Method for producing components and build-up device

Abstract

The invention relates to a build-up device (1) for producing components (13) and a method for producing components (13). In order to provide a universal layering technology which is also suitable for producing large components, a method is proposed for producing components (13) with the aid of a build-up device (1), which build-up device (1) comprises a material accumulation device (3) which is designed for the layer-by-layer accumulation of material (11, 15,...) in layer planes (23) by applying the material (11, 15,...) to a stationary build-up face (20) with the formation of a material accumulation (22), which layer planes (23) are oriented at an angle to the surface of the build-up face (20), wherein the material accumulation device (3) is moved from place to place following a predefined build-up path (19), wherein at preferably each of these places on the build-up face (20) there is a layer-by-layer accumulation of material (11, 15,...) and at at least a number of these places there is a selective solidifying of particular regions (24) of the material (11, 15), accumulated layer-by-layer, in a number of layers (21) of the material accumulation (22).

Description

[0001] Description

[0002] Process for the production of components and assembly device

[0003] The invention relates to a method for producing components and a construction device.

[0004] Additive manufacturing processes, in particular layer-by-layer building processes, are known in the art. Layer-by-layer building processes are used to manufacture components from solidifiable materials, such as resin, plastic, metal, or ceramic, applied in layers. Layers of a building material are successively applied one on top of the other. Before the next layers are applied, the areas in the respective layers corresponding to the cross-section of the object to be manufactured are selectively solidified. Solidification is achieved, for example, by locally heating a powdered layered raw material using a radiation source.

[0005] Additive manufacturing processes are typically used for the production of small quantities, for example for the manufacture of prototypes or in small series production. Additive manufacturing processes are also particularly suitable for the production of components with complex geometries. For these reasons, additive manufacturing processes are primarily used for comparatively small, comparatively complex components made of metal or plastic in the areas of toolmaking, automotive engineering, aerospace engineering and medical technology. The components produced in this way typically have dimensions of up to around 100 centimeters. Many components are only a few centimeters in size. Additive manufacturing processes are also being used in the construction industry, particularly in the production of precast concrete elements for building and civil engineering.Known processes include the extrusion of concrete strands and particle-bed printing of concrete parts. These give rise to various problems, particularly in connection with the production of components with dimensions of several meters.

[0006] An object of the present invention is to provide a universal layer construction technique which is also suitable for the production of large components.

[0007] This object is achieved by a method according to claim 1 or claim 2 or by a construction device according to claim 10 or claim 11. Advantageous embodiments of the invention are specified in the subclaims.

[0008] The advantages and embodiments explained below in connection with the methods also apply analogously to the construction devices according to the invention and vice versa.

[0009] A first method according to the invention for producing components takes place with the aid of a building device, wherein the building device comprises a preferably transportable material accumulation device which is designed for the layer-by-layer accumulation of material, in particular of solidifiable material (building material), in layer planes by preferably applying the material over a surface to a stationary, i.e.immobile, immobile construction surface forming an accumulation of material, which layer planes are aligned obliquely to the surface of the construction surface, and wherein the material accumulation device is moved from location to location in a construction direction following a predetermined construction path, and wherein at preferably each of these locations on the construction surface a layer-by-layer accumulation of material and at at least a number of these locations a selective solidification of certain regions of the layer-by-layer accumulated material in a number of layers, i.e. in one or more layers, of the material accumulation takes place.

[0010] A second method according to the invention for producing components takes place with the aid of a building device, the building device comprising a preferably transportable material accumulation device which is designed for the layer-by-layer accumulation of material, in particular of non-solidifiable material (e.g. support material), in layer planes by preferably applying the material over a large area to a stationary, i.e. immovable, immobile building surface to form a material accumulation, which layer planes are aligned obliquely to the surface of the building surface, and the building device furthermore comprises a material addition device which is designed for the selective, i.e. not layer-by-layer, but punctiform or non-planar, application or introduction of material, in particular of solidifiable material (building material), onto or onto.into the material accumulation, and wherein the material accumulation device is moved from location to location in a build-up direction following a predetermined build-up path, and wherein at preferably each of these locations on the build-up surface a layer-by-layer accumulation of material takes place and at at least a number of these locations a selective application or introduction of material onto or into the material accumulation, and wherein at at least a number of these locations a selective solidification of certain regions of the layer-by-layer accumulated material in a number of layers, i.e. in one or more layers, of the material accumulation and / or a solidification of the material selectively applied to or introduced into the material accumulation takes place.

[0011] A first building device according to the invention for the production of components comprises a preferably transportable material accumulation device which is designed for the layer-by-layer accumulation of material, in particular of solidifiable material (building material) in layer planes by preferably applying the material flatly to a building surface to form a material accumulation, which layer planes are aligned obliquely to the surface of the building surface, and a material consolidation device which is designed for the selective consolidation of certain regions of the accumulated material in a number of layers, i.e. in one or more layers, of the material accumulation.

