Printing system and 3D printing method

Abstract

The invention relates to a printing system (1) for automatically producing a building part (2) by means of 3D printing on a print bed (3), wherein the printing system (1) comprises: a first discharge device (5) for forming a strand of construction material (B) at a first discharge portion (16) of the first discharge device (5), wherein the first discharge device (5) can be moved relative to the print bed (3) in order to automatically arrange the construction material (B) on the print bed (3) in at least one construction material layer (4) of the building part (2); and at least one second discharge device (6) for discharging at least one functional material (F), different from the construction material (B), at a second discharge portion (17) of the second discharge device (6), wherein the second discharge device (6) can be moved relative to the print bed (3) in order to automatically coat the at least one construction material layer (4), at least in portions, with the functional material (F) in order to form at least one functional material layer (19) of the building part (2), wherein the first discharge portion (16) and the second discharge portion (17) are formed separately.

Description

[0001] Printing system and 3D printing process

[0002] FIELD OF APPLICATION AND STATE OF THE ART

[0003] The invention relates to a printing system for the automatic production of a structural component by means of 3D printing on a print bed. The invention also relates to a 3D printing method for the automatic production of a structural component using such a printing system.

[0004] TASK AND SOLUTION

[0005] It is an object of the invention to provide a printing system for automatically producing a structural component by means of 3D printing on a printing bed and a 3D printing method for automatically producing a structural component by means of such a printing system, which have improved properties.

[0006] This problem is solved by the subject matter of the independent patent claims. Preferred embodiments are the subject matter of the dependent patent claims.

[0007] A printing system according to the invention serves for the automatic production of a building component by means of 3D printing on a print bed. In particular, the print bed is not a component of the printing system. The printing system can have a base that is designed to be arranged fixedly on the print bed. In this respect, in the present context, the base can alternatively be used as a reference for any adjustability relative to the print bed. The print bed can be a hall floor of a production hall or the subsurface of a construction site. Alternatively, the print bed can be formed by a platform of the printing system. The printing system has a first discharge device that serves to form a strand of building material at a first discharge section of the first discharge device.The first discharge device is adjustable relative to the print bed in order to automatically arrange the building material in at least one building material layer of the building component on the print bed. In particular, the building material can be automatically deposited on the print bed by means of the first discharge device. In this way, a stack with several building material layers can be created that are arranged one above the other along a vertical line. Adjacent building material layers in the stack are preferably connected to one another in a material-to-material manner and / or with a uniform material, so that the stack can form a coherent layered body of the building component. The printing system has a second discharge device for discharging at least one functional material that is different from the building material. The functional material can be discharged at a second discharge section of the second discharge device.The second discharge device is adjustable relative to the print bed in order to automatically coat at least one building material layer with the functional material, at least in part, to form at least one functional material layer of the building component. In particular, the building material layer can be coated with functional material in a web-like manner. The at least one building material layer can be coated with functional material along a meandering path to form at least one flat region of the functional material layer. The first discharge section and the second discharge section are designed separately from one another. The functional material and the building material can therefore be discharged separately from one another, in particular at different points in the printing system. This advantageously prevents mutual contamination of the building material with the functional material, and vice versa.Furthermore, the printing system advantageously makes it possible to at least partially or even completely eliminate manual post-processing of the at least one building material layer by manually coating it with functional material. In this respect, the inaccuracies associated with such manual post-processing can be at least partially or even completely avoided. Conversely, the printing system enables particularly precise and reliable production of the structural component with at least one building material layer and at least one functional material layer.

[0008] The structural component can be a composite structural component or a composite structural component with at least one building material layer and at least one functional material layer. Such a composite structural component allows the advantageous properties of both the building material and the functional material to be combined in one and the same component. For the building material, such advantageous properties can include, for example, thixotropy, which allows the extruded building material to retain its shape in the building material layer without the need for formwork even before curing, as well as curability after extrusion to preserve the 3D-printed shape. Furthermore, the cured building material can make a predominant contribution to the strength of the composite structural component.For the functional material, such advantageous properties can be, for example, low thermal and / or acoustic conductivity, a smooth or structured surface, wettability of the surface, an adhesive and / or cohesive effect, a color or toughness.

[0009] The building material is preferably a thick aggregate. The thick aggregate can be a paste-like mixture of different materials. The thick aggregate can be mortar, cement, screed, or concrete, each in a mixable and / or pourable state. In the mixable and / or pourable state, the thick aggregate has not yet hardened or set. The term "configured" can be used synonymously with the term "formed."

[0010] The term “comprises” or “has” can be used synonymously with the term “comprises”.

[0011] In this context, “control” can mean “steer” and / or “regulate”.

[0012] In this context, "discharging" can refer to the process by which a substance leaves a discharge device. In contrast to such discharging, the term "application" can refer to bringing the substance into contact with a substrate. As a result of the application, the previously discharged substance can adhere to the substrate and possibly be distributed there. Between discharge and application, the substance can be transported without a line through an external environment of the printing system in order to overcome a free distance between a discharge location and an application location.

