this way, additive manufacturing can be achieved with a simple and cost-effective manufacturing device, which achieves optimal bonding within the manufactured object. Furthermore, the kinetic energy of the starting material after heating in the friction arrangement preferably results in only minimal heat input into the object and / or into a semi-finished product during production, thereby avoiding or at least reducing damage to the object or, if the object is part of a composite body, to other components of the composite body.Especially compared to arc welding, the heat input can be reduced, although depending on the acceleration design, a moderate heat input can also be maintained. Finally, in some embodiments, the friction arrangement enables rapid heating and thus a high material throughput, which leads to high build speeds, especially during layer buildup.

[0035] According to one embodiment, the friction arrangement heats the starting material by friction.

[0036] The friction arrangement at least partially liquefies and / or at least partially plasticizes and / or at least partially breaks down into particles, as well. The melt and / or particles thus produced are then accelerated by the friction arrangement in order to exhibit kinetic energy in addition to thermal energy. If the starting material is not liquefied by the friction arrangement, in some embodiments, liquefaction and / or plasticization can also occur upon impact with the already manufactured areas of the object by appropriately selecting the kinetic energy. Alternatively, the selection of the kinetic energy can prevent a melt from forming upon impact, which would prevent the particles from sticking together due to mechanical forces caused by their deformation upon impact.

[0037] Preferably, the friction assembly is heated. Heating is advantageously achieved by inductive heating of the friction assembly. Alternatively or additionally, heating of the friction assembly is preferably achieved by inductive heating of adjacent machine elements, which introduce heat into the friction assembly. In this way, the heat introduced into the friction assembly by heating can be introduced into the starting material, thereby increasing the thermal energy in the starting material. Combined with the kinetic energy of the starting material, a higher total energy can be provided to reliably bond the starting material to previously manufactured areas of the object.

[0038] The starting material is preferably preheated during feeding. Preheating particularly advantageously occurs immediately before reaching the friction assembly. This reduces the heat energy required by the friction assembly to melt the starting material. Preheating is preferably carried out by inductive heating of the starting material. For this purpose, for example, a coil can be provided through or past which the strand-like starting material is guided before reaching the friction assembly. Additionally or alternatively, the starting material can be preheated using other forms of energy. Resistance heaters, radiant heaters, plasma, microwaves, lasers, or other forms of heating can be used, such as the supply of heat energy through friction.

[0039] Advantageously, the friction arrangement provides a material discharge of the starting material of at least 5 kg / h, preferably at least 10 kg / h, particularly preferably at least 20 kg / h. This leads to rapid production of the object through rapid construction, in particular layer construction. Large or numerous objects can therefore be produced in a short time. The method can also be used to produce objects that are part of a composite component, wherein other components of the composite component are and / or have been produced using other manufacturing processes, in particular other additive manufacturing processes. The rapid manufacturability of the object thus avoids delays in the production of the composite component due to long production times for the object.

[0040] In an advantageous embodiment, the object is manufactured from different starting materials. This is preferably achieved by feeding different starting materials to the same friction arrangement either simultaneously or sequentially. Alternatively or additionally, several friction arrangements are provided, to which different starting materials are fed, whereby all friction arrangements are intended to produce the same object. In particular, the input of kinetic energy results in a multitude of possibilities for applying areas or layers of different materials in order to manufacture the object. Different steels, steel and copper, as well as nickel and copper, can preferably be combined in this way. Alternatively, other materials such as different plastics can also be combined with one another, with metallic materials, or with other materials.

[0041] An advantageous embodiment provides for additive manufacturing of a component by layer-by-layer application of mineral and / or inorganic building material, in particular concrete and / or mortar, especially not yet fully set, to a surface and / or by layer-by-layer production of mineral and / or inorganic building material, in particular concrete and / or mortar, on a surface. During the application, preferably already mixed concrete or mortar is dispensed. During the layer-by-layer production of concrete or mortar, the concrete is mixed in a particle bed only at the desired locations to produce the layer, for example by selectively binding particle bed processes and / or the selective addition of water or another activator.Furthermore, an object is manufactured using a method as described above, wherein the object can preferably be reinforcement within the component, which is manufactured during the additive manufacturing of the component using a method according to the invention. The component thus represents a composite of concrete and reinforcement, which can be manufactured entirely by additive manufacturing, in particular without any of the components being prefabricated. This allows different geometries to be produced. It can be advantageous if the layered buildup of the reinforcement precedes the layered buildup of the concrete by a few layers, or if this occurs in the reverse order.

[0042] The invention further relates to a manufacturing device for the additive manufacturing of an object. The manufacturing device comprises a friction assembly to which a strand-shaped starting material can be fed. The starting material is preferably fed by the friction assembly itself and / or by an (additional) feed device. The friction assembly is designed to accelerate the starting material along a discharge direction in order to apply the starting material, in particular layer by layer, to a build platform and / or to a semi-finished product and / or to already manufactured regions of the object for manufacturing the object. Thus, the manufacturing device can be used, in particular, to carry out a previously described method for manufacturing the object.Due to the friction arrangement, the strand-like starting material is advantageously at least partially liquefiable and / or at least partially plasticizable and / or at least partially decomposable into particles and / or heatable. The production device allows application of the starting material by positive connection, in particular mechanical interlocking, due to the kinetic energy of the accelerated starting material as well as deformation upon impact with the build platform and / or a semi-finished product or the already manufactured areas and / or by material connection with already manufactured areas, in particular due to melting of the starting material. Preferably, the production device enables a build-up, in particular a layered build-up, through a combination of frictional heat and kinetic energy.

[0043] The manufacturing device preferably has a control device. The control device is, in particular, programmed to execute or cause the method according to the invention in each 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.