[0012] A second building device according to the invention for the production of components comprises a preferably transportable material accumulation device which is designed for the layer-by-layer accumulation of material, in particular of non-consolidatable material (e.g. support material) in layer planes by preferably applying the material over a large area to a building surface to form a material accumulation, which layer planes are aligned obliquely to the surface of the building surface, and a material addition device for the selective, i.e. not layer-by-layer, but point-by-point or non-area-by-point, application or introduction of material, in particular of consolidatable material (building material), onto or into the material accumulation, and a material consolidating device which is designed to consolidate the material selectively applied to or introduced into the material accumulation in a number of layers, i.e.in one or more layers, the material accumulation.

[0013] According to one embodiment of the invention, the layered accumulation of the material is carried out in such a way that, layer by layer, a geometrically defined surface of the accumulation of material is formed, in particular by heaping granular material, thereby forming a fill, or by spreading spreadable material, in particular granular material mixed with liquid, or gel-like material. In other words, a formless building material is used for the layered accumulation.

[0014] According to one embodiment of the invention, pourable materials are used as granular materials (particulate material). Examples include: sand, clay, glass, expanded clay, expanded glass, crushed silica, grit, activated carbon, plastic powder, and metal powder, as well as mixtures of such materials, including those in various grain sizes.

[0015] According to one embodiment of the invention, the spreadable materials used are spreadable gels or pastes, or the above-mentioned pourable materials when mixed with a liquid, for example with oil, water, thixotropic agent, plasticizer, plasticizer or concrete admixture.

[0016] Layered accumulation means the accumulation of material in successive, superimposed layers. In other words, the material is placed on top of one another in layers. Accumulation refers to the formation of an accumulation, i.e., a heap. The accumulation of material serves as a particle bed in the sense of additive manufacturing.

[0017] By moving the material accumulation device over the build surface along the build path from location to location, components of unlimited length can in principle be produced.

[0018] Since the build-up area is stationary, the accumulation of material and therefore the component to be manufactured are not moved. In particular, the component areas to be selectively solidified also remain stationary, i.e. they stay in one place and are not moved. This applies while the material accumulation device is moving and / or until the accumulation of material is finished and / or until the production of the last section of the component to be manufactured is completed and / or until the areas to be solidified have completely or essentially completely solidified. After complete solidification, the components can be moved to another location for further use. In contrast to all previously known additive manufacturing processes in a particle bed, this is a stationary additive component manufacturing process.

[0019] The accumulation of material in layer planes that are oriented obliquely to the surface of the build-up area means that the layer planes are not aligned parallel to the surface of the build-up area, but rather form an acute angle of between 0° and 90° with it. This angle is enclosed between the plane of the applied layer and the plane of the surface of the build-up plane.

[0020] According to one embodiment of the invention, the

[0021] Layers are applied at a repose or strike angle of between 30 and 60° to the surface of the build-up area. With a suitable inclination of the layer planes, slippage of the layered material and thus subsequent changes to the defined geometric surface of the material accumulation are avoided.

[0022] With a stationary build-up surface and a material accumulation device moving in the build-up direction, a suitable inclination of the layer planes ensures that the layers of the material accumulation and their defined geometric surface as well as, if applicable, the material selectively applied to or introduced into the material accumulation remain stable and can be selectively consolidated in a precise manner.

[0023] The invention is particularly suitable for the production of large components. According to one embodiment of the invention, the component to be manufactured has a box size between 0.3 m and 500 m.

[0024] Since large components are naturally relatively heavy, considerable internal stresses can build up during the hardening process. Large components can also have very long hardening times. It therefore makes economic sense not to move these components during the build process.

[0025] According to one embodiment of the invention, the build-up device comprises a mechanical guide system which defines a build-up path along which the material accumulation device is movable.

[0026] According to one embodiment of the invention, the material accumulation device comprises a preferably rectangular frame, which is designed as a guide for an accumulation unit movable within and / or along the frame. The width of the frame, or more precisely, the width over which the accumulation unit can accumulate material on the construction surface, determines the width of the construction field.

[0027] According to one embodiment of the invention, the accumulation unit comprises a material dispensing unit, such as a nozzle or the like.

[0028] According to one embodiment of the invention, the material accumulation device comprises a feed device connected to the material output unit for conveying the material.

[0029] According to one embodiment of the invention, the material accumulation device is designed to accumulate the material in layers such that the layer planes are inclined opposite to the construction direction.

[0030] According to one embodiment of the invention, the material accumulation device is designed to accumulate the material in layers with defined layer thicknesses, in particular in thin layers. In particular, the material accumulation device is designed to accumulate the material in layers with layer thicknesses between 0.3 mm and 30 mm.

[0031] In the simplest case, the layers are applied in such a way that successive layers are applied parallel to one another. The thicknesses of successive layers may differ from one another.

[0032] According to one embodiment of the invention, the material accumulation device is designed to accumulate the material in layers with different layer thicknesses. According to one embodiment of the invention, during the formation of the material accumulation, at least one layer of the material is applied at a location on the construction surface. In this case, only a small area of ​​the entire construction surface is provided with a layer. Due to the formation of inclined material layers on the construction surface, the thickness of the material accumulation within a location on the construction surface is different at each location.

[0033] According to one embodiment of the invention, the material accumulation device is designed to accumulate different materials in layers.

[0034] According to one embodiment of the invention, the building device comprises a plurality of material accumulation devices, each of these material accumulation devices being designed to accumulate a different material in layers.