[0013] The term "discharge" can be used synonymously with the term "extrusion," at least in the context of the construction material. The first discharge section can be a nozzle opening or an extrusion die.

[0014] In an embodiment of the invention, the printing system comprises a movement unit that is adjustable relative to the print bed in at least three degrees of freedom. The discharge devices are arranged on the movement unit such that the discharge devices, together with the movement unit, are automatically adjustable relative to the print bed. The first discharge section can be automatically adjustable or non-adjustable relative to the movement unit. Alternatively or additionally, the second discharge section can be automatically adjustable or non-adjustable relative to the movement unit. Accordingly, the two discharge sections can be automatically adjustable or non-adjustable relative to one another. This advantageously enables the production of particularly complex-shaped structural components.

[0015] In a further embodiment of the invention, the first discharge device and the second discharge device are designed differently. In particular, the discharge devices differ in a shape, in particular a cross section, of a discharge opening forming the respective discharge section of the respective discharge device. In particular, the discharge devices alternatively or additionally differ in an amount of a cross-sectional area of ​​a discharge opening forming the respective discharge section of the respective discharge device, in particular wherein the cross-sectional area of ​​the discharge opening of the first discharge device is at least 2 times to 50,000 times, in particular 10 times to 20,000 times, as large as the cross-sectional area of ​​the discharge opening of the second discharge device. Depending on the building material and / or functional material used, the discharge devices can thus ensure a particularly good, ieprecise and / or reliable and / or fast discharge.

[0016] In a further embodiment of the invention, at least one functional material is selected from the following group: insulating material for thermal and / or acoustic insulation of the structural component, plastering material for plastering the structural component, adhesion promoter for increasing adhesion, in particular for at least one further building material and / or at least one further building material layer, adhesive for bonding an additional component to the structural component, dye, in particular bound in a binder, for coloring the structural component, and crack inhibitor, in particular in the form of water or an evaporation-inhibiting substance, for inhibiting crack formation in the structural component, in particular in the at least one building material layer. At least one such functional material can be used.Several of the aforementioned functional materials can be used, which can be arranged in different functional material layers next to each other or one above the other on the building material layer. If an insulating material is used as the functional material, manual insulation of the building part can be advantageously dispensed with. If a plastering material is used as the functional material, manual plastering of the building part can be advantageously dispensed with. If an adhesion promoter is used as the functional material, a particularly robust connection can be achieved between adjacent stacked building material layers. When the adhesion promoter is used, a particularly robust connection of a further functional material with the at least one building material layer can also be achieved.If an adhesive is used as the functional material, an additional component, for example in the form of a window element or a door element, can be attached to the structural part, in particular without manual application of the adhesive. If a dye is used as the functional material, manual painting of the structural part can advantageously be dispensed with. If a crack inhibitor is used as the functional material, the result is a particularly robust structural part that has a particularly low tendency to tear. It is conceivable that different functional materials are discharged one after the other in serial passes using one and the same second discharge device. Alternatively or additionally, a plurality of second discharge devices can be provided, each of which is designed for the simultaneous, i.e. parallel, or serial discharge of one or more functional materials.

[0017] In a further embodiment of the invention, the printing system comprises a print head that is adjustable relative to the print bed. The print head comprises the first discharge device and—alternatively or additionally—the second discharge device. Alternatively, the printing system comprises a separate print head for each discharge device. Such a print head enables particularly accurate discharge of the building material and / or functional material, so that the building material and / or functional material can be applied to a target position with particular precision.

[0018] In a further embodiment of the invention, the printing system comprises a positioning device for the controlled positioning of the first discharge device and / or the second discharge device relative to the print bed. The positioning system can comprise a measuring system and a driven adjustment device that interact with each other. By means of the positioning device, the discharge devices can be adjusted relative to the print bed depending on, in particular, digital, structural data in order to produce the structural part depending on the structural data.

[0019] In a further embodiment of the invention, the printing system has a controllable robot arm, in particular as a movement unit. The robot arm can be referred to as a manipulator. The robot arm has a robot section that is adjustable relative to the print bed in at least three, in particular at least four, degrees of freedom. The first discharge device and the second discharge device are arranged, in particular fastened, to the robot section. In particular, the robot arm has a plurality of arm members that are articulated relative to one another about associated articulation axes, i.e., in particular, pivotable, and - alternatively or additionally - rotatable transversely to the articulation axes. A robot arm of this type enables the production of structural components with particularly complex geometric shapes, i.e., in particular, structural components with a wide variety of different shapes.In particular, such a robot arm makes it possible to apply functional material at least in some areas to all surface areas of the at least one building material layer that do not touch the printing bed.

[0020] In a further embodiment of the invention, the second discharge device has a spraying device for discharging the at least one functional substance in the form of a spray jet. Alternatively or additionally, the second discharge device has a foaming device for discharging the at least one functional substance in foam form. Alternatively or additionally, the second discharge device has an application device, in particular a brush and / or a roller, for applying the at least one functional substance discharged by means of the second discharge device to the at least one building material layer. By means of the spraying device, a functional substance, in particular a low-viscosity one, can advantageously be applied particularly evenly. By means of the foaming device, a functional substance that is foamable or self-foaming as a result of a chemical reaction at atmospheric pressure and / or upon contact with air can advantageously be discharged.Such a self-foaming functional material can be, for example, an insulating material, in particular one containing polyurethane. Using the application device, the functional material can be distributed particularly evenly over the at least one layer of building material.