[0044] 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. In some embodiments, the production device can alternatively or additionally achieve a material bond within the discharged starting material, such as a metal bond.

[0045] The friction arrangement preferably has at least one friction disc. The friction disc is rotatable in particular by at least one drive device. The starting material can be placed against a friction surface of the friction disc in order to be accelerated and preferably also heated by friction. For this purpose, it is particularly preferably provided that at least the friction surface of the friction disc has a heat-resistant and / or wear-resistant surface and / or coating. Such a coating is particularly advantageously made from a ceramic material. Alternatively or additionally, the friction disc is preferably made at least partially from a heat-resistant and / or wear-resistant material, in particular from a ceramic material. Furthermore, it is particularly provided that an angular velocity of the friction disc is adaptable to a feed rate of the starting material along the friction arrangement.The angular velocity is set such that, in particular, a path velocity of that region of the friction disc which comes into contact with the starting material is at least a factor of 10, preferably at least a factor of 100, particularly preferably at least a factor of 1000, greater than the feed rate of the starting material along the friction arrangement, such as by at least a factor of 200, at least a factor of 300, at least a factor of 400 or at least a factor of 500. The path velocity is calculated by multiplying the angular velocity of the friction disc by the distance of the region which comes into contact with the starting material from the axis of rotation of the friction disc. The contact region of the friction disc can be approximately viewed as a point or an arc of a circle. In this way, optimal heating of the starting material through friction can be achieved.

[0046] The friction arrangement particularly preferably comprises a first friction disc and a second friction disc. The first friction disc and the second friction disc are rotatable in opposite directions of rotation, in particular by at least one drive device. Particularly advantageously, each friction disc is assigned its own drive device, and each friction disc can be brought into operative connection with the drive device assigned to it. The starting material can be passed between the friction surfaces of the first friction disc and the second friction disc in order to be accelerated and, preferably, also heated by friction. For this purpose, it is particularly preferred that at least the friction surfaces of the first friction disc and / or second friction disc have a heat-resistant and / or wear-resistant surface and / or coating. Such a coating is particularly advantageously made from a ceramic material.Alternatively or additionally, the first friction disc and / or second friction disc are preferably made at least partially of a heat-resistant and / or wear-resistant material, in particular of a ceramic material. Furthermore, it is particularly provided that an angular velocity of the first friction disc and / or the second friction disc can be adapted to a feed rate of the starting material along the friction arrangement.The angular velocity is set such that, in particular, a path velocity of that region of the first friction disc and / or the second friction disc which comes into contact with the starting material is greater by at least a factor of 10, preferably by at least a factor of 100, particularly preferably by at least a factor of 1000, than the feed rate of the starting material along the friction arrangement, such as by at least a factor of 200, by at least a factor of 300, by at least a factor of 400 or by at least a factor of 500. The path velocity is calculated by multiplying the angular velocity of the first friction disc and / or second friction disc by the distance of the region which comes into contact with the starting material from the axis of rotation of the respective friction disc.The contact area of ​​the first friction disc and / or the second friction disc can be approximately viewed as a point or a circular arc. In this way, optimal heating of the starting material through friction can be achieved. The angular velocities of the first friction disc and the second friction disc preferably have at least approximately the same value. In an advantageous embodiment, the angular velocities of the first friction disc and / or the second friction disc are adjusted during the process and are thus variable and not constant. For example, it is provided to change the angular velocities of the two friction discs at least temporarily by a certain value.

[0047] Furthermore, it is particularly preferably provided that the at least one friction disc, in particular the first friction disc and / or the second friction disc, is / are at least partially conical. This allows optimal introduction of frictional energy into the starting material and thus optimal heating of the starting material. Alternatively or additionally, the at least one friction disc or the first friction disc and / or the second friction disc can each be driven via a shaft. If multiple friction discs are provided, the respective shafts are preferably not oriented parallel. This also leads, particularly advantageously together with the aforementioned conical design of the friction disc(s), to optimal heat input into the starting material. The friction arrangement thus preferably enables rapid heating of the starting material, thereby enabling a high material throughput.Preferably, the angle between the two shafts of the two friction discs can be varied. This can be done either statically, preferably before the start of additive manufacturing, or dynamically during processing with the described device.

[0048] Preferably, the distance between the two friction discs can be adjusted by a preferably axial adjustment mechanism on the respective shafts. A corresponding adjustment mechanism can be provided on just one shaft or on both shafts. Such primarily axial adjustment of at least one friction disc on the associated shaft can occur before and / or during the process.

[0049] The at least one friction disc, in particular the first friction disc and / or the second friction disc, is / are preferably heatable by means of at least one heating device. This is particularly advantageously achieved by inductive heating and / or by heat input through thermal radiation. By heating the at least one friction disc, in particular the first friction disc and / or the second friction disc, by means of a heating device, the friction energy required to heat the starting material is reduced. This leads, on the one hand, to less wear on the friction arrangement and starting material, and, on the other hand, the starting material can be heated more quickly, thereby enabling a higher material throughput.In addition, a more uniform temperature level can be achieved in the process in this way because the friction discs do not cool down, or at least not to a great extent, after the conveying of the strand-shaped starting material has stopped, as would be the case without additional heating of the friction discs.

[0050] The first friction disc and the second friction disc can advantageously be rotated at different speeds by the at least one drive device to generate a spin in the dispensed starting material. This spin, in particular, allows the movement trajectory of the starting material to be stabilized after it leaves the friction arrangement. This allows for higher accuracies in the production of the object.

[0051] In some embodiments, the rotational speeds of two or more friction discs can be changed or adjusted to mutually different speeds during the process by a controller, preferably cyclically, cyclically repeating or randomly within predetermined limit speeds.