[0035] The materials applied in layers can be selectively solidifiable build-up materials or non-solidifiable build-up materials.

[0036] Selective solidification can be achieved using various solidification mechanisms or methods. According to one embodiment of the invention, the material solidification device is designed to apply or introduce solidification material and / or solidification energy onto or into the material accumulation for selectively solidifying the material. If solidification material is used, this can be, for example, glue or the like. If solidification energy is used for layer-by-layer or layer-spanning solidification, this can be, for example, high-energy radiation, such as laser radiation.

[0037] If the material consolidation device serves to apply or introduce material, the material consolidation device according to one embodiment of the invention has the same structural and functional features as the material accumulation device.

[0038] According to one embodiment of the invention, the material consolidation device is designed to consolidate the build-up material by activating it with the aid of suitable measures. For this purpose, the material already accumulated in layers or the material selectively applied or introduced can already be an activatable build-up material, for example because it is already a build-up material mixed from various components; or the existing build-up material can be activated or is activated by adding consolidating material. For this purpose, consolidating material is selectively introduced into the build-up material, in particular additional build-up material or binder for curing the build-up material.

[0039] According to one embodiment of the invention, the material hardening device is designed to selectively harden material by curing.

[0040] According to one embodiment of the invention, the material consolidation device is designed for selectively consolidating material by chemical activation with a binder, such as magnesia cement, Portland cement, gypsum, or water glass. According to one embodiment of the invention, the material consolidation device is designed for selectively consolidating material by applying single- or multi-component adhesives, such as cyanoacrylate, polyurethane, or epoxy.

[0041] According to one embodiment of the invention, the material solidification device is designed for selectively solidifying material by melting. For example, the local solidification of the construction material can be achieved by melting materials such as thermoplastics.

[0042] According to one embodiment of the invention, the material consolidation device is fixedly or movably connected to the material accumulation device, in particular to its frame. Preferably, the material consolidation device and the material accumulation device thus form a moving unit, so that the material consolidation device can be handled or transported together with the material accumulation device.

[0043] According to one embodiment of the invention, the entire assembly device, and in any case the material accumulation device, is transportable, preferably together with those devices that form a moving unit with the material accumulation device. In particular, the frame is transportable. In this way, it is easily possible to transport the device, as a whole or in parts, to another location after the completion of a component for the immediate assembly of a further component. According to one embodiment of the invention, the predetermined assembly path consists of path sections, each of these path sections being assigned to one of the locations at which the material is accumulated layer by layer.

[0044] According to one embodiment of the invention, the material accumulation device is moved along the build-up path from location to location at intervals. This means that material can be accumulated at any location, in particular to create a layer, and optionally, selective solidification can occur before the material accumulation device is moved along the path to the next location.

[0045] According to one embodiment of the invention, a material accumulation device movable in the direction of construction provides a fresh material bed or coating in the form of a material layer, which is then selectively solidified. This layer is inclined at a suitable angle of bed or coating, preferably between 30° and 60°.

[0046] According to one embodiment of the invention, the material accumulation device is moved layer by layer in the build-up direction. In other words, the material accumulation device is displaced from location to location in the feed direction by one layer thickness in order to build up the component layer by layer. The free volume created by the layer displacement is filled with build-up material, for example, using a doctor blade, and, if necessary, compacted into the new layer.

[0047] According to one embodiment of the invention, after each movement of the material accumulation device along the build-up path, i.e. at each location or locations to which the build-up device is moved during the manufacture of the at least one component, at least one layer, i.e. one or more layers, of the material is accumulated.

[0048] According to one embodiment of the invention, the layered accumulation of material takes place at all locations to which the material accumulation device is moved during the manufacture of the at least one component, while the solidification of the accumulated material takes place either at all locations or only at selected locations, i.e. from time to time or not after each application of a layer.

[0049] According to one embodiment of the invention, the solidification of the accumulated material occurs layer by layer, in particular for each layer or for selected layers. In other words, selective solidification occurs in a number of layers of the material accumulation.

[0050] According to one embodiment of the invention, a selective solidification of regions within a layer and / or a selective solidification of regions extending over several layers (cross-layer solidification) takes place, wherein one or more regions applied to or introduced into the material accumulation are connected to one or more other regions of the underlying layers.

[0051] According to one embodiment of the invention, at least one part of a component is produced at each location in such a way that after a number of movements of the material accumulation device along the defined build-up path from location to location, at least one component to be produced results, which consists of interconnected parts.

[0052] Unlike known layered construction methods, in the present invention, the construction area of ​​the build device is not limited from the outset by the dimensions of a substrate or build plate or a container. A confined process space in the conventional sense is not required for the implementation of the invention.

[0053] Despite the potentially unlimited length of the component to be manufactured, its width is limited by the working width of the assembly device. However, provided a sufficiently wide assembly area is available, according to one embodiment of the invention, it is possible to arrange several material accumulation devices next to one another and operate them simultaneously in order to increase the width of the component to be manufactured accordingly.

[0054] If only one material accumulation device is available, according to one embodiment of the invention, a second long component of this component width can be attached to a first long component with a limited component width in order to double the component width, etc. For this purpose, the material accumulation device can be moved from its first operating position into an immediately adjacent second operating position after the production of the first component, etc. For the production of the second component, a correspondingly adapted second build path is preferably provided.