[0021] In a further embodiment of the invention, the pressure system comprises a pumping device for conveying at least one flowable, in particular liquid, functional substance. In particular, the pumping device is fed from a supply of flowable functional substance. Preferably, the second discharge device can be supplied with flowable functional substance by means of the pumping device. This enables reliable and preferably uniform discharge of the functional substance. The term "discharge" can be used synonymously with the term "extrusion" in connection with the flowable functional substance. The second discharge section can be a nozzle opening or an extrusion die.

[0022] In a further embodiment of the invention, the printing system comprises a transport device for transporting at least one solid functional material, in particular in the form of granules or an elongated or flat semi-finished product. The transport system can be pneumatically and / or hydraulically and / or mechanically designed, in particular drivable. In particular, the transport device is fed from a supply of solid functional material. In particular, the second discharge device can be supplied with solid functional material by means of the transport device. The use of solid functional material offers the advantage that no setting time is required for the functional material layer produced with the solid functional material to harden.

[0023] In a further embodiment of the invention, the printing system comprises a connecting device, in particular a connecting line. The connecting device is connected to the second discharge device, such that the at least one functional substance can be fed to the second discharge device by means of the connecting device. The connecting device runs at least partially along a robot arm, in particular a manipulator, of the printing system. The connecting device advantageously makes it possible to arrange a supply and / or the pumping device for the functional substance at a distance from the discharge device. The supply and / or the pumping device can be arranged fixedly with respect to the print bed, such that the supply and / or the pumping device do not have to be adjusted relative to the print bed.

[0024] In a further embodiment of the invention, the printing system has a sensor device for monitoring the coating of the at least one building material layer with the at least one functional material. By means of the sensor device, a layer thickness of the functional material layer can be monitored. By means of the sensor device, an extension, i.e. layer width and / or layer length, of the functional material layer can be monitored. Alternatively or additionally, the printing system has a, in particular electronic, control unit. The control unit is designed to control the adjustment of the first discharge device and - alternatively or additionally - of the second discharge device. The control device is also designed to control the discharge of building material and - alternatively or additionally - of functional material. In particular, the control unit is connected to the sensor device for data transmission.The control unit advantageously enables a coordinated adjustment of the discharge devices as well as a coordinated discharge of building and functional materials.

[0025] A 3D printing method according to the invention serves for the automatic production of a building component using a printing system according to the invention as described above. The above-explained advantages of the printing system according to the invention therefore also apply to the 3D printing method according to the invention. The method comprises a step a), according to which an automatic arrangement of building material in at least one building material layer takes place on the print bed. The 3D printing method additionally comprises a step b), according to which an automatic coating of the at least one building material layer with functional material takes place, in particular at least in certain regions, in particular wherein the coating takes place in web form. The arrangement of the building material according to step a) and - alternatively or additionally - the automatic coating according to step b) can take place depending on, in particular digital, building data.

[0026] In a configuration of the 3D printing process, when performing step b), a substantially horizontally oriented upper side of the at least one building material layer and—alternatively or additionally—at least one flank side of the at least one building material layer oriented at an angle, in particular vertically, to the upper side are coated, in particular at least in some areas, with a functional material. In this way, structural components with particularly complex geometric shapes can be produced.

[0027] In a further embodiment of the 3D printing process, step b) is carried out after step a), in particular after arranging a predetermined number of building material layers of the structural component. This offers the advantage that the building material in the building material layers can set at least partially, in particular superficially, or completely before the functional material layer is applied. The functional material can be applied wet-on-dry to the at least one building material layer. Alternatively, step b) is carried out at a temporal overlap with step a), in particular wherein the building material and the functional material are dispensed with a spatial offset from one another. Carrying out steps a) and b) at a temporal overlap enables the structural component to be manufactured in a particularly short production time.In addition, it can be beneficial for the adhesion of the functional material layer if the building material of the construction layer has not yet cured or is not yet fully cured. The functional material can be applied wet-on-wet to at least one construction layer.

[0028] BRIEF DESCRIPTION OF THE DRAWINGS

[0029] Further advantages and features of the invention will become apparent from the claims and the following description of a preferred embodiment of the invention, which is illustrated with reference to the drawings. Like reference numerals refer to like, similar, or functionally identical components.

[0030] It is understood that the features mentioned above and those to be explained below can be used not only in the combination specified in each case, but also in other combinations or on their own, without departing from the scope of the present invention.

[0031] The only Fig. 1 shows a schematic side view of an embodiment of a printing system according to the invention for producing a structural part by means of 3D printing after carrying out a 3D printing method according to the invention.