[0052] Preferably, a friction surface is located on at least one flat surface and / or flat side of a friction disc. Alternatively or additionally, a friction surface is located on at least one circumferential surface of a friction disc. In certain embodiments, a friction surface of a friction disc can be designed at any conceivable angle with respect to a rotational axis of the friction disc. In some embodiments, at least one friction disc or friction discs are not or at least predominantly not conical and / or at least substantially do not have any friction surfaces that are conical, but rather these are at least substantially cylindrical, so that the friction surfaces are formed at least predominantly on the circumferential surfaces of the friction discs.

[0053] In certain embodiments of the invention, three, four or more friction discs may be used, which may be designed with the features according to the invention in order to form at least one friction arrangement or a part thereof.

[0054] In some embodiments of the invention, the friction discs may have different diameters, geometries, surfaces and / or materials.

[0055] In certain embodiments of the invention, at least one friction disc of a friction arrangement has a rotational speed of more than 1000 rpm, preferably more than 5000 rpm and particularly preferably more than 10000 rpm during the acceleration of starting material.

[0056] In some embodiments, at least one friction disc of a friction assembly has a rotational speed of over 15,000 rpm, preferably over 20,000 rpm, more preferably over 30,000 rpm, and most preferably over 40,000 rpm, such as over 50,000 rpm, during acceleration of starting material.

[0057] In advantageous embodiments of the invention, the friction discs have diameters of at least 20 mm, preferably of at least 40 mm and particularly preferably of at least 55 mm, such as 60 mm or 70 mm.

[0058] In some embodiments, at least one friction disc has a diameter and / or an effective diameter of at least 75 mm, preferably of at least 100 mm, particularly preferably of at least 125 mm, and very particularly of at least 150 mm, such as between 80 mm and 160 mm or between 100 mm and 200 mm.

[0059] In some embodiments, an outer diameter of at least one friction disc can also be considered at least approximately as an effective diameter within which a friction arrangement is formed.

[0060] In some embodiments of the invention, the friction disks can have significantly different rotational speeds from one another, such as a difference of at least 200 rpm, preferably of at least 1000 rpm and particularly preferably of over 3000 rpm, such as for example of over 5000 rpm or of over 10,000 rpm. A preheating device is particularly advantageously provided which serves to preheat the starting material before it reaches the friction arrangement. This reduces the heating power required by the friction arrangement. Preheating is carried out in particular by inductive heating, for example by guiding the strand-shaped starting material through or past a coil. By reducing the heating power of the friction arrangement, which is generated by friction energy, stress / wear on the friction arrangement and the starting material can be reduced due to the reduced friction.

[0061] In certain embodiments, for example when processing aluminum or copper alloys with high thermal conductivity, it may be advantageous to cool the strand-shaped starting material, preferably immediately before the intake area of ​​the friction discs. Such cooling can be achieved by guiding the strand-shaped starting material through a tube, with the radial distance between the strand-shaped starting material and the tube having as small a clearance as possible in diameter. Such a tube is preferably provided with a cooling device extending circumferentially around the tube. In this way, heat can be dissipated from the strand-shaped starting material, thus preventing premature softening.In another embodiment, the described tube for cooling the strand-like starting material has a certain amount of clearance relative to the strand, so that a gap—viewed in the cross-section of the tube, in particular annular—is formed between the starting material guided through the tube and the inner wall of the tube facing the starting material. Compressed air or a protective gas such as nitrogen can be passed through this gap, thus achieving directed cooling of the strand-like starting material.

[0062] The device can have a control / regulating device with which technical parameters such as speeds, feeds, distances between the friction discs, temperatures of the friction discs and temperature of the strand-shaped starting material as well as other parameters can be controlled or regulated.

[0063] In certain embodiments, the temperature of the conveyed or accelerated starting material can preferably be measured in the area between the friction discs and the build platform or the object, preferably by an infrared thermometer.

[0064] For the manufacturing method and / or the manufacturing device described above, it is preferably provided that the starting material is a metal wire, a plastic in strand form, or a composite material in strand form. Strand-shaped starting material is particularly cheaper to purchase and use than, for example, powdered or granular starting material. By using the friction arrangement to heat the starting material, the manufacturing device and / or the manufacturing method can be easily adapted to a different starting material. For this purpose, the friction power to be generated is preferably adjusted by the friction arrangement, for example by the speed of the friction discs and / or the feed of the starting material and / or the distance between the friction discs and / or the angular position of the friction discs and / or the temperatures of the starting material and / or the friction discs.

[0065] In some embodiments of the invention, multiple strand-like starting materials can be used simultaneously. In other words, for example, two strand-like starting materials made of different materials can be fed at least temporarily to a friction arrangement comprising at least two friction disks at the same or different feed rate and thus heated and / or accelerated. In this way, for example, a varying material matrix can be achieved on the object. For example, two semicircular, strand-like starting materials made of two different materials can be processed, which, due to a mirror-inverted arrangement—viewed in cross-section—form at least an approximately circular contour.

[0066] The invention further relates to the use of a manufacturing device as described above for the additive production of reinforcement for a component. In particular, the reinforcement can be produced during additive manufacturing of the component, wherein the component is produced by layer-by-layer application of mineral and / or inorganic building material, in particular concrete and / or mortar, to a surface. Alternatively or additionally, the mineral and / or inorganic building material, in particular concrete and / or mortar, can also be produced directly layer by layer. In this case, it is particularly to be understood that the steps of layer-by-layer production of the component and the steps of layer-by-layer production of the reinforcement are carried out simultaneously or at different times / interleaved. Thus, one or more layers of reinforcement can be produced alternately, followed by one or more layers of the component.Alternatively, layers of component and reinforcement can be produced simultaneously. Additive manufacturing of reinforcement and component, without requiring either of these components to be fully prefabricated, creates a simple and cost-effective way to produce different geometries.

