Method for producing at least one component by means of additive manufacturing, and motor vehicle

Abstract

The invention relates to a method for producing a component by means of additive manufacturing and to a motor vehicle comprising at least one component produced by means of additive manufacturing, wherein a numerical simulation is used to create a virtual model (10) of the component, at least one virtual reference plane (21, 22, 23) is defined in the virtual model (10), and wherein the virtual model (10) is aligned in such a way relative to a virtual plane of reference (25) of a manufacturing device for implementing an additive manufacturing method that the virtual reference plane (21, 22, 23) is plane-parallel with the virtual plane of reference (25); furthermore, a transfer of digital data of the virtual model (10) to the manufacturing device is performed, and at least one real component (50) is manufactured by means of additive manufacturing in relation to a real plane of reference (65) of the manufacturing device, the manufacture being performed in accordance with the virtual model (10) and its alignment with respect to the virtual plane of reference (25).

Description

[0001] Description

[0002] Method for producing at least one component by means of generative manufacturing, and motor vehicle

[0003] The invention relates to a method for producing at least one component by means of generative manufacturing and to a motor vehicle which has at least one component produced according to the method according to the invention.

[0004] When manufacturing objects or parts of objects using generative or additive manufacturing processes, the object to be manufactured is built up layer by layer from a formless or powdered material. Binders or thermal energy are introduced into each layer to solidify it. The remaining powdered material that has not solidified is then removed.

[0005] To increase the productivity of such processes, continuous process concepts are increasingly becoming the focus of technical development. The manufactured items should undergo the planned production steps largely automatically, with their transport to the individual processing stations taking place continuously via appropriately automated transport systems.

[0006] Due to the layered structure of the component, the orientation of a component during its additive manufacturing process can influence different component properties, such as strength along certain axes. Different orientations of identical components therefore lead to different components, at least in terms of their strength properties.

[0007] Accordingly, increased effort is required in terms of quality control of these different components in order to ensure series production with the desired properties of the components.

[0008] Different approaches to the generative manufacturing of components are known that make it possible to influence the component properties based on specific alignments or movements of the component and / or a print head.

[0009] US 2016 067 740 A1 discloses a method for printing a 3D object without the need to print a support structure for overhanging or cantilevered parts of the 3D object. The 3D printer includes a tilt adjustment mechanism that tilts the build plate about at least one axis to align the top surface and the 3D object relative to the nozzle during extrusion of the printing material. Tilting can be performed such that a previously extruded portion of the printing material is vertically aligned with the nozzle to receive the extruded printing material to form an overhanging element of the 3D object.

[0010] US 2017291372 A1 discloses a three-dimensional (3D) printing method, devices, systems, and software that include rotating a partially formed 3D object during the formation of a desired 3D object. The desired 3D object may include a cavity, a recess, or a protrusion. The rotation may occur along an axis other than a vertical axis. A model of the desired 3D object may be oriented according to a specific orientation. The orienting may be relative to the horizontal plane and / or the vertical plane. The orientation may occur relative to a plane parallel to the platform and / or perpendicular to the gravitational vector.

[0011] US 2019248064 A1 teaches various methods for additive manufacturing (3D printing) of complex structures from surfaces, at least some of which are orthogonal to each other. It also mentions build orientations used to produce such complex metal structures using a build chamber of an additive manufacturing printer. These novel build orientations enable the production of components with a minimum of support structure.

[0012] The present invention is based on the object of providing a method for producing at least one component by means of generative manufacturing, which makes it possible to produce components with the same properties in a simple and cost-effective manner.

[0013] The object is achieved according to the invention by a method for producing at least one component by means of generative manufacturing according to claim 1. Advantageous embodiments of this method are specified in subclaims 2-13.

[0014] In addition, a motor vehicle is provided which has at least one component manufactured according to the method according to the invention.

[0015] A first aspect of the invention is a method for producing at least one component by means of generative manufacturing, in which a virtual model of at least one component is created by means of numerical simulation, at least one virtual reference plane is defined in the virtual model, and the virtual model is aligned with respect to a virtual reference plane of a manufacturing facility for carrying out a generative manufacturing process such that the virtual reference plane is plane-parallel to the virtual reference plane. Furthermore, digital data of the virtual model is transferred to the manufacturing facility, and at least one real component is manufactured according to the virtual model and its alignment to the virtual reference plane by means of generative manufacturing with respect to a real reference plane of the manufacturing facility.