[0032] DETAILED DESCRIPTION OF THE EMBODIMENT

[0033] A printing system 1 according to the invention is configured for the automatic production of a structural component 2 by means of 3D printing on a print bed 3. 3D printing can be understood as additive manufacturing. The print bed 3 is not a component of the printing system 1 in the present case. The print bed 3 can be a plane that is present, for example, on the floor of a production hall or on the subsurface of a construction site. The printing system 1 can have a base that can be arranged fixedly on the print bed 3 and is arranged accordingly in the present case.

[0034] The printing system 1 has a first discharge device 5. The first discharge device 5 serves to form a strand of building material B at a first discharge section 16 of the first discharge device 5. At the first discharge section 16, the strand of building material B can leave the discharge device 5 when the building material is discharged by means of the discharge device 5. The first discharge section 16 can, for example, be designed as a nozzle opening through which the strand of building material can be extruded. The first discharge device 5 is adjustable relative to the print bed 3. The first discharge device 5 is adjustable relative to the print bed 3 such that the building material B can be automatically arranged on the print bed 3 in at least one building material layer 4 of the building part 2.For example, the building material B can be automatically deposited on the printing bed in at least one building material layer 4 by adjusting the first discharge device 5 relative to the printing bed 3. In this way, a layered structure of several building material layers 4 stacked on top of one another can be arranged or deposited on the printing bed 3.

[0035] The printing system 1 also has at least one second discharge device 6. The second discharge device 6 serves to discharge at least one functional material F that is different from the building material B at a second discharge section 17 of the second discharge device 6. During discharge of the functional material F, the functional material F can leave the second discharge device 6 at the second discharge section 17. The second discharge section 17 can, for example, be designed as a nozzle opening through which the functional material F can be discharged. The second discharge device 6 is adjustable relative to the printing bed 3 in order to automatically coat at least one building material layer 4 at least partially with the functional material F. As a result of this coating, at least one functional material layer 19 of the building component 2 can be formed.For example, the second discharge device 6 is adjustable relative to the printing bed 3 such that the building material layer 4 can be coated with functional material F in a web-like manner. The first discharge section 16 and the second discharge section 17 are formed separately from one another. Each of the discharge devices 5, 6 thus has its own discharge section 16, 17. In other words, the strand of building material B can be discharged at a different location than the functional material F. The first and second discharge sections 16, 17 can be arranged at a distance from one another, in particular at a constant or variable distance.

[0036] In the present case, the printing system 1 has a movement unit 20. The movement unit 20 is adjustable relative to the print bed 3 in at least three degrees of freedom. In the illustration in Fig. 1, the degrees of freedom are represented by double arrows. In this case, the movement unit 20 is adjustable in five degrees of freedom. Three of these degrees of freedom are defined by three spatial axes oriented perpendicular to one another. One of the spatial axes runs vertically, with the other two spatial axes running perpendicular to one another and horizontally. The vertical spatial axis, which runs in the illustration plane of the illustration in Fig. 1, can be referred to as the z-axis. The spatial axis running horizontally and in the illustration plane of the illustration in Fig. 1 can be referred to as the y-axis. The spatial axis shown obliquely in the illustration in Fig. 1 can run perpendicular to the illustration plane and can be referred to as the x-axis.The x-, y-, and z-axes can form a three-dimensional Cartesian coordinate system. In this case, the movement unit 20 is rotatable about the vertical spatial axis relative to the print bed 3. Furthermore, the movement unit 20 is rotatable or pivotable about a horizontally extending articulation axis K relative to the print bed 3. In this case, this results in at least five degrees of freedom of movement of the movement unit 20 relative to the print bed 3.

[0037] In order to be able to apply the functional material layer 19 both to a top side 14 of the at least one building material layer 4 and to a lateral flank side 15 of the at least one building material layer 4, it may be expedient for the movement unit 20 to be adjustable in at least four degrees of freedom. For example, the movement unit 20 can expediently be linearly adjustable at least along the three spatial axes and rotatable relative to the print bed 3 at least about the vertical spatial axis.

[0038] For example, the first discharge device 5 and the second discharge device 6 are designed differently. The discharge devices 5, 6 can differ in the shape of a discharge opening 18 of the respective discharge device 5, 6, which forms the respective discharge section 16, 17. Each discharge opening 18 can have a cross-section. The shape of the cross-section of the discharge openings 18 can be different. The cross-section can be oriented perpendicular to a discharge direction of the respective discharge device 5, 6, along which discharge can take place. For example, the discharge opening 18 of the first discharge device 5 can have a quadrangular, for example rectangular, shape. The rectangular shape can be square or non-square. "Rectangular" can mean "essentially rectangular."A "substantially rectangular" shape can, for example, have rounded or beveled corners. Other substantially quadrangular shapes, such as trapezoidal or oblique parallelogram shapes, are also possible. The discharge opening 18 of the second discharge device 6 can have a rounded or round shape. Such a rounded or round shape can be circular or elliptical. It is understood that other shapes are also conceivable for the cross-sections of both discharge openings 18, for example triangular shapes or other polygonal shapes. Other rounded shapes are also conceivable, in particular in the form of a freeform or non-circular shape.