[0055] According to one embodiment of the invention, the assembly path is defined such that the at least one component to be manufactured is connected to an existing component which is arranged at least partially, namely with a connecting region for connecting the component to be manufactured, on the assembly surface. The described flexibility with regard to the assembly path allows for attachment to an existing component, repair of an existing component, or completion of a component, in particular for component production in several steps.

[0056] According to one embodiment of the invention, the construction surface is the surface of a piece of land. In other words, there is no substrate plate, construction plate, or similar device component. The material is preferably piled up on a concrete, tar, or gravel surface. In the simplest case, the construction area is formed by a suitable, sufficiently solid, load-bearing base, i.e., the ground. Alternatively, the construction surface is provided by a suitable object, such as a construction plate. Even in this case, however, the construction surface remains stationary during manufacture of the component, i.e., it is not moved.

[0057] Another advantage is that materials can be processed which require a very long time to solidify. All that is required is a sufficiently large area of ​​land, for example outdoors, on which the manufactured component can remain for the purpose of solidification for the required period of time. This may, for example, be a period of 28 days for concrete or an even longer period if the component is manufactured at low temperatures, such as 3° or 5° Celsius. According to one embodiment of the invention, the construction surface runs horizontally with respect to the direction of gravity. However, the construction surface can also run at an angle to this.

[0058] According to one embodiment of the invention, the mounting surface has a flat surface. However, the mounting surface can also have a non-flat surface.

[0059] According to one embodiment of the invention, the predetermined build path is defined as a function of the surface shape of the build area. In other words, the build path is defined as a function of the surface shape of the build area.

[0060] According to one embodiment of the invention, the material accumulation device is moved from one location on the build-up surface to another location on the build-up surface between two successive layer application processes.

[0061] According to one embodiment of the invention, the movement of the material accumulation device from location to location is a substantially horizontal movement and / or a movement that is substantially parallel to the surface of the build-up area. The build-up path can be straight or curved.

[0062] According to one embodiment of the invention, the material accumulation (piling or spreading of material) is supported by side walls in the direction of construction for a certain material-specific time and / or over a defined construction length until sufficient green part strength is achieved. This is particularly useful when producing large, essentially long components. In this case, sufficient green part strength means sufficient stability of the component to prevent damage due to the flow of unconsolidated construction material.

[0063] According to one embodiment of the invention, this necessary support is provided during the stabilization period by laterally applied material fills or material removal. This is particularly useful when manufacturing large, essentially curved components.

[0064] According to one embodiment of the invention, the layer thickness is constant over the width and / or length of the build-up field, whereby the control of the material accumulation device can be carried out particularly easily.

[0065] According to one embodiment of the invention, in the case of curved build-up paths, the layer thickness is provided to be varied over the width and / or length of the build-up field, in particular such that the layer thickness decreases towards the inside of the curve and / or increases towards the outside of the curve.

[0066] According to one embodiment of the invention, the material accumulation, in particular the non-solidified portions of the material accumulation, serves at least partially as a support for the at least one component to be produced or one of its sub-components, at least during the period in which the solidification of the at least one component to be produced or its sub-component has not yet occurred sufficiently to ensure the inherent stability of the component or its sub-component. In other words, the presence of a support is provided until essentially complete solidification or until the completion of solidification.

[0067] According to one embodiment of the invention, the material accumulation device is designed to accumulate additional material for lateral support of the layered accumulation of material along the build-up direction. This additional material does not necessarily have to be accumulated in layers. The additional material can be a support material not suitable as build-up material and / or build-up material.

[0068] According to one embodiment of the invention, build-up and / or support material is poured onto the lateral boundaries of the build-up field and these material fills remain there until sufficient green part strength has been achieved in the activated areas of the component.

[0069] According to one embodiment of the invention, a formwork serves to provide lateral support for the layered accumulation of material along the construction direction, in particular a stationary formwork or a sliding formwork that can be moved with or independently of the material accumulation device. The formwork is preferably formed by retaining walls. According to one embodiment of the invention, this formwork remains in place until sufficient green part strength has been achieved in the activated areas of the component.

[0070] According to one embodiment of the invention, the assembly device comprises at least one material storage container and at least one feed device connecting the material storage container to the material accumulation device, designed to convey the material. The at least one material storage container is preferably connected to the material accumulation device in such a way that it moves along with the material accumulation device in the direction of the assembly path.

[0071] According to one embodiment of the invention, several devices of the erection device, preferably all devices of the erection device with the exception of the formwork walls that may be provided, are connected to one another in such a way that they move along with the material accumulation device in the direction of the erection path or in such a way that they allow a movement of the material accumulation device in the erection direction.

[0072] According to one embodiment of the invention, the assembly device comprises a control unit for the coordinated, i.e., coordinated operation of the devices of the assembly device. The method according to the invention can be carried out computer-aided with the aid of a data processing unit that is suitably configured to control the functions of the devices of the assembly device, in particular by providing control data that define the assembly path.