[0016] During production, the real component is therefore manufactured according to its virtual model and its virtual orientation, whereby the arrangement of the real reference plane in relation to the real reference plane is the same as the arrangement of the virtual reference plane in relation to the virtual reference plane. To the extent that the component itself has the reference plane, during production a real reference plane of the component to be manufactured corresponding to the virtual reference plane runs parallel to a real reference plane corresponding to the virtual reference plane. This means that the respective reference planes and datum planes are parallel planes. A component can also be understood here as a semi-finished product or a green compact of a finished end product. The virtual model of the component is, for example, a digital model.

[0017] Additive manufacturing can, for example, be a 3D printing process, so that the device for carrying out a generative manufacturing process is a printing device. Accordingly, when printing the component, the virtual model of the component is positioned in a virtual printing space before printing and aligned such that the virtual reference plane is arranged parallel to a virtual reference plane of the virtual printing device. The printing process is then carried out according to this alignment, so that, provided the body of the component has a plane that corresponds to the reference plane, the real reference plane also runs parallel to a real reference plane of the printing device.

[0018] The virtual reference plane can be defined by a surface in the virtual model. In an alternative embodiment, the virtual reference plane is defined by three reference points located in one plane.

[0019] In one embodiment, it is provided that the virtual reference plane is part of a virtual reference element of the body of the virtual model of the component, which corresponds to an otherwise functional component of the generatively manufactured real component.

[0020] Such an otherwise functional component of the actual component is a component that, in addition to forming the reference plane, also has another function, such as a strength function, a force-exerting function, a blocking function, or similar. Accordingly, the reference element can be a body element such as a step, a projection, or a recess.

[0021] The use of such a reference element makes it possible to determine the position in which the component was arranged in the build space during the manufacturing process, even after the component has been manufactured, since the printing direction always runs parallel to the surface of a print bed. The course of the individual printed layers in the reference element makes it possible to understand the position in which the component was printed. In order to achieve consistent mechanical properties and strength of the component, it is necessary that the component is printed in a consistent component position. If the course of the printed layers in the reference element deviates, it could therefore be concluded that the component was manufactured in a different component position than originally defined in the virtual model. The use of the reference element therefore also serves as a quality assurance and copy protection measure.

[0022] The virtual reference plane can have a virtual marker that identifies it as a virtual reference plane. This virtual marker can be a visually recognizable marker, such as a specific color, a pattern, or even an additional shape element.

[0023] An alternative embodiment provides that the virtual reference plane is part of an additional virtual reference element of the body of the virtual model of the component, which merely serves the function of forming the virtual reference plane. For example, the reference plane is formed on an additional body element or reference element of the body of the virtual model, which merely serves the function of forming the reference plane.

[0024] The method for producing at least one component by means of additive manufacturing can be carried out in such a way that the additional reference element is not produced or is not completely produced in the additive manufacturing process.

[0025] Accordingly, it is intended that the virtual model of the component has a reference element, such as a body element with the reference plane, based on which the virtual model is aligned in the virtual production space and, consequently, the alignment of the component to be manufactured in the real production space also takes place. However, the component is not manufactured in additive manufacturing with this reference element and, consequently, also not with the reference surface. The reference element can be an integral part of the body of the virtual model of the component or a separate part of the virtual model from the body of the virtual model of the component.

[0026] In the latter case, the virtual model comprises two units: a virtual model of the body of the component to be manufactured, and a separate reference element in virtual space that forms at least one reference plane. The orientation of the virtual model of the body relative to the separate reference element that forms the virtual reference plane is firmly defined.

[0027] The real reference plane can be a plane formed by the surface of a printing bed of a printing device designed as a device for carrying out a generative manufacturing process.

[0028] Furthermore, the additive manufacturing process can be used to build the component layer by layer in multiple planes, with the virtual model being aligned such that the virtual reference plane is aligned at a defined angle to the planes of the layered build. Accordingly, the layered build of the component proceeds in planes that are aligned at a defined angle to the virtual and, consequently, the real reference plane.

[0029] In an advantageous embodiment, the virtual reference plane is aligned parallel to the planes of the layered structure, or the layered structure of the component runs in planes that are aligned parallel to the virtual reference plane. This allows for advantageous influence on the strength properties of the component.

[0030] Furthermore, the virtual model can contain multiple component bodies. This virtual model also defines a virtual reference plane, based on which the virtual model is aligned with the virtual reference plane and thus also with the real reference plane, and the component is manufactured accordingly. This enables space-saving positioning, especially of multiple components, in the print chamber in the orientation according to the invention, and thus efficient print production, as it allows for optimal utilization of the print chamber.