[0039] Alternatively or additionally, the first and second discharge devices 5, 6 differ in an amount of a cross-sectional area of ​​the discharge opening 18 forming the respective discharge section 16, 17. The cross-sectional area can be oriented perpendicular to the discharge direction of the respective discharge device 5, 6. For example, the absolute value of the cross-sectional area of ​​the first discharge section 16—as in the present case—is greater than the absolute value of the cross-sectional area of ​​the second discharge section 17. The cross-sectional area of ​​the discharge opening 18 of the first discharge device 5 can be at least 2 times to 50,000 times as large as the cross-sectional area of ​​the discharge opening 18 of the second discharge device 6. The cross-sectional area of ​​the discharge opening 18 of the first discharge device 5 can be 10 times to 20,000 times as large as the cross-sectional area of ​​the discharge opening 18 of the second discharge device 6.The cross-sectional area of ​​the discharge opening 18 of the first discharge device 5 can be larger by a factor of 20 to 10,000, in particular 50 to 1,000, than the cross-sectional area of ​​the discharge opening 18 of the second discharge device 6.

[0040] Various materials can be considered as functional material F, which can be used alone or in combination with one another to arrange at least one or more functional material layers 19 on the at least one building material layer 4. Each functional material layer 19 can be attached in certain areas to the at least one building material layer 4 or to a stack of building material layers 4. It is understood that different functional material layers 19 can be present in different areas, each formed with different or identical functional materials F. The multiple functional layers 19 can overlap one another, be in butt-joint contact, or be arranged at a distance from one another.

[0041] The functional material F can, for example, be an insulating material for thermal and / or acoustic insulation of the building component 2. The functional material F can be a plastering material for plastering the building component 2. The functional material F can be an adhesion promoter to increase adhesion, for example for at least one further functional material F and - alternatively or additionally - for at least one further building material layer 4. The functional material F can be an adhesive for bonding an additional component to the building component 2. Such a component can, for example, be a window or door unit for a building comprising the building component 2. The functional material F can also be a dye for coloring the building component 2. The dye can be bound in a binder.By means of the dye, the at least one building material layer 4 can be provided with a functional material layer 19 as a coating for the building component 2. The functional material can also be a crack inhibitor for inhibiting crack formation in the building component 2, in particular in the at least one building material layer 4. The crack inhibitor can be in the form of an evaporation-inhibiting substance. Such an evaporation-inhibiting substance can serve to inhibit evaporation of liquid present in the building material B. For example, the evaporation-inhibiting substance can be gas-impermeable. The evaporation-inhibiting substance can be essentially in the liquid and / or solid phase under standard conditions (STP conditions) and, for example, have little or no tendency towards evaporation and / or outgassing. A paraffin-based solution, for example, can be used as an evaporation-inhibiting substance.

[0042] It is conceivable that different functional materials F are dispensed and / or applied one after the other in serial passes by means of one and the same second dispensing device 6. Alternatively or additionally, it is conceivable that several second dispensing devices 6 are present, each of which is designed for the simultaneous, i.e., simultaneous, or serial dispensing and / or application of a separate functional material F. A separate functional material layer 19 can then be produced by means of each of these several second dispensing devices 6.

[0043] In the present case, the printing system 1 has a print head 7 that is adjustable relative to the print bed 3. The print head 7 has the first discharge device 5 and the second discharge device 6. Alternatively, only one of the discharge devices 5, 6 can be included in the print head 7. The printing system 1 can have a separate print head 7 for each discharge device 5, 6. For example, the printing system 1 has a positioning device 8. The positioning device 8 serves for the controlled positioning of the first discharge device 5 and - alternatively or additionally - the second discharge device 6 relative to the print bed 3. The positioning device 8 can have a measuring system for detecting a current position of the discharge devices 5, 6 relative to the print bed 3, as well as an adjustment device, in particular an electrically driven one, by means of which the discharge devices 5, 6 can be adjusted relative to the print bed 3.The measuring system and the adjustment device can interact with each other in order to achieve a reliable positioning of the at least one building material layer 4 and / or the at least one functional material layer 19.

[0044] In the present case, the printing system 1 has a controllable robot arm 9. "Control" in this context can mean "control" and / or "regulate." The robot arm 9 can be referred to as a manipulator 10. The robot arm 9 has a robot section 11 that is adjustable relative to the print bed 3 in at least three, in particular at least four, degrees of freedom. In the embodiment shown, the adjustable robot section 11 functions as a movement unit 20. With regard to the mobility of the robot section 11 relative to the print bed 3, reference is made to the mobility of the movement unit 20 already explained above. The first discharge device 5 and the second discharge device 6 are arranged on the robot section 11. The first discharge device 5 and the second discharge device 6 can be attached to the robot section 11. The robot arm 9 can have several arm links 12.The arm links 12 can be articulated relative to one another about associated articulation axes K and—alternatively or additionally—rotationally movable transversely to the articulation axes K. The articulation axes K can be joint axes of joint devices, each of which, for example, connects two arm links 12 to one another so that they can move relative to one another. For example, such a joint device can be a hinge joint with a single articulation axis K. It is understood that instead of hinge joints with only a single articulation axis K, other types of joints can also be used to connect two adjacent arm links 12 to one another so that they can move relative to one another. For example, two adjacent arm links 12 can be connected to one another with a ball joint. Alternatively or additionally, two adjacent arm links 12 of the robot arm 10 can be connected to one another in a gimbal manner.