[0073] According to one embodiment of the invention, the material accumulated in layers is a solidifiable material (building material, component-forming material), which is subsequently selectively solidified. In other words, in this first construction variant, components are produced layer by layer from building material. Preferably, a method according to claim 1 and / or a construction device according to claim 10 is used.According to one embodiment of the invention, a first material, in particular a support material, is accumulated in layers and a second material is applied in layers to the accumulation of material or selectively introduced into the accumulation of material, displacing the layered first material and / or filling existing cavities in the layered first material and / or mixing with the layered first material, wherein the first and / or the second material is a solidifiable material and is solidified following the accumulation or application or introduction. Selective introduction of the second material is understood to mean introduction of material not in layers, but in particular local, punctual introduction. The second material is in particular a building material or a covering material, i.e.a material for producing a second component, which envelops the first component to be produced. In other words, in this second construction variant, a component is produced by means of a support material applied in layers. Preferably, a method according to claim 2 and / or a construction device according to claim 11 is used.

[0074] According to one embodiment of the invention, the selective application or introduction of the second material takes place by means of injection, in particular with the aid of a suitable nozzle.

[0075] The first material is applied in a similar way to the application of the build-up material in the first build-up variant. If the first material is displaced by the selectively introduced second material, the first material can be displaced completely or almost completely. The first material does not have to be displaced layer by layer, but can be displaced across layers, i.e. across a large number of layers. In other words, the second material can be introduced into areas across layers. In particular, with this build-up variant, different second materials can be introduced into different areas of the first material. The introduced second materials do not have to be solid or spreadable materials. Liquids can also be introduced into the interior of the component to be manufactured as second materials.With the help of this second design variant, components made of different materials, especially components with locally different material properties, can be manufactured particularly easily.

[0076] According to one embodiment of the invention, the assembly device comprises a material removal device configured to selectively remove layered material from the material accumulation at locations where material is subsequently selectively introduced into the material accumulation. The material removal device preferably cooperates with the material addition device; in particular, it is connected to the material addition device such that both devices form a moving unit.

[0077] According to one embodiment of the invention, the selectively introduced second material can be a solidification material which forms a separation volume for the building material, so that the component is separated from the rest of the building material over a plurality of layers. In this case, the second material can also be introduced by the solidification device. If the building material is not already a material composed of various components which also includes a reinforcing material, according to one embodiment of the invention, additional reinforcing material is introduced into the material accumulation or applied to the material accumulation. In other words, the component to be produced is reinforced by introducing one or more reinforcing materials into selected regions of the as yet unsolidified building material.Even a single layer applied to the construction surface is considered an accumulation within the meaning of the patent. The reinforcement material can be applied selectively or in layers. Examples of suitable reinforcement materials are essentially fibrous materials such as glass fibers, carbon fibers, natural fibers, and metal fibers.

[0078] According to one embodiment of the invention, the building material contains substances for increasing the angle of repose of the building material.

[0079] According to one embodiment of the invention, at least one functional element is additionally selectively introduced into the material accumulation, particularly into the not yet solidified build-up material and / or into the not yet solidified support material, by displacing material and / or filling existing cavities in the material. Such a procedure can be carried out both in conjunction with the first construction variant and in conjunction with the second construction variant.

[0080] In this way, hybrid components can be easily produced, i.e. components that consist of one or more materials and additionally have embedded functional elements. These functional elements can be components or component parts, such as rods, tubes or cables, or electrical or electronic components, such as sensors. According to one embodiment of the invention, the functional elements are not introduced arbitrarily, but rather in a targeted manner in specific orientations or in specific regions in the not yet solidified build-up material or in non-solidified regions of the build-up material.

[0081] According to one embodiment of the invention, reinforcements can be integrated into the components to be manufactured in almost any way by using reinforcement structures as functional elements. These reinforcement structures, for example in the form of metallic rods, can be welded within the not yet solidified construction material, for example using one of the following welding processes: resistance welding, welding under oxygen exclusion without inert gas or active gas, MIG-MAG welding.

[0082] According to one embodiment of the invention, the assembly device comprises a functional element addition device for selectively applying or inserting at least one functional element onto or into the material accumulation. Selective application or insertion is understood to mean not layer-by-layer, but in particular a selective, local application or insertion of the functional element. Alternatively, the application or insertion of the functional element can also be carried out manually.

[0083] According to one embodiment of the invention, all devices or device components directly used for placing or introducing material onto or into the material accumulation as well as all devices or device components directly used for solidifying the material are connected to the material accumulation device in such a way that they are moved from place to place together with the material accumulation device.

[0084] According to one embodiment of the invention, the assembly device is designed in such a way that the manufactured components can be easily removed from the accumulation of material after they have solidified.

[0085] The components manufactured according to the invention can then be subjected to surface treatment if required.

[0086] The invention is particularly suitable for the production of large concrete components, especially components with dimensions of several meters. The invention is particularly suitable for the production of precast concrete elements for building and civil engineering. Since such concrete elements are particularly easy and inexpensive to produce, they are particularly suitable for use as permanent formwork at another location.

[0087] A particularly advantageous feature is that the components can be manufactured on site. This eliminates the need to transport components from a precast plant to the construction site, thus reducing transport costs, which can be considerable for large components.

[0088] The invention provides a universal layered construction technique that is also suitable for the production of large components. The application of the invention is not limited to precast concrete components or the construction sector. The invention, with its advantages, can also be used for the classic additive manufacturing of small components, even using plastics or metals.