[0067] In some embodiments, a strand-shaped starting material contains at least one metal such as aluminum, magnesium, copper, brass, bronze, iron, steel, structural steel, quality steel, heat-treated steel, case-hardened steel, stainless steel, tool steel, molybdenum, platinum, tantalum, niobium, titanium, gold, silver, bronze, nickel, chromium, tin, zinc, lead, and bismuth. In some embodiments, a material jet and / or at least components of a material jet have a temperature of at least 500°C, preferably of at least 700°C, more preferably of at least 800°C, and most preferably of at least 900°C, for example between 500°C and 1400°C, between 700°C and 1600°C, or between 1000°C and 1800°C, at least immediately after leaving the process zone.

[0068] In some embodiments, a material jet has, at least in parts and / or regions, speeds of at least 50 m / s, preferably of at least 100 m / s, particularly preferably of at least 150 m / s and most particularly preferably of at least 200 m / s.

[0069] 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:

[0070] Fig. 1 a schematic view of a component with reinforcement during additive manufacturing,

[0071] Fig. 2 is a first schematic view of a manufacturing device according to a

[0072] Embodiment of the invention,

[0073] Fig. 3 is a second schematic view of the manufacturing device according to the

[0074] Embodiment of the invention,

[0075] Fig. 4 is a first schematic detailed view of a friction arrangement of the

[0076] Manufacturing device according to the embodiment of the invention,

[0077] Fig. 5 a second schematic detailed view of a friction arrangement of the

[0078] Manufacturing device according to the embodiment of the invention,

[0079] Fig. 6 a third schematic detailed view of a friction arrangement of the

[0080] Manufacturing device according to the embodiment of the invention,

[0081] Fig. 7 a fourth schematic detailed view of a friction arrangement of the

[0082] Manufacturing device according to the embodiment of the invention,

[0083] Fig. 8 is a fifth schematic view of a manufacturing device according to the

[0084] Embodiment of the invention with tilt angles

[0085] Fig. 9 Schematic diagram of the friction blasting process using the manufacturing device according to the embodiment of the invention,

[0086] Fig. 10 is a schematic view of the manufacturing process of a component with reinforcement during an additive manufacturing process, Fig. 11 is a schematic view of a manufacturing device according to an alternative embodiment of the invention with a friction disc, and

[0087] Fig. 12 is a schematic view of a manufacturing device according to a further alternative embodiment of the invention with a friction disc and support roller.

[0088] Figure 1 schematically shows a manufacturing device 1 according to an embodiment of the invention. The manufacturing device 1 serves for the additive manufacturing of an object 10 and has a friction assembly 2 (not shown in Figure 1) to which a strand-shaped starting material 11 is fed, for example, by a feed device of any design (not shown). The strand-shaped starting material 11 is, for example, a metal wire. The object 10 can be built up by the manufacturing device 1, in particular layer by layer.

[0089] The friction arrangement 2 serves to heat the starting material 11 and to accelerate the starting material 11 along a discharge direction 100. The starting material is either melted or broken down into solid particles by the friction arrangement 2, whereby the thus processed starting material impacts a build platform 12 or already manufactured areas of the object 10. The manufactured areas of the object 10 are, in particular, already manufactured layers. In particular, the starting material 11 can thus be output from the friction arrangement 2 as a jet or as shot. By impacting already manufactured areas of the object 10, the thermal energy and the kinetic energy of the starting material 11 are used to create a reliable connection to the already manufactured areas. This is achieved, for example, by a material-to-material and / or form-fitting connection with the already manufactured area.

[0090] In the example shown in Figure 1, it is intended to manufacture a component 13 from concrete, wherein the object 10 is a reinforcement for the component 13. The component 13 is additively manufactured by applying concrete, in particular layer by layer, using a concrete dispenser 9 to a surface 12a or to already manufactured areas. Alternatively, the concrete can also be produced directly, in particular layer by layer, on the surface 12a or on already manufactured areas. In this example, the surface 12a corresponds to the construction platform 12. The reinforcement is additively manufactured by the manufacturing device 1, wherein at least one or more layers of reinforcement are always applied first, followed by at least one or more layers of the component 13. The component 13 and the reinforcement can thus be manufactured in variable shapes, thereby increasing flexibility in the manufacture of components 13 with reinforcement.If the object 10 is reinforcement as described above, a high surface quality of the object 10 is undesirable. Roughness, grooves, and / or undercuts lead to an optimized bond between the concrete and the reinforcement. However, the production device 1 also enables the production of objects 10 with a higher surface quality. The advantage of a reduced surface quality is the rapid production of individual areas or layers, which reduces the overall production time of the object 10 and thus also of the component 13.

[0091] Thanks to the friction arrangement 2 for heating and accelerating the starting material 11, the manufacturing device 1 can be manufactured very easily and cost-effectively. At the same time, objects 10 with high stability and quality can be produced quickly. The starting material 11 used for this purpose is strand-shaped and therefore less expensive than other types of starting materials, such as powdered materials.

[0092] By combining kinetic energy and thermal energy, not all of the energy required to build a layer needs to be provided by thermal energy. Waste heat during the production of a layer is thus minimized. This is particularly advantageous in the previously described application of reinforcement, as heat input into already manufactured layers of the concrete component 13 is minimized during the production of the reinforcement. If layers of the concrete component 13 and the metal reinforcement are produced alternately, the concrete will not yet be fully cured when the reinforcement layers are produced. If excessive waste heat were to occur during the production of the reinforcement, this would have a detrimental effect on the concrete, which is prevented by the production device 1.

