Apparatus for manufacturing three-dimensional objects

Abstract

To provide device for producing a three-dimensional object with the advantage that the operator does not need to be in contact with the device, i.e., the support apparatus and the three-dimensional object to be formed, among other things.SOLUTION: The device for producing three-dimensional object by solidifying a material solidifiable by radiation, especially in layers or continuously, including a support apparatus 16 for holding the solidified three-dimensional object and a removal apparatus 42 for automatically removing the three-dimensional object held on the support apparatus.SELECTED DRAWING: Figure 1

Description

[Technical field]

[0001] The present invention relates to an apparatus for producing three-dimensional objects by solidifying, in particular layer-wise or continuously, a material that can be solidified by radiation, the apparatus comprising a support device for holding the solidified three-dimensional object. [Background technology]

[0002] An apparatus of the type mentioned at the outset in the form of a so-called 3D printer is known, for example, from DE 10 2013 107 571 A1. After completion, i.e. hardening, the solidified three-dimensional object is held on a support device and is still contaminated by unsolidified solidifiable material. When removing the three-dimensional object from the support device, there is a problem in particular that an operator or user of the apparatus may become contaminated. [Prior art documents] [Patent documents]

[0003] [Patent Document 1] DE 10 2013 107 571 A1 Summary of the Invention [Problem to be solved by the invention]

[0004] SUMMARY OF THE DISCLOSURE The object of the invention is therefore to improve an apparatus of the type mentioned at the outset, in such a way that the production of three-dimensional objects is made easier. [Means for solving the problem]

[0005] This object is achieved according to the invention in an apparatus of the type described at the beginning in that the apparatus comprises a removal device for automatically removing the three-dimensional object held on the support device.

[0006] Further development of the device for manufacturing a three-dimensional object in this way has the advantage, in particular, that the operator does not need to come into contact with the device, i.e., in particular with the support device and the three-dimensional object being formed. In particular, such a removal device allows the manufacturing of the three-dimensional object to be fully automated. In this way, the removal operation of the manufactured three-dimensional object can be carried out in a defined and therefore standardized manner, so that the manufacturing time can be significantly reduced. Immediately after the removal of the three-dimensional object using the removal device, the device can be used to manufacture a further three-dimensional object.

[0007] If the removal tool comprises at least one removal element, and this at least one removal element and the support tool are arranged or formed to be movable relative to each other, the device can be formed in a simple manner. Thus, in order to remove the three-dimensional object from the support tool, it is only necessary to move the at least one removal element and the support tool relative to each other. This allows for a movable arrangement or configuration of the at least one removal element and the support tool. In particular, two or more removal elements may be provided. For example, two or more removal elements can be moved in succession relative to the support tool, or the support tool can be moved relative to these removal elements, for optimal separation of the manufactured three-dimensional object.

[0008] If the at least one detachment element comprises one or more blades with cutters or is configured in the form of a blade with at least one cutter, the three-dimensional object held on the support device can be easily and reliably detached. In particular, the cutter may be arranged and moved relative to the support device so that it abuts against the support device or moves relative to the support device at a small distance from the support device. For example, the blade may be configured in the form of a double blade with two cutters. The detachment element may in particular carry or include one, two, three or more blades. In particular, the detachment element may include a support element for one or more blades.

[0009] Advantageously, the blade has a blade body with a front blade body side and a rear blade body side, the blade body having at least one side surface which is inclined with respect to the front blade body side and / or the rear blade body side to form the cutter with a cutting edge. In particular, the blade body may have two inclined side surfaces. Preferably, the cutting edge defines an acute angle between the inclined side surfaces. In particular, if the removal element has several blades, all of the blades may be configured as described above.

[0010] The at least one beveled side preferably forms an obtuse angle with the blade body front side. In this way, the transition between the beveled side and the blade body front side can be made very flat. In particular, the edge rounding between the beveled side and the blade body front side can be made in a simple manner.

[0011] It is further advantageous if the blade body has two inclined sides to form a cutter, the intersection of these two inclined sides defining the cutting edge, in this way a double-sided sharp cutting edge can be formed.

[0012] Advantageously, the at least one beveled side forms an obtuse angle with the rear side of the blade body, which allows for a flat transition between the beveled side and the rear side of the blade body, in particular this transition forming an edge in the case of a plane and which can be rounded in a simple manner.

[0013] Preferably, the blade body has only one inclined side surface which forms an acute angle with the rear side of the blade body, and the intersection line between this inclined side surface and the rear side of the blade body defines the cutting edge. This configuration makes it possible to form the cutting edge in a simple manner.