[0089] In addition to the embodiments of the invention described here, further embodiments are possible, in particular embodiments in which a layer-by-layer accumulation of material, in particular by pouring or spreading, and a selective application or introduction of material and / or functional elements onto or into the material accumulation are combined in a different way, in particular using other materials or material combinations and / or using other consolidation requirements and / or consolidation processes. In this way, very different components can be produced. This makes the layered construction technology according to the invention universally applicable. In this case, at least the following features of the invention are preferably always retained: A layer-by-layer accumulation and a selective consolidation of material takes place. The construction surface is stationary.At least one material accumulation device is moved from location to location, following a predetermined build-up path. The layer planes are aligned obliquely to the surface of the build-up area.

[0090] Examples of the invention are explained in more detail below with reference to the drawings. Herein:

[0091] Fig. 1 Parts of a construction device and a component to be manufactured in a side view,

[0092] Fig. 2 parts of a construction device and a component to be manufactured in a perspective view from the front, Fig. 3 parts of a construction device and a component to be manufactured in a perspective view from the side,

[0093] Fig. 4 Parts of a construction device from the front,

[0094] Fig. 5 Parts of a construction device and a component to be manufactured from the side,

[0095] Fig. 6 Parts of a construction device and a component to be manufactured from the front,

[0096] Fig. 7 shows a section of a component to be manufactured,

[0097] Fig. 8 shows a section through part of a component to be manufactured,

[0098] Fig. 9 a part of a component to be manufactured in section,

[0099] Fig. 10 a part of a component to be manufactured in section,

[0100] Fig. 11 a part of a component to be manufactured in section,

[0101] Fig. 12 shows a section through part of a component to be manufactured.

[0102] All figures depict the invention not to scale, but merely schematically and with only its essential components. Like reference numerals correspond to elements with the same or comparable function.

[0103] All embodiments describe the production of precast concrete parts. A first embodiment describes the layer-by-layer accumulation of solidifiable material (building material, component-forming material), which is then selectively solidified. A building device 1 is used for this purpose. A rectangular frame 4, which can be moved in the building direction 2, is part of a transportable material accumulation device 3 of the building device 1. The frame 4 serves as a guide for an accumulation unit 5, which can be moved along the frame 4 and with the aid of which accumulation unit 5, which can be moved solidifiable building material 11 is applied in flat layers 21 onto a building surface 20, whereby a material accumulation 22 with a defined surface 26 is formed, see Fig. 1. In the figures, only the most recently applied layers 21 of the material accumulations 22 are shown.

[0104] The movement of the accumulation unit 5 along the longitudinal beams of the frame 4 is indicated in Fig. 1 by a double arrow; in addition, the accumulation unit 5 can also be moved along the transverse beams of the frame 4. A nozzle 10 of the accumulation unit 5 serves to dispense the material. The layer planes 23 are aligned at an angle 25 obliquely to the surface of the build-up area 20 and are inclined counter to the build-up direction 2. The ground serves as the build-up area 20, which does not have to be an essentially flat surface, see Fig. 3.

[0105] The frame 4 is moved layer by layer in the build direction 2 from location to location over the build surface 20, see Fig. 2. A material storage container 6 is connected to the material accumulation device 3 in such a way that it moves in the direction of the build path 19. A feed device for conveying the build material 11, which connects the storage container 6 to the accumulation unit 5, is not required in the example shown, since the storage container 6 is directly connected to the accumulation unit 5. In the example described here, gravel is used as the build material 11.

[0106] Subsequently, at all or selected locations, specific areas 24 of the building material 11 are selectively solidified so that the interconnected sections 12 of the component 13 to be produced are gradually produced. A solidification device 7 for selectively solidifying the building material 11 is connected to the frame 4 and is moved therewith, see Fig. 4. In the example described here, cement is used as the solidification material (not shown) and is introduced into the building material 11 with the aid of the solidification device 7. The solidification material is introduced into the accumulation of material 22 via a nozzle 8 which is movable along the frame 4. The movements of the nozzle 8 along the frame 4 are indicated in Fig. 4 with the two double arrows. If the solidification takes place alternatively, e.g.by means of energy input, a radiation source (not shown) can be movably attached to the frame 4 instead of the nozzle 8.

[0107] The regions 24 of the build-up material 11 activated in this way remain stationary until the component 13 has completely hardened.

[0108] The assembly path 19 is predetermined by a suitable mechanical guidance system (not shown).

[0109] The material accumulation 22 is, from the time the building material 11 leaves the accumulation unit 5, until the

[0110] Time at which sufficient green part strength of the activated areas 24 of the component 13 is present, supported laterally in the construction direction 2 by walls 9, see Fig. 5. Alternatively, the material accumulation 22 is supported laterally in the construction direction 2 by material fills 10 from the time at which the construction material 11 leaves the accumulation unit 5 until the time at which sufficient green part strength of the activated areas 24 of the component 13 is present, see Fig. 6, wherein these material fills 10 are poured onto the lateral boundaries of the movable frame 4. The construction material or a support material different from the construction material is used for the material fills 10.

[0111] The movement of the material accumulation device 3 from location to location along a predetermined build-up path 19 as well as the devices of the build-up device 1 described in connection with the first embodiment are also used in an identical or suitably modified manner in the further embodiments described below.