[0093] The structure of the friction arrangement 2 is shown in different views in Figures 2 and 3. Figures 4 to 7 show individual details of the friction arrangement 2. All of these figures are described together below.

[0094] The friction arrangement 2 has a first friction disc 3 and a second friction disc 4. The first friction disc 3 is coupled to a first drive device 5a via a first shaft 6a, such that the first drive device 5a can rotate the first friction disc 3. Analogously, the second friction disc 4 is connected to a second drive device 5b via a second shaft 6b, such that the second drive device 5b can rotate the second friction disc 4. Alternatively, a common drive device can also be provided, which serves to drive both friction discs 3, 4 (not shown). It is provided that the first friction disc 3 and the second friction disc 4 preferably rotate in opposite directions of rotation. The strand-shaped starting material 11 is, for example, a metal wire or a strand-shaped plastic.If the starting material 11 is fed to the friction arrangement 2, the starting material 11 is passed between the first friction disc 3 and the second friction disc 4, in particular between the friction surfaces of the first friction disc 3 and the second friction disc 4. This creates friction between the starting material 11 and the first friction disc 3 and the second friction disc 4, in particular between the starting material 11 and the friction surfaces of the first friction disc 3 and the second friction disc 4. It is particularly advantageous if the starting material 11 is passed between the end faces of the first friction disc 3 and the second friction disc 4. For this purpose, the first friction disc 3 and the second friction disc 4 are rotated by the corresponding drive device 5a, 5b.

[0095] Passing the starting material 11 between the rotating first friction disc 3 and the rotating second friction disc 4 leads to heating of the starting material 11 and in particular to at least partial melting of the starting material 11. After the starting material 11 has passed through the first friction disc 3 and the second friction disc 4, it is discharged as a molten jet or as a collection of solid particles, preferably as a material jet, along the discharge direction 100 to the build platform 12. Particularly advantageously, the starting material 11 is brought to an elevated temperature level by the first friction disc 3 and the second friction disc 4 and simultaneously accelerated in the discharge direction 100.

[0096] The friction energy to be introduced can be adjusted by the angular velocities of the first friction disc 3 and the second friction disc 4 as well as by a feed rate of the starting material 11. Preferably, the area of ​​the first friction disc 3 and / or the second friction disc 4 that comes into contact with the starting material 11 moves around the rotational axis of the respective friction disc 3, 4 at a speed that is at least a factor of 10, preferably at least a factor of 100, particularly preferably at least a factor of 1000, greater than the previously described feed rate of the starting material 11. These parameters allow the friction arrangement 2 to be optimally adapted to the starting material 11 to be used.

[0097] Particularly advantageously, the first friction disc 3 and the second friction disc 4 can have different angular velocities. This introduces a spin into the starting material 11. This spin stabilizes the movement trajectory of the starting material 11 after leaving the friction assembly 2 until it impacts the build platform 12 or the already manufactured areas of the object 10. This allows predefined shapes of the object 10 to be produced as precisely as possible. In particular, the surface quality of the object 10 can be optimized.

[0098] The first friction disc 3 and the second friction disc 4 are preferably conical. In particular, a thickness of the first friction disc 3 and / or the second friction disc 4, measured along the respective rotational axis of the friction discs 3, 4, decreases in the radial direction. Alternatively or additionally, the first shaft 6a and the second shaft 6b, and thus the associated rotational axes of the first friction disc 3 and the second friction disc 4, are oriented at an angle to one another (and thus not aligned parallel). This allows for an optimized contact surface with which the friction discs 3, 4 bear against the starting material 11 and heat the starting material 11 through friction.

[0099] The first friction disc 3 and / or the second friction disc 4 are preferably made of a heat-resistant and / or wear-resistant material, in particular a ceramic material. Alternatively or additionally, the first friction disc 3 and / or the second friction disc 4 have a heat-resistant and / or wear-resistant coating, which is advantageously made of a ceramic material. Thus, wear on the friction assembly 2 is minimized and the durability / service life of the friction assembly 2 is maximized.

[0100] The friction device 2 allows the starting material 11 to be heated quickly and reliably. Material discharge of the starting material 11 from the friction assembly 2 is thus maximized. Preferably, a material discharge of at least 10 kg / h, more preferably of at least 20 kg / h, and most preferably of at least 25 kg / h is provided. Thus, the objects 10 can be manufactured efficiently.

[0101] Furthermore, it is preferably provided that the starting material 11 is preheated immediately before reaching the friction assembly 2. Preheating is carried out by a preheating device 8 (see Figure 2) and preferably by inductive heating of the starting material 11. In the example shown in Figure 2, the preheating device 8 is a coil through which the starting material 11 is passed. If an electric current flows through the coil of the preheating device 8, a current is induced in a metallic starting material 11, which leads to heating of the starting material 11. Thus, less friction power needs to be generated by the friction assembly 2 to reach the same temperature level of the starting material 11 as without the preheating device 8. This reduces the overall heating time and also ensures lower loading of the friction assembly 2.

[0102] Preferably, it is also provided that the first friction disc 3 and / or the second friction disc 4 are heated via at least one heating device 7. Here, too, inductive heating is preferably provided, since no physical contact between the heating device 7 and the friction discs 3, 4 is necessary. By heating the first friction disc 3 and / or the second friction disc 4, the required friction power of the friction arrangement 2 is reduced, which in turn results in a higher heating rate and / or a lower load on the friction arrangement 2.