[0014] If the blade body front side and the blade body rear side extend parallel to one another, the removal element can be formed in a simple and cost-effective manner, thus in particular the removal element can be made from a flat sheet metal.

[0015] According to a further preferred embodiment of the invention, the cutting edge may be defined by two cutting surfaces that define the cutter and meet at a cutting angle, the cutting angle having a value in the range of about 10° to about 50°. In particular, the cutting angle may have a value in the range of about 20° to about 40°. The cutting surface may in particular be formed by an inclined side surface or the rear side of the blade body or the front side of the blade body. A particularly small cutting angle has the advantage that only small forces, in particular shear forces, act on the manufactured three-dimensional object when moving the removal element and the support tool relative to each other. In other words, the removal or chipping of the three-dimensional object from the support tool can be performed in a simple manner with a low risk of damaging the three-dimensional object.

[0016] It is advantageous if the at least one detachment element abuts the support device with its cutting edge when detaching the three-dimensional object or is arranged at a distance from the support device in order to detach the three-dimensional object. The three-dimensional object formed can be chipped off, in particular when the cutting edge abuts the support device. For example, the support device comprises a planar support plate to which the three-dimensional object is attached. With the cutting edge at a distance from the support device, in particular one or several layers of the three-dimensional object can be left on the support device in a targeted manner. This is advantageous, in particular, when the morphology of, for example, the first layer or several layers for forming the three-dimensional object cannot be ensured in a defined and desired manner. Furthermore, in the case of a detachment device comprising two or more cutting edges, the cutting edges can be arranged on the one hand abutting the support device and on the other hand at a distance from the support device. This allows an improved detachment of the three-dimensional object from the support device.

[0017] Preferably, the at least one detachment element and a support surface defined by the support device, on which the three-dimensional object is held, form a detachment angle, in particular if this detachment angle is as small as possible, the minimum deformation of the three-dimensional object can be further kept as small as possible.

[0018] Advantageously, one of the two cutting surfaces faces away from the support surface, and this cutting surface and the support surface form the detachment angle between them. The detachment angle thus forms a wedge angle that defines the detachment, lifting or scraping of the three-dimensional object from the support device. In particular, by appropriately selecting the detachment angle, deformation during detachment of the three-dimensional object can be minimized.

[0019] Preferably, the detachment angle has a value in the range of about 0° to about 20°. In particular, the detachment angle may be in the range of 0° to about 10°. The smaller the detachment angle, the easier it is to detach the three-dimensional object from the support device.

[0020] It is preferred if the device comprises a detachment angle setting device for setting the detachment angle. This allows, in particular, the detachment angle to be changed as required. In particular, a change in the detachment angle may be advantageous if the solidifiable material is changed when using the device. In this way, in particular three-dimensional objects having different hardnesses can be detached at different detachment angles between the detachment element and the support device. The larger the cutting angle, and therefore the detachment angle, the less wear the cutting edge will usually undergo. The smaller the cutting angle, the greater the wear and the higher the risk of damage to the cutting edge.

[0021] If the detachment angle cannot be changed, the detachment tool can be made in a particularly simple and cost-effective manner.

[0022] It is preferred if the removal tool comprises two removal elements arranged at a distance from each other. This allows the introduction of the two removal elements one after the other between the three-dimensional object and the support device in order to separate them from each other. Providing two or optionally more removal elements can ensure a particularly clean removal of the three-dimensional object from the support device. Thus, immediately after removal, further three-dimensional objects can be formed. Further cleaning of the support device or its support surface is not absolutely necessary.

[0023] To achieve a clean separation of the three-dimensional object from the support device, it is preferred that the two cutting edges of the two removal elements are arranged at a distance from each other and that the two cutting edges define cutting edge surfaces that extend parallel or substantially parallel to the support surface. For example, both cutting edges may be abutted against the surface or arranged at a small distance from it. Thus, as described above, the three-dimensional object formed can be separated from the support device in its entirety or with the exception of a small part that remains on the support surface.

[0024] It would further be advantageous if the cutter comprises a serrated cutting edge with a plurality of cutting edge portions arranged offset parallel to one another, which cutting edge portions define a common cutting edge surface extending parallel or substantially parallel to the support surface. In particular, such a serrated cutting edge can be advantageously used if the support device, for example its support plate, has recesses. The first layer of the three-dimensional object may form protrusions that penetrate or protrude into these recesses. This protrusion is removed by successive cutting edges. In particular, the serrated cutting edge may be arranged such that the cutting edge portion that forms its most protruding cutting edge portion is first in contact with the three-dimensional object. This portion can then contact an area of ​​the three-dimensional object that does not protrude into the recess of the support device. This recessed cutting edge portion can then be pushed between the already raised lower surface of the three-dimensional object and the support surface without unintentionally damaging the three-dimensional object. Such a serrated cutting edge can improve the removal of the three-dimensional object from a support plate with recesses in a simple manner.