[0031] In a further embodiment of the method, it is provided that several virtual reference planes extending at an angle to one another are defined in the virtual model, and the virtual model is aligned with respect to several virtual reference planes of the manufacturing facility for carrying out the additive manufacturing process such that the virtual reference planes are parallel to the virtual reference planes. Digital data from the virtual model is transferred to the manufacturing facility, and at least one component is manufactured in the manufacturing facility using additive manufacturing according to the virtual model and its alignment to the virtual reference planes.

[0032] Real reference planes of the component to be manufactured corresponding to the virtual reference planes run parallel to the real reference planes corresponding to the virtual reference planes.

[0033] In this case, several virtual reference planes running perpendicular to each other can be defined in the virtual model, so that, for example, a cube is present as a reference element or solid element in the virtual model. Alternatively, such a solid element can also be another geometric element, such as a pyramid.

[0034] According to this orientation, at least one component is then manufactured according to the virtual model using generative manufacturing in the production facility.

[0035] Where appropriate, it is provided that there are three mutually perpendicular virtual reference planes and, correspondingly, three mutually perpendicular virtual reference planes, wherein each of the virtual reference planes can be uniquely assigned to a respective virtual reference plane.

[0036] In this version, it is also useful to arrange markings in order to clearly assign the reference planes to the reference planes.

[0037] In a specific embodiment of the method for producing at least one component using additive manufacturing, the virtual model is aligned and positioned relative to the virtual reference plane of the manufacturing facility for performing an additive manufacturing process in such a way that the virtual reference plane is aligned with the virtual reference plane. An alternative embodiment provides for the virtual reference plane not to be aligned with the virtual reference plane, but rather for a parallel alignment.

[0038] The invention is supplemented by a motor vehicle, in particular a passenger car, which has at least one component manufactured according to the inventive method for producing at least one component by means of additive manufacturing. The invention is explained below with reference to the exemplary embodiment illustrated in the accompanying drawings.

[0039] It shows

[0040] Fig. 1 : a virtual model of a component to be manufactured in side view;

[0041] Fig. 2: a section of the virtual model shown in Figure 1, and

[0042] Fig. 3: a partial area of ​​a real manufactured component in perspective view.

[0043] Figure 1 shows a virtual model 10 of a component to be manufactured in a virtual space 1. This can, for example, be the virtual model 10 of a plastic coat hook to be produced by 3D printing.

[0044] On the body of the virtual model 10, a virtual reference element 20 is formed as a body element, which is an integral part of the model of the body of the component.

[0045] This virtual reference element 20 forms a first virtual reference plane 21 in the form of a surface. A virtual marking 24 is provided in this surface or in this first virtual reference plane 21, here in the form of a letter combination YZ, which is intended to indicate that the first virtual reference plane 21 is to be arranged parallel to a YZ plane.

[0046] The virtual reference element 20 further comprises a second virtual reference plane 22 and a third virtual reference plane 23, with all three virtual reference planes 21, 22, 23 being arranged perpendicular to one another. The virtual reference element 20 is therefore designed like a portion of a cube.

[0047] Figure 2 shows an enlarged view of the virtual reference element 20 with its three reference planes 21, 22, and 23. It is also evident that the first virtual reference plane 21 is aligned parallel to a virtual reference plane 25.

[0048] Accordingly, in virtual space 1, it is ensured that plane parallelism is realized between the first virtual reference plane 21 and the virtual reference plane 25, so that by transferring the data representing the virtual model 10 to a manufacturing facility, such as a 3D printing facility, the component to be manufactured can be produced with a corresponding orientation, and thus component properties, such as strengths along certain axes, can be influenced. Figure 3 shows a corresponding state, which represents a real component 50 in a real manufacturing space 40, which corresponds to the virtual model. It can be seen here that the virtual reference element 20 has also been transferred into a real reference element 60 with the same geometry.

[0049] Accordingly, the real component 50 also has a first real reference plane 61 in the form of a surface, as well as a second real reference plane 62 and a third real reference plane 63 running perpendicularly thereto.

[0050] The virtual marking 24 shown in Figures 1 and 2 has also been transferred into a real marking 64.

[0051] Just as the first virtual reference plane 21 shown in Figure 2 runs parallel to the virtual reference plane 25, the first real reference plane 61 also runs parallel to the real reference plane 65 in the real production space 40. Accordingly, an alignment of the real component 50 in the real production space 40 is realized according to the virtual model and its alignment, so that the production of the real component can take place in the desired manner, for example parallel to application planes 3D printing processes.