[0045] The second discharge device 6 has, for example, a spray device for discharging the at least one functional substance F in the form of a spray jet. The spray device can have a spray nozzle. The functional substance F can be atomized in the spray jet. Alternatively or additionally, the second discharge device 6 has, for example, a foaming device for discharging the at least one functional substance F in foam form. The foaming device can have a foaming nozzle that can admix a gas to the functional substance F for foaming. Alternatively or additionally, it is conceivable for a gas to foam the functional substance F to arise as a result of a crosslinking reaction of polymeric or monomeric components of the functional substance F and thus does not have to be introduced from the outside by means of the foaming device, for example.

[0046] Alternatively or additionally, the second discharge device 6 has, for example, an application device which comprises a brush and - alternatively or additionally - a roller. The application device serves to apply the at least one functional substance F discharged by means of the second discharge device 6 to the at least one building material layer 4. "Discharge" can refer to the process in which the functional substance F leaves the discharge device 5, 6. In contrast, "application" can refer to the process which corresponds to bringing the substance into contact with a substrate. In this case, the substrate can be the at least one building material layer 4 and the applied substance can be, for example, the functional substance F. As a result of the application, the applied substance can adhere to the substrate and, if appropriate, be distributed there.

[0047] The printing system 1 has, for example, a pumping device for conveying at least one flowable, in particular liquid, functional substance F. The pumping device can be fed from a supply of flowable functional substance F, wherein the second discharge device 6 can be supplied with the flowable functional substance F by means of the pumping device. Alternatively or additionally, the printing system 1 can have a transport device, for example a pneumatic and / or hydraulic and / or mechanical one, for transporting at least one solid functional substance F. The solid functional substance F is in a solid state of aggregation. The solid functional substance F can, for example, be in the form of granules or an elongated or flat semi-finished product, in particular in the form of a wire, rod, film, or plate. The transport device can be fed from a supply of solid functional substance F.The second discharge device 6 can be supplied with solid functional material F by means of the transport device. The supply of functional material F can be arranged fixed to the print bed. In the case of a pneumatic transport device, the functional material F can be transported by means of the transport device in a gas or liquid stream. A mechanical transport device can be, for example, in the form of a belt conveyor, a paddle conveyor, a screw conveyor, or a bucket chain.

[0048] The printing system 1 comprises, for example, a connecting device, in particular in the form of a connecting line. The connecting device is connected to the second discharge device 6, so that the at least one functional substance F can be fed to the second discharge device 6 by means of the connecting device. The connecting device runs, for example, at least partially along the robot arm 9, in particular the manipulator 10, of the printing system 1. The connecting device or connecting line can be routed along the entire length of the robot arm 9.

[0049] A corresponding connecting device can also be provided for the building material B, connecting the first discharge device 5 to a reservoir for storing the building material B. The connecting device for the building material B can run at least partially along the robot arm 9. The connecting device or connecting line for the building material B can be routed along the entire length of the robot arm 9. The connecting device for the building material B can connect the first discharge device 5 to a building material pumping unit.

[0050] The building material pump unit can have delivery cylinders with variable-volume delivery chambers. To change the volumes of the delivery chambers, in particular in opposite directions, the delivery cylinders can each have an adjustable delivery piston. The building material pump unit can also comprise an S-shaped S-pipe, one end of which is fluidly connected to a pressure port acting as the pump outlet. The S-pipe can be arranged in a storage chamber that can be filled with building material from above for storing building material. The S-pipe can be rotatably mounted at one end on the pressure port within the storage chamber. The variable-volume delivery chambers can open into the storage chamber. The S-pipe can be pivotable in the storage chamber relative to the delivery chambers in such a way that it can be fluidly connected alternately to one of the delivery chambers.In this way, due to the counteraction of the pivoting of the S-pipe and a change in the volume of the conveying chambers, building material located in the storage chamber can be alternately sucked in by means of the conveying chambers and pumped out through the conveying chambers, through the S-pipe, and via the discharge nozzle. An agitator can be arranged in the storage chamber of the building material pumping unit. Downstream of the thick matter pumping unit and upstream of the first discharge device 5, a buffer storage for temporarily storing building material B and / or an additional conveying device, for example in the form of an eccentric screw pump, for supplying the first discharge device 5 with building material B can be arranged in the connecting device or connecting line for the building material B.

[0051] The printing system 1 comprises, for example, a sensor device. This sensor device can be used to monitor the coating of the at least one building material layer 4 with the at least one functional material F. Alternatively or additionally, the printing system can comprise a control unit 13, in particular an electronic one. The control unit 13 can be configured to control the adjustment of the first discharge device 5 and—alternatively or additionally—the second discharge device 6. Alternatively or additionally, the control unit 13 can be designed to control the discharge of building material B and / or functional material F. The electronic control unit 13 can be connected to the sensor device for data transmission.