[0025] It is advantageous if the cutting edge has a front cutting edge portion and a cutting edge portion that is recessed relative to the front cutting edge portion, the cutting angle of the front cutting edge portion being smaller than the cutting angle of the recessed cutting edge portion. Forming such a sawtooth cutter has the advantage, in particular, that the front cutting edge portion with a smaller cutting angle can engage between the three-dimensional object and the support device, and then the recessed cutting edge portion can engage between the three-dimensional object that has already been somewhat removed and the support device. This allows a gentle and reliable removal of the three-dimensional object from the support surface of the support device. In particular, in the case of a support plate of a support device that is provided with recesses or perforations in order to prevent unintentional separation of protrusions on the three-dimensional object, the recessed cutting edge portion of the sawtooth cutting edge can be advantageously used.

[0026] In order to ensure a reliable removal of the three-dimensional object from the support device, it is advantageous if the at least one removal element has an elastic configuration. In this way, a pressing force can be applied to the support device in a simple manner. In this way, in particular, a uniform abutment of the removal element, for example its one or more blades, against the support device can be achieved. In particular, the one or more blades may have an elastic configuration.

[0027] The at least one detachment element is preferably made of a detachment element material, which has a modulus of elasticity with a value ranging from about 100000 MPa to about 250000 MPa. In particular, the detachment element material may have a modulus of elasticity with a value ranging from about 170000 MPa to 210000 MPa. A detachment material with such a modulus of elasticity is in particular a steel with spring elastic properties.

[0028] If the at least one detachment element is at least partially made of metal, in particular the blade, the three-dimensional object can be easily and reliably detached from the support device, thus in particular achieving a long service life of the detachment device.

[0029] If the metal is steel, the removal tool can be made in a cost-effective manner, in particular it can be spring steel, which has the advantage in particular that the at least one removal element can be pressed against the support tool with a defined pretension.

[0030] Advantageously, the removal tool comprises a pressing tool for pressing the at least one removal element against the support surface, in this way it can be ensured that the cutting edge of the at least one removal element always abuts reliably against the support surface during a relative movement with respect to the support surface in order to achieve a defined removal of the three-dimensional object from the support tool.

[0031] If the pressing device comprises at least one pressing element for pressing the at least one detachment element against the support surface, the pressing device can be formed in a simple manner. For example, the support device may comprise a pressing device which presses the support surface against the at least one detachment element by means of a drive means. The pretension can here in particular be set by the path of travel of the support device relative to the at least one detachment element, if the detachment element is made of an elastic or flexible material.

[0032] Advantageously, the removal tool comprises a holding device for holding the at least one removal element. In particular, the holding device can be configured to releasably and connectably hold the at least one removal element. This allows the at least one removal element to be replaced, in particular, if it is damaged, in particular if its cutting edge or cutting edge portion becomes blunt or broken.

[0033] It is preferred if the at least one detachment element is held on the holding device in a holding position and detached from the holding device in a detaching position, this configuration in particular making it possible to replace the detachment element as required in the above-mentioned manner.

[0034] It is advantageous if the holding device and the support device are arranged to be displaceable relative to one another. In this way, in particular the removal element held by the holding device can be moved relative to the support device or the support device can be moved relative to the at least one removal element. In particular, the holding device and the support device can be arranged to be displaceable relative to one another parallel to the support surface. This makes it possible in particular to move the at least one removal element parallel to the support surface or to move the support surface parallel to the at least one removal element, in particular parallel to its cutting edge or cutting edge portion.

[0035] According to a preferred embodiment of the invention, the removal tool, in particular the at least one removal element and the support tool, may be disengaged in a build position, where at least one three-dimensional object is formed by solidifying the radiation-solidifiable material, in particular in layers or continuously, and may be in contact with each other in a removal position, where the at least one three-dimensional object is separated from the support tool. The removal element and the support tool may cooperate as described above to remove the at least one three-dimensional object from the support tool. In the build position, the removal tool may be arranged in particular retracted and optionally protected to allow unhindered solidification of the material to be solidified to form the at least one three-dimensional object.

[0036] It is preferred if the device comprises a protective device for protecting the removal tool, in particular in the modeling position, which may in particular serve to protect the removal tool from contamination with solidifiable material which may in particular impair the cutting effect of a removal element having a cutter.