[0052] List of reference symbols

[0053] Virtual space

[0054] Virtual model

[0055] Virtual reference element

[0056] First virtual reference plane

[0057] Second virtual reference plane

[0058] Third virtual reference level

[0059] Virtual marking

[0060] Virtual reference plane

[0061] Real production space

[0062] Real component

[0063] Real reference element

[0064] First real reference plane

[0065] Second real reference plane

[0066] Third real reference level

[0067] Real marking

[0068] Real reference level

Claims

Claims: A method for manufacturing at least one component by means of additive manufacturing, in which a virtual model (10) of at least one component is created by means of numerical simulation, at least one virtual reference plane (21, 22, 23) is defined in the virtual model (10), and the virtual model (10) is aligned with respect to a virtual reference plane (25) of a manufacturing device for carrying out an additive manufacturing process such that the virtual reference plane (21, 22, 23) is plane-parallel to the virtual reference plane (25), a transfer of digital data of the virtual model (10) to the manufacturing device is carried out, and at least one real component (50) is manufactured according to the virtual model (10) and its alignment with the virtual reference plane (25) by means of additive manufacturing with respect to a real reference plane (65) of the manufacturing device.A method for manufacturing at least one component by additive manufacturing according to claim 1, characterized in that the virtual reference plane (21, 22, 23) is defined by a surface in the virtual model (10). A method for manufacturing at least one component by additive manufacturing according to one of claims 1 and 2, characterized in that the virtual reference plane (21, 22, 23) is part of a virtual reference element (20) of the body of the virtual model (10) of the component, which corresponds to another functional component of the additively manufactured real component (50). A method for manufacturing at least one component by additive manufacturing according to claim 3, characterized in that the virtual reference plane (21, 22, 23) has a virtual marker (24) that identifies it as a virtual reference plane (21, 22, 23).Method for producing at least one component by means of additive manufacturing according to one of claims 1 and 2, characterized in that the virtual reference plane (21,22,23) is part of an additional virtual reference element (20) of the body of the virtual model (10) of the component, which has only the function of forming the virtual reference plane (21,22,23). A method for manufacturing at least one component by additive manufacturing according to claim 5, characterized in that the additional virtual reference element (20) is not produced, or not completely produced, by the additive manufacturing process. A method for manufacturing at least one component by additive manufacturing according to any one of claims 3 to 6, characterized in that the virtual reference element (20) is an integral part of the body of the virtual model (10) of the component. A method for manufacturing at least one component by additive manufacturing according to any one of claims 5 and 6, characterized in that the virtual reference element (20) is a component of the virtual model (10) that is separate from the body of the virtual model (10) of the component.A method for manufacturing at least one component by additive manufacturing according to one of the preceding claims, characterized in that the real reference plane (65) is a plane formed by the surface of a print bed of a printing device designed as a device for carrying out an additive manufacturing process. A method for manufacturing at least one component by additive manufacturing according to one of the preceding claims, characterized in that in the additive manufacturing process, the real component (50) is built up layer by layer in several planes, wherein the virtual model (10) is oriented such that the virtual reference plane (21, 22, 23) is aligned at a defined angle to the planes of the layer by layer.A method for manufacturing at least one component by additive manufacturing according to one of the preceding claims, characterized in that the virtual model (10) comprises several bodies of components. A method for manufacturing at least one component by additive manufacturing according to one of the preceding claims, characterized in that several mutually angular virtual reference planes (21, 22, 23) are defined in the virtual model (10) and the virtual model (10) is aligned with respect to several virtual reference planes of the manufacturing equipment for carrying out the additive manufacturing process such that the virtual reference planes (21, 22, 23) are plane-parallel to the virtual reference planes, and a transfer of digital data from the virtual model to the manufacturing equipment takes place. and at least one component is manufactured in the manufacturing facility by means of additive manufacturing according to the virtual model (10) and its orientation to the virtual reference planes. A method for manufacturing at least one component by means of additive manufacturing according to one of the preceding claims, characterized in that the virtual model (10) is aligned and positioned with respect to the virtual reference plane (25) of the manufacturing facility for carrying out an additive manufacturing process such that the virtual reference plane (21, 22, 23) is adjacent to the virtual reference plane (25). A motor vehicle, in particular a passenger car, comprising at least one component manufactured according to the method for manufacturing at least one component by means of additive manufacturing according to one of claims 1 to 13.

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