[0103] By means of the friction arrangement 2, different starting materials 11 can also be processed into a single object 10. For example, steel and copper or even nickel and copper can be combined easily and with little effort to produce an object 10 from multi-materials. The processing of plastic, in particular high-performance plastic such as PEEK, can also be implemented easily and with little effort using the production device 1 in order to produce corresponding objects 10. Such plastics can advantageously also be short-fiber reinforced. If short fibers are provided within the starting material 11, they can preferably be oriented along the dispensing direction 100, since the kinetic energy of the heated starting material 11 after acceleration causes the short fibers to act as pins when they hit already manufactured layers of the object 10.This means that the short fibers in the dispensing direction 100 "get stuck" in the already produced layer and thus maintain the alignment along the dispensing direction 100. This leads to increased bonding of successive layers of the object 10 to each other.

[0104] In addition to the application mentioned above for producing reinforcements, where only a relatively rough accuracy is necessary, the previously described production device 1 can also be used for other applications, since in particular a diameter of the jet of starting material 11 emitted by the friction arrangement 2 of up to 0.5 mm can be achieved.

[0105] In addition to the above written description of the invention, reference is hereby explicitly made to the drawings of the invention in Figs. 1 to 7 for its supplementary disclosure.

[0106] Fig. 8 shows a further illustration of the manufacturing device 1 with the friction arrangement 2. The first friction disc 3 and the second friction disc 4 are conical, although in some embodiments (not shown) these can differ in angles and diameters. In the illustrated Fig. 8, the first friction disc 3 and the second friction disc 4 are identical in their geometry. The axes of rotation of the first friction disc 3 and the second friction disc 4 can be parallel or at least partially parallel to a build platform surface 12a, or they can have predetermined angular positions, as shown by way of example in Fig. 8. A first angle α describes a rotation or tilt in a first direction that rotates about a z-axis.The second angle ß describes a rotation or tilt in a second direction, wherein the angle ß extends between the surface 12a of the build platform 12 and the axis of rotation of the friction disc 3 and / or the friction disc 4. The angles α and β can be applied independently of one another. Thus, at least one of the friction discs 3, 4 can be rotated or tilted by only an angle α or only an angle β, or one friction disc 3, 4 or both friction discs 3, 4 can be rotated or tilted by both angles. A rotation or tilt can either be fixedly predetermined by the production device 1 through its mechanical structure, or it can be adjustable, preferably executable by at least one controller, and particularly preferably in response to at least one parameter. The angle α preferably comprises values ​​between 0° and 90°. The angle β preferably comprises values ​​between 0° and 45°.An angle β can optionally be replaced by an angle γ to achieve a tilt about the y-axis. In some embodiments, the first friction disc 3 and the second friction disc 4 have different angles α and / or angle β relative to each other, for example, different by up to 5°, preferably different by up to 15°, and particularly preferably different by up to 30°.

[0107] Fig. 9 shows a schematic diagram of the friction blasting process according to an embodiment of the invention using the manufacturing device 1. The manufacturing device 1 is used for the additive manufacturing of an object 10 and has a friction assembly 2 to which a strand-shaped starting material 11 is fed, for example, by a wire feed mechanism 16 of any design or another possibility for conveying strand-shaped starting material 11 in a predetermined manner. The strand-shaped starting material 11 is, for example, a metal wire, e.g., made of a specific steel alloy for steel reinforcement. The object 10 can be built up by the manufacturing device 1, in particular layer by layer.

[0108] The friction assembly 2 serves to accelerate the starting material 11 along a discharge direction 100 and preferably to heat the starting material 11. A friction assembly 2 basically consists of at least one friction disc rotating in a rotation direction 200. In the schematic diagram shown in Fig. 9, the first friction disc 3 and the second friction disc 4 rotate in opposite directions in their respective rotation directions 200.

[0109] The strand-like starting material 11 is either heated, melted, and / or broken down into solid particles by the friction arrangement 2. The breaking down and / or acceleration and / or heating of the starting material 11 takes place in the process zone 14. The resulting material jet, consisting of preferably hot, very fast particles 17, is preferably discharged as a granular material jet and / or in shot form and moves in the discharge direction 100. This material jet impinges either on the build platform 12, a defined surface 12a, on the uppermost object layer of the object 10, and / or on a semi-finished product.

[0110] When the build area 15 impacts already manufactured areas of the object 10, the thermal energy and kinetic energy of the (accelerated) starting material 11 are used to create a reliable connection to the already manufactured areas of the object 10. A new object layer 10a is created. This connection is achieved, for example, by a material-to-material and / or form-fitting connection with the already manufactured area of ​​the object 10.

[0111] According to the embodiment shown in Fig. 9, the starting material 11 is preheated immediately before reaching the friction arrangement 2. The preheating is carried out by a preheating device 8, preferably by inductive heating of the starting material 11. In an inductively designed preheating device 8, an electric current flows through at least one coil (not shown) through which a metallic, strand-shaped starting material 11 is passed. In this way, a current is induced in a metallic starting material 11, preferably within a steel wire, which current leads to heating of the starting material 11. The preheating device 8 can alternatively or additionally be designed differently, for example by at least one resistance heating device and / or by at least one heat radiation device.

[0112] By using a preheating device 8, less friction power must be applied by the friction arrangement 2 in order to reach the same temperature level of the starting material 11 as without a preheating device 8. This can, on the one hand, reduce the overall heating time and, on the other hand, ensure a lower load on the friction arrangement 2.

[0113] Preferably, it is also provided that the first friction disc 3 and / or the second friction disc 4 is / are heated via at least one heating device 7 (not shown in Fig. 9). Here, too, inductive heating is preferably provided, since no physical contact between the heating device 7 and the friction discs 3, 4 is necessary. By heating the first friction disc 3 and / or the second friction disc 4, the required friction power of the friction arrangement 2 is reduced, since the friction discs 3, 4 are preferably already brought to the required and / or predetermined process temperatures. This, in turn, results in higher heating rates of the starting material 11 and / or a lower load on the friction arrangement 2.