[0052] The printing system 1 is configured to carry out a 3D printing method according to the invention. The 3D printing method serves to automatically manufacture the building component 2 by means of the printing system 1. The 3D printing method comprises a step a). According to step a), building material B is arranged in at least one building material layer 4 on the printing bed 3. The 3D printing method additionally comprises a step b). According to step b), the at least one building material layer 4 is automatically coated with functional material F. In particular, the at least one building material layer 4 is coated at least partially with the functional material F. The coating of the building material layer 4 with functional material F can be carried out in a web-like manner. The arrangement of building material B according to step a) can be carried out depending on, in particular digital, building data. The building data can be available, for example, as a digital 3D model. The 3D model can be a layered model.

[0053] For example, when carrying out step b), a substantially horizontally oriented upper side 14 of the at least one building material layer 4 is coated with functional material F. Alternatively or additionally, a flank side 15 of the at least one building material layer 4, which flank side 15 is oriented at an angle, in particular vertically, to the upper side 14 is coated with functional material F. The upper side 14 can be coated with functional material F in regions or over its entire surface. The flank side 15 can be coated with functional material F in regions or over its entire surface. A seam can be formed between two adjacent building material layers 4. This seam can be overlapped or covered by the functional material layer 19. There can be horizontally and / or vertically running seams which are covered by the functional material layer 19. A functional material layer 19 can be present in the seam itself, i.e. between two adjacent building material layers 4.In principle, it is also conceivable for a functional material layer 19 to be arranged between the print bed 3 and a bottommost building material layer 4. In other words: To connect the bottommost building material layer 4 to the print bed 3, a functional material layer 19 can first be arranged on the print bed 3, onto which the building material B in the bottommost building material layer 4 can then be deposited.

[0054] For example, step b) is performed chronologically after step a). Step b) can be performed when a predetermined number of building material layers 4 of the structural component 2 have been arranged on the print bed 3. Alternatively, step b) can be performed at a temporal overlap with step a). The building material B and the functional material F can be applied with a spatial offset from one another. The functional material F can therefore already be applied when a building material layer 4 has not yet been completely created.

[0055] A height of the at least one building material layer 4, in particular along a direction of gravity, can be at least 4 cm. The height can be, for example, 4 cm to 10 cm. A horizontal width of the building material layer 4, in particular perpendicular to the direction of gravity and perpendicular to an adjustment direction of the first discharge device 5, can be at least 10 cm. The width can be 10 cm to 40 cm. A layer thickness of the functional material layer 19 can be less than the height of the building material layer 4. A layer width of the functional material layer 19 can be less than the width of the building material layer 4. The layer width of the functional material layer 19 can be 5 times to 100 times smaller than the width of the building material layer 4. In the case where an insulating material is used as the functional material F, the functional material layer 19 can also have a greater layer thickness than the height of the building material layer 4 and / or a greater layer width than the width of the building material layer 4.If insulating material is used as the functional material F, the layer width of the functional material layer 19 can be at least twice as large, for example 5 times as large, as the width of the building material layer 4. The layer width of the functional material layer 19 can be at least as large as the height of the building material layer 4, in particular if the functional material layer 19 is applied to the flank side 15. If the functional material layer 19 is applied to the top side 14, the layer width of the functional material layer 19 can be 10 times smaller than the height of the building material layer 4. The layer thickness extends, for example, perpendicular to a surface of the building material layer 4 coated with the functional layer 19. The layer width extends, for example, perpendicular to the layer thickness. The layer width can extend perpendicular to an adjustment direction of the second discharge device 6.