[0112] A second exemplary embodiment describes the production of a component 13 by means of a support material 15 applied in layers. For this purpose, a first material, here a support material 15, is accumulated in layers using a correspondingly designed building device 1, as described in connection with the first exemplary embodiment, and a second material, here a building material 11, is introduced from time to time selectively and across layers into the material accumulation 22 with the aid of a material addition device 16, e.g. by means of injection with the aid of a nozzle, see Fig. 7. In the example illustrated here, the introduction takes place by displacing the first material 15 accumulated in layers. For example, the first material 15 is a rock of suitable grain size as the support material and the second

[0113] Material 11 is a concrete that can be hardened by curing.

[0114] A third exemplary embodiment also describes the production of a component 13 by means of a support material 15 applied in layers. However, in contrast to the second exemplary embodiment, the second material, a build-up material 11, is also applied in layers (see Fig. 8). For this purpose, the existing material accumulation device 3 is equipped accordingly, or two material accumulation devices are used. Here, too, the second material 11 is applied by displacing the first material 15 applied in layers.

[0115] A fourth exemplary embodiment likewise describes the production of a component 13 by means of a support material applied in layers. As a second material, a building material 11 is applied in layers. This serves to form a concrete component 13. During the movement along the building path 19, from time to time a further second material is additionally selectively introduced into the material accumulation 22, namely a foam material 17 suitable for insulation, which is introduced into regions immediately adjacent to the building material 11 in such a way that it envelops the regions 24 of the concrete component 13 to be consolidated, see Fig. 9. This results in a precast concrete component 13 with an insulating shell.

[0116] Not shown is a variant of the fourth exemplary embodiment in which an additional layer is applied to the material accumulation 22 at defined locations, which serves as a moisture seal for the insulated precast concrete component 13. A fifth exemplary embodiment describes the production of a component 13 on the basis of one of the previous exemplary embodiments, wherein at least one functional element 18 is introduced into the material accumulation 22. In the example shown, reinforcing elements in the form of metal rods are introduced as functional elements 18 into the material accumulation 22 selectively at defined locations in defined spatial directions, displacing as yet unsolidified building material 11, see Fig. 10.

[0117] Not shown is a variant of the fifth embodiment in which, from time to time, a further second material is additionally selectively introduced into the material accumulation 22, namely a rust-protection material which is introduced into regions immediately adjacent to the reinforcement element 18 in such a way that it envelops the reinforcement element 18. In this way, for example, an insulated precast concrete element 18 with enveloping reinforcement can be produced.

[0118] Fig. 11 shows a variant of the fifth embodiment in which a multi-part component 13 is produced from different materials, wherein a building material 11 which is selectively activated in regions 24 and which is simultaneously also a covering material for a functional element 18 is applied layer by layer so that the component 13 is produced at least in partial regions in layers from the building material 11, while other partial regions within the material accumulation 22 consist of other building materials 17 which are selectively introduced, not in layers.

[0119] Fig. 12 shows a sixth embodiment in which a

[0120] Component 13 is manufactured from different materials. As in the first exemplary embodiment, the building material 11, which simultaneously also serves as a support material, is applied layer by layer and the component 13 is produced at least in partial areas layer by layer by solidification of building material 11. The construction of other partial areas within the building material 11 serving as a support material, however, takes place, as in the second exemplary embodiment, with the aid of a different building material 17, which is not applied layer by layer but is selectively introduced while displacing the building material 11.

[0121] Further embodiments can be created by any combination of the described and illustrated examples and variants.

[0122] All features presented in the description, the following claims, and the drawings may be essential to the invention, both individually and in any combination. These features or combinations of features may each constitute an independent invention, the right to claim which is expressly reserved.

[0123] When specifying a combination of features defining an invention, individual features from the description of an embodiment need not necessarily be combined with one or more or all other features specified in the description of that embodiment; in this respect, any sub-combination of features of one or more embodiments is expressly disclosed.

[0124] Furthermore, physical features of the device can be reformulated to become process features, and process features can be reformulated to become physical features of the device. Features reformulated in this way are implicitly disclosed.

[0125] Reference symbol list

[0126] 1 assembly device

[0127] 2 Construction direction

[0128] 3 Material accumulation device

[0129] 4 frames

[0130] 5 accumulation unit

[0131] 6 storage containers

[0132] 7 Consolidation device

[0133] 8 Nozzle for solidification material

[0134] 9 Retaining wall

[0135] 10 Nozzle for building material

[0136] 11 Construction material

[0137] 12 sections

[0138] 13 component to be manufactured

[0139] 14 Consolidation material

[0140] 15 Support material

[0141] 16 Material addition device

[0142] 17 additional construction material

[0143] 18 functional element

[0144] 19 Development path

[0145] 20 construction area

[0146] 21 shift

[0147] 22 Material accumulation

[0148] 23 layer level

[0149] 24 Solidification area

[0150] 25 angles

[0151] 26 Surface of a layer

Claims

Claims 1. Method for producing components (13) with the aid of a construction device (1), which construction device (1) comprises a material accumulation device (3) which is designed for the layer-by-layer accumulation of material (11, 15, ...) in layer planes (23) by applying the material (11, 15, ...) to a stationary construction surface (20) to form a material accumulation (22), which layer planes (23) are aligned obliquely to the surface of the construction surface (20), wherein the material accumulation device (3) is moved from location to location following a predetermined construction path (19), wherein at preferably each of these locations on the construction surface (20) a layer-by-layer accumulation of material (11, 15, ...) and at at least a number of these locations a selective solidification of certain regions (24) of the layer-by-layer accumulated material (11, 15, ...) in a number of layers (21) of the Material accumulation (22) occurs.