[0114] In addition to the aforementioned application for producing reinforcements, where only a relatively rough accuracy is necessary, the production device 1 can also be used for other applications, since, for example, a diameter of the jet of starting material 11 emitted by the friction arrangement 2 of less than 1 mm and preferably of less than 0.5 mm can be achieved.

[0115] Fig. 10 schematically illustrates in more detail the additive manufacturing of a concrete component 13 into which reinforcement 10a is incorporated during the construction process using a manufacturing device 1. The reinforcement 10a is additively manufactured by the manufacturing device 1, preferably first applying one or more layers of reinforcement 10a and then applying one or more layers of the component 13. The component 13 and the reinforcement 10a can thus be manufactured in variable shapes, increasing flexibility in the manufacture of components 13 with reinforcement 10a.

[0116] For the layered construction of component 13, free-flowing material is first applied to a construction platform 12 or surface 12a using the concrete dispenser 9. In a subsequent step, the material is selectively mixed with binder by a binder dispenser 18 or activator dispenser. This solidifies the material at these points, creating component 13. During the construction process, component 13 is embedded in free-flowing material, which must then be removed. Other methods for applying concrete layer by layer in 3D printing, such as extrusion methods (not shown), are also suitable for inserting reinforcement 10a.

[0117] The wire-shaped starting material 11, from which the object 10 (or the reinforcement 10a) is manufactured, is fed to the production device 1. The material jet is discharged in the discharge direction 100 and connects with the object layer of the object 10. The object 10 preferably always protrudes at least one or preferably several layers from the concrete so that the object 10 can cool down and the concrete is thus not subjected to as much thermal stress. The object 10 is preferably incorporated layer by layer into the component 13, whereby it becomes the reinforcement 10a. If the object 10 is a reinforcement 10a as described above, a high surface quality of the object 10 is preferably undesirable. Roughness, grooves and / or undercuts lead instead to an optimized bond of the concrete to the reinforcement 10a.Furthermore, targeted structures can be created on the surface to improve the bond between the reinforcement and the surrounding concrete. These structures can preferably be designed similarly to ribs on reinforcing steel, but can also take on other geometric shapes that improve the bond.

[0118] However, the manufacturing device 1 also enables the production of objects 10 with higher surface quality. The advantage of a reduced surface quality is the rapid manufacture of individual areas or layers, which reduces the overall production time of the object 10 and thus also of the component 13. The friction arrangement 2 for heating and / or accelerating the starting material 11 makes the manufacturing device 1 very simple and cost-effective to manufacture. At the same time, objects 10 with high stability and quality can be produced quickly. The starting material 11 used is strand-shaped and therefore less expensive than other types of starting materials, such as powdered materials.

[0119] By combining kinetic energy and thermal energy, not all of the energy required to build a layer needs to be provided by thermal energy. Waste heat during the production of a layer is thus minimized. This is particularly advantageous in the previously described application of reinforcement 10a, since heat input into already manufactured layers of component 13 made of concrete is minimized during the production of reinforcement 10a. If alternating layers of component 13 made of concrete and reinforcement 10a made of metal are produced, the concrete is preferably not yet fully cured when the layers of reinforcement 10a are produced. If excessive waste heat were to occur during the production of reinforcement 10a, this would have a detrimental effect on the concrete, which is at least largely prevented by production device 1.

[0120] Fig. 11 shows a friction assembly 2 with only one friction disk 3. In this embodiment, strand-shaped starting material 11 is fed to the friction assembly 2 by means of a conveyor mechanism (not shown). In particular, the conveyor mechanism presses the starting material 11 against the friction disk 3. The starting material 11 is preheated in a preheating device 8, as in the previously described friction assemblies. The friction disk 3 is driven by a shaft 6a and the associated drive device 5a (not shown) and rotates in the rotation direction 200. In the process zone 14, the friction disk 3 heats the starting material 11 and discharges the accelerated material in the discharge direction 100.

[0121] Fig. 12 also shows a friction arrangement 2 with only one friction disk 3, which corresponds in principle to the embodiment of Fig. 11. In the embodiment shown, the strand-like starting material 11 is guided and supported into the process zone 14 by a support roller 19. For precise guidance, particularly in the axial direction of the support roller 19, this can be provided, for example, with a groove or a V-groove (not shown) around its circumference. The axial direction is, in particular, orthogonal to the axis of rotation or along the outer / circumferential surface of the support roller 19. The support roller 19 preferably rotates at least approximately at the same circumferential speed as the conveying speed of the strand-like starting material 11, i.e., in particular, significantly slower than the friction disk 3.The support roller 19 should preferably be arranged at least a short distance upstream of the process zone 14 relative to the strand-like starting material 11, so that the process conditions occurring, such as the very high temperatures, cannot unnecessarily negatively influence and / or damage the support roller 19. Optionally or additionally, other machine elements can also be used instead of a support roller 19 for guiding and / or supporting the strand-like starting material 11 against a friction disk 3.