Claims

Patent claims Printing system (1) for the automatic production of a building part (2) by means of 3D printing on a printing bed (3), wherein the printing system (1) comprises: a first discharge device (5) for forming a strand of building material (B) at a first discharge section (16) of the first discharge device (5), wherein the first discharge device (5) is adjustable relative to the printing bed (3) in order to automatically arrange, in particular to deposit, the building material (B) in at least one building material layer (4) of the building part (2) on the printing bed (3), and - at least one second discharge device (6) for discharging at least one functional material (F) different from the building material (B) at a second discharge section (17) of the second discharge device (6), wherein the second discharge device (6) is adjustable relative to the printing bed (3) in order to automatically coat the at least one building material layer (4) with the functional material (F) at least in regions, in particular in web form, to form at least one functional material layer (19) of the building part (2), - wherein the first discharge section (16) and the second discharge section (17) are formed separately from each other. Printing system (1) according to the preceding claim, - wherein the printing system (1) has a movement unit (20) which is adjustable relative to the printing bed (3) in at least three degrees of freedom, - wherein the discharge devices (5, 6) are arranged on the movement unit (20) such that the discharge devices (5, 6) are adjustable together with the movement unit (20) relative to the printing bed (3), in particular wherein the first discharge section (16) is adjustable or non-adjustable relative to the movement unit (20) and / or in particular wherein the second discharge section (17) is adjustable or non-adjustable relative to the movement unit (20). Printing system (1) according to one of the preceding claims, - wherein the first discharge device (5) and the second discharge device (6) are designed differently, in particular wherein the discharge devices (5, 6) are different in: a shape, in particular a cross-section, a discharge opening (18) of the respective discharge device (5, 6) forming the respective discharge section (16, 17), and / or an amount of a cross-sectional area of ​​a discharge opening (18) of the respective discharge device (5, 6) forming the respective discharge section (16, 17), in particular wherein the cross-sectional area of ​​the discharge opening (18) of the first discharge device (5) is at least 2 times to 50,000 times, in particular 10 times to 20,000 times, as large as the cross-sectional area of ​​the discharge opening (18) of the second discharge device (6).Printing system (1) according to one of the preceding claims, wherein at least one functional material (F) is selected from the following group: insulating material for thermal and / or acoustic insulation of the building part (2), plastering material for plastering the building part (2), adhesion promoter material for increasing adhesion, in particular for at least one further functional material (F) and / or at least one further building material layer (4), adhesive for bonding an additional component to the building part (2), dye, in particular bound in a binder, for coloring the building part (2), and crack inhibitor, in particular in the form of water or an evaporation-inhibiting substance, for inhibiting crack formation in the building part. (2), in particular in the at least one building material layer (4). Printing system (1) according to one of the preceding claims, - wherein the printing system (1) comprises a print head (7) which is movable relative to the printing bed (3) is adjustable, wherein the print head (7) has the first discharge device (5) and / or the second discharge device (6), or - wherein the printing system (1) has a separate print head (7) for each discharge device (5, 6). The printing system (1) according to one of the preceding claims, wherein the printing system (1) has a positioning device (8) for the controlled positioning of the first discharge device (5) and / or the second discharge device (6) relative to the print bed (3). The printing system (1) according to one of the preceding claims, - wherein the printing system (1), in particular as a movement unit (20), has a controllable robot arm (9), in particular a manipulator (10), with a robot section (11) adjustable relative to the printing bed (3) in at least three, in particular at least four, degrees of freedom, - wherein the first discharge device (5) and the second discharge device (6) are arranged, in particular fastened, to the robot section (11), in particular wherein the robot arm (9) has a plurality of arm members (12) that are pivotally movable relative to one another about associated pivot axes (K) and / or rotationally movable transversely to the pivot axes (K). Printing system (1) according to one of the preceding claims, - wherein the second discharge device (6) has a spray device for discharging the at least one functional substance (F) in the form of a spray jet, and / or - wherein the second discharge device (6) has a foaming device for discharging the at least one functional substance (F) in foam form, and / or - wherein the second discharge device (6) comprises an application device, in particular a brush and / or a roller, for applying the at least one functional substance (F) discharged by the second discharge device (6) to the at least one building material layer (4). Printing system (1) according to one of the preceding claims, - wherein the pressure system (1) comprises a pumping device for conveying at least one flowable, in particular liquid, functional substance (F), in particular wherein the pumping device is fed from a supply of flowable functional substance (F), and the second discharge device (6) can be supplied with flowable functional substance (F) by means of the pumping device. Pressure system (1) according to one of the preceding claims, - wherein the printing system (1) comprises a transport device, in particular a pneumatic and / or hydraulic and / or mechanical one, for transporting at least one solid functional material (F), in particular in the form of a granulate or an elongated or flat semi-finished product, in particular wherein the transport device is fed from a supply of solid functional material (F) and the second discharge device (6) can be supplied with solid functional material (F) by means of the transport device. Printing system (1) according to one of the preceding claims, - wherein the pressure system (1) has a connecting device, in particular a connecting line, - wherein the connecting device is connected to the second discharge device (6), so that the at least one functional substance (F) can be fed to the second discharge device (6) by means of the connecting device, - wherein the connecting device extends at least partially along a robot arm (9), in particular a manipulator (10), of the printing system (1). Printing system (1) according to one of the preceding claims, - wherein the printing system (1) has a sensor device for monitoring the coating of the at least one building material layer (4) with the at least one functional material (F), and / or - wherein the printing system (1) has a control unit (13), in particular an electronic one, wherein the control unit (13) is configured to control the adjustment of the first discharge device (5) and / or the second discharge device (6) and to control the discharge of building material (B) and / or functional material (F), in particular wherein the control unit (13) is connected to the sensor device for data transmission. 3D printing method for the automatic production of a building component (2) by means of a printing system (1) according to one of the preceding claims, wherein the method comprises the following steps: a) automatically arranging building material (B) in at least one building material layer (4) on the printing bed (3), b) automatically coating the at least one building material layer (4) with functional material (F), in particular wherein the coating takes place in web form.3D printing method according to the preceding claim, wherein, when performing step b), a substantially horizontally oriented upper side (14) of the at least one building material layer (4) and / or at least one flank side (15) of the at least one building material layer (4) oriented at an angle, in particular vertically, to the upper side (14) are coated with functional material (F). 3D printing method according to one of the two preceding claims. - wherein step b) is carried out after step a), in particular after arranging a predetermined number of building material layers (4) of the building part (2), or - wherein step b) is carried out in temporal overlap with step a), in particular wherein the discharge of the building material (B) and the functional material (F) takes place with a local offset to one another.

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