2. Method for producing components (13) with the aid of a construction device (1), which construction device (2) comprises a material accumulation device (3) which is designed for the layer-by-layer accumulation of material (11, 15, ...) in layer planes (23) by applying the material (11, 15, ...) to a stationary construction surface (23) to form a material accumulation (22), which layer planes (23) are aligned obliquely to the surface of the mounting surface (23), which construction device (1) further comprises a material addition device (16) which is designed for the selective application or introduction of material (11, 15, ...) onto or into the material accumulation (22), wherein the material accumulation device (3) is moved from location to location following a predetermined construction path (19), wherein at preferably each of these locations on the construction surface (22) a layer-by-layer accumulation of material (11, 15, ...) takes place and at at least a number of these locations a selective application or introduction of material (11, 15, ...) onto or into the material accumulation (22), and wherein at at least a number of these locations a selective solidification of certain regions (24) of the layer-by-layer accumulated material (11, 15, ...) in a number of layers (21) of the material accumulation (22) and / or a solidification of the material selectively applied to or into the material accumulation (22) material (11, 15, ...) applied or introduced.

3. Method according to claim 1 or 2, characterized in that the layer-by-layer accumulation of the material (11, 15, ...) is carried out in such a way that layer by layer a defined surface (26) of the material accumulation (22) is formed.

4. Method according to one of claims 1 to 3, characterized in that the construction surface (20) is the surface of a property.

5. Method according to one of claims 1 to 4, characterized in that the material accumulation (22) serves at least partially as a support for the at least one component (13) to be produced or one of its parts (12), at least during the period in which the solidification of the at least one component (13) to be produced or its part (12) has not yet taken place to such an extent as to ensure inherent stability of the component (13) or its part (12).

6. Method according to one of claims 1 to 5, characterized in that the material (11, 15, ...) accumulated in layers is a solidifiable material which is subsequently selectively solidified.

7. Method according to one of claims 1 to 6, characterized in that a first material (15, ...) is accumulated in layers and a second material (11, ...) is introduced into the material by displacing the layered first material (15, ...) and / or by filling existing cavities in the layered first material (15, ...) and / or by mixing with the layered first material (15, ...) is either applied layer by layer to the material accumulation (22) or selectively introduced into the material accumulation (22), wherein the first and / or the second material (15, 11, ...) is a solidifiable material and is solidified following the piling or depositing or introduction.

8. Method according to claim 6 or 7, characterized in that additional reinforcing material is introduced into the material accumulation (22).

9. Method according to one of claims 6 to 8, characterized in that in addition at least one functional element (18) is displaced by material (11, 15, ...) and / or by Filling existing cavities in the material (11, 15, ...) is selectively introduced into the material accumulation (22).

10. A construction device (1) for the production of components, comprising a material accumulation device (3) which is designed for the layer-by-layer accumulation of material (11, 15, ...) in layer planes (23) by applying the material (11, 15, ...) to a Construction surface (20) forming a material accumulation (22), which layer planes (23) are aligned obliquely to the surface of the construction surface (20), and a material consolidation device (7) which is designed to selectively solidify certain regions (24) of the accumulated material (11, 15, ...) in a number of layers (21) of the material accumulation (22).

11. Assembly device (1) for the production of components (13), comprising a material accumulation device (3) which is designed for the layer-by-layer accumulation of material (11, 15, ...) in layer planes (23) by applying the material (11, 15, ...) to a construction surface (20) to form a material accumulation (22), which layer planes (23) are aligned obliquely to the surface of the construction surface (20), a material addition device (16) for the selective application or introduction of material (11, 15, ...) onto or into the material accumulation (22), and a material consolidation device (7) which is designed for the selective consolidation of certain regions (24) of the layer-by-layer accumulated material (11, 15, ...) and / or for the consolidation of the material (11, 15, ...) selectively applied to or introduced into the material accumulation (22) in a number of layers (21) the accumulation of material (22) .

12. A build-up device (1) according to claim 10 or 11, comprising a mechanical guide system which defines a build-up path (19) along which the material accumulation device (3) is movable.

13. Construction device (1) according to one of claims 10 to 12, characterized in that the material accumulation device (3) has a frame (4) which is designed as a guide for an accumulation unit (5) movable within and / or along the frame (4).

14. Construction device (1) according to one of claims 10 to 13, characterized in that the material consolidation device (7) is designed for applying or introducing consolidation material (14) and / or Solidification energy on or into the material accumulation (22) for selectively solidifying the material (11, 15, ...).

15. Construction device (1) according to one of claims 10 to 14, comprising a functional element adding device for selectively applying or introducing at least one Functional element (18) onto or into the material accumulation (22).

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