[0122] List of reference symbols

[0123] 1 manufacturing device

[0124] 2 friction arrangement

[0125] 3 first friction disc

[0126] 4 second friction disc

[0127] 5a first drive device

[0128] 5b second drive device

[0129] 6a first wave

[0130] 6b second wave

[0131] 7 Heating device

[0132] 8 Preheating device

[0133] 9 Concrete output

[0134] 10 objects

[0135] 10a Reinforcement

[0136] 11 Source material

[0137] 12 Construction platform

[0138] 12a Surface

[0139] 13 Component

[0140] 14 Process zone

[0141] 15 Construction area

[0142] 16 Wire feed mechanism

[0143] 17 Material jet

[0144] 18 Binder edition

[0145] 19 Support roller

[0146] 100 Output direction

[0147] 200 Rotation direction

Claims

Claims 1. Method for the additive manufacturing of an object (10), comprising the steps . Feeding a strand-shaped starting material (11) to a friction arrangement (2), and . Accelerating the starting material (11) along an output direction (100) by the friction arrangement (2) in order to apply the starting material (11), in particular layer by layer, to a build platform (12) and / or to already manufactured areas of the object (10) for the manufacture of the object (10), . wherein the strand-like starting material (11) is at least partially liquefied and / or at least partially plasticized and / or at least partially broken down into particles by the friction arrangement (2).

2. Method according to claim 1, characterized in that the friction arrangement (2) heats the starting material (11) by friction.

3. Method according to one of the preceding claims, characterized in that the friction arrangement (2) is heated, wherein the heating is preferably carried out by inductive heating of the friction arrangement (2) and / or preferably by inductive heating of adjacent machine elements which introduce heat into the friction arrangement (2).

4. Method according to one of the preceding claims, characterized in that the starting material (11) is preheated during feeding, in particular immediately before reaching the friction arrangement (2), wherein the preheating is preferably carried out by inductive heating of the starting material (11).

5. Method according to one of the preceding claims, characterized in that the friction arrangement (2) provides a material discharge of the starting material (11) of at least 5 kg / h, preferably at least 10 kg / h, particularly preferably at least 20 kg / h.

6. Method according to one of the preceding claims, characterized in that the object (10) is produced from different starting materials (11), in particular by either supplying different starting materials (11) to the same friction arrangement (2) simultaneously or successively and / or by providing several friction arrangements (2) to which different starting materials (11) are supplied, wherein all friction arrangements (2) are preferably provided for the production of the same object (10). A method according to one of the preceding claims, characterized in that an additive manufacturing of a component (13) is carried out by layer-by-layer application of mineral and / or inorganic building material, in particular concrete and / or mortar, onto a surface and / or by layer-by-layer production of mineral and / or inorganic building material, in particular concrete and / or mortar, onto a surface, wherein the object (10) is preferably a reinforcement (10a) within the component (13) which is manufactured during the additive manufacturing of the component (13) by means of a method according to one of the preceding claims.Manufacturing device (1) for the additive manufacturing of an object (10), comprising a friction arrangement (2) to which a strand-shaped starting material (11) can be fed, wherein the friction arrangement (2) is configured to accelerate the starting material (11) along an output direction (100) in order to apply the starting material (11), in particular layer by layer, to a build platform (12) and / or to already manufactured areas of the object (10) for the manufacture of the object (10), wherein the friction arrangement (2) is configured to at least partially liquefy and / or at least partially plasticize and / or at least partially break down the strand-shaped starting material (11) into particles.Manufacturing device (1) according to claim 8, characterized in that the friction arrangement (2) has at least one friction disc (3, 4) which is rotatable by at least one drive device (5a, 5b) and wherein the starting material (11) can be applied to a friction surface of the friction disc (3, 4) in order to be accelerated and, in particular, heated by friction, and wherein, in particular, a linear speed of that area of ​​the friction disc (3, 4) which comes into contact with the starting material (11) is greater by at least a factor of 10, preferably by at least a factor of 100, particularly preferably by at least a factor of 1000, than a feed rate of the starting material (11) along the friction arrangement (2).Manufacturing device (1) according to claim 9, characterized in that the friction arrangement (2) comprises a first friction disc (3) and a second friction disc (4), wherein the first friction disc (3) and the second friction disc (4) are rotatable in opposite directions of rotation by at least one drive device (5a, 5b) and wherein the starting material (11) can be passed between the friction surfaces of the first friction disc (3) and the second friction disc (4) in order to be accelerated, and in particular heated by friction, and wherein in particular a linear velocity of that area of ​​the first friction disc (3) and / or the second friction disc (4) which comes into contact with the starting material (11) is increased by at least a factor of 10, preferably by at least a factor of 100, particularly preferably by at least one. factor 1000, greater than a feed rate of the starting material (11) along the friction arrangement (2).

11. Manufacturing device (1) according to claim 9 or 10, characterized in that the at least one friction disc (3, 4), in particular the first friction disc (3) and / or the second friction disc (4), is / are at least partially conical and / or can be driven via a shaft (6a, 6b) each, wherein the shafts (6a, 6b) are preferably oriented non-parallel.

12. Manufacturing device (1) according to one of claims 9 to 11, characterized in that the at least one friction disc (3, 4), in particular the first friction disc (3) and / or the second friction disc (4), can be heated by means of at least one heating device (7), in particular by inductive heating.

13. Manufacturing device (1) according to one of claims 10 to 12, characterized in that the first friction disc (3) and the second friction disc (4) can be rotated at different speeds by the at least one drive device (5a, 5b).

14. Manufacturing device (1) according to one of claims 8 to 12, characterized by a preheating device (8) which is designed to preheat the starting material (11) before it reaches the friction arrangement (2), in particular by inductive heating.

15. Method according to one of claims 1 to 7 or manufacturing device (1) according to one of claims 8 to 13, characterized in that the starting material (11) is a metal wire, a plastic in strand form or a composite material in strand form.

16. Use of a manufacturing device (1) according to one of claims 8 to 14 for the additive manufacturing of a reinforcement (10a) of a component (13), in particular during an additive manufacturing of the component (13) by layering mineral and / or inorganic building material, in particular concrete and / or mortar, onto a surface and / or by layering mineral and / or inorganic building material, in particular concrete and / or mortar, onto a surface (12a).

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