[0037] The protective device preferably comprises at least one protective element for protecting the at least one removal element, which may in particular be configured to protect the blade, in such a way that contamination or damage to the at least one removal element at the modeling position can be prevented or at least the risk of contamination or damage can be reduced.

[0038] According to a further preferred embodiment, the apparatus may comprise a drive tool for moving the removal tool and the support tool relative to each other. In particular, this drive tool allows the apparatus to be moved from the modeling position to the removal position and vice versa. To allow this relative movement, the drive tool may in particular be directly or indirectly coupled to the removal tool and / or to the support tool. The drive tool may optionally be coupled only to the removal tool or only to the support tool in order to move only the removal tool or only the support tool.

[0039] Advantageously, the driving device is adapted to cooperate with the holding device to move the holding device relative to the apparatus, in particular the driving device is capable of moving the holding device relative to the support device.

[0040] Advantageously, at least one of the driving instruments is configured to cooperate with the support instrument to move the support instrument parallel to the support surface relative to the device. For example, the removal instrument may be arranged or formed stationary, in particular immovable, relative to the device. To remove the three-dimensional object from the support instrument, the support instrument can then be moved by the at least one of the driving instruments, in particular relative to the removal instrument.

[0041] It is preferred if the apparatus comprises a container for the solidifiable material, the support device being arranged so as to be movable in a direction parallel or substantially parallel to the direction of gravity, as well as in a direction counter or substantially counter to the direction of gravity. This configuration in particular allows the solidifiable material contained in the container to be solidified in layers, thus forming a three-dimensional object on the support device. The support device can then run parallel or counter to the direction of gravity, so that the three-dimensional object can be further formed in layers or continuously.

[0042] The device preferably comprises a collection container for the three-dimensional object detached from the support device, which in particular can prevent the detached three-dimensional object from falling into the container for the solidifiable material after being detached from the support device. The collection container may in particular be arranged or formed spatially adjacent to the container for the solidifiable material, in particular below at least one removal element, so that the detached three-dimensional object can automatically fall into the collection container from the support device moving on the at least one removal element.

[0043] It is preferred if the collection vessel, in particular its bottom, is perforated so that unsolidified settable material can be drained from the collection vessel, this configuration in particular facilitates the removal of not yet solidified settable material from the detached three-dimensional object.

[0044] To facilitate removal of unset solidifiable material from the collection vessel, the collection vessel advantageously has a bottom that is inclined relative to the direction of gravity.

[0045] According to a further preferred embodiment of the invention, the at least one removal element may be arranged or formed immovably on the device, in particular with respect to the container for the solidifiable material, and the support device may be arranged on the device to be movable in a direction or plane crossing the direction of gravity. The at least one removal element may be arranged on the device, in particular spatially adjacent to the container for the solidifiable material. To remove the three-dimensional object from the support device, the support device can be moved on the removal element in a direction crossing the direction of gravity to remove the three-dimensional object. If the at least one removal element is arranged adjacent to the container for the solidifiable material, the removed three-dimensional object cannot fall into the container. Furthermore, it is easier to then arrange a collection container or a transport device below the removal element to catch and optionally further transport the removed three-dimensional object.

[0046] It may further be advantageous if the at least one detachment element is arranged on the device such that it is movable in a plane or direction extending transversely to the direction of gravity, in particular if the support device can only be moved parallel and against the direction of gravity, the at least one detachment element can thus be moved beyond the support device in order to detach the three-dimensional object held on the support device.

[0047] The collection container is preferably arranged on the device so as to be movable in a plane or direction extending transversely to the direction of gravity. This configuration is particularly advantageous when the at least one removal element is arranged on the device so as to be movable in a plane or direction extending transversely to the direction of gravity. The collection container can then be moved to a position below the support device so that the three-dimensional object separated by the at least one removal element can be captured by the collection container.

[0048] It is preferred if the collection container is arranged to be movable in synchronism with the at least one removal element or independently of the at least one removal element. Synchronous movability has the advantage in particular that the collection container can always be moved automatically, for example in conjunction with the movement of the at least one removal element, to the location where the three-dimensional object is to be removed from the support device and that the removed three-dimensional object can be captured in the collection container simply and reliably. Mobility of the collection container independent of the at least one removal element has the advantage in particular that the collection container only has to be moved to the capture position when the three-dimensional object is actually removed from the support device.

[0049] The collection container is preferably arranged below the at least one removal element in the direction of gravity or is movably arranged below the removal element, so that the removed three-dimensional objects can fall directly into the collection container due to the gravity acting on them.

[0050] According to a further preferred embodiment of the invention, the apparatus may comprise a transport device for the three-dimensional object detached from the support device, which transport device may in particular be configured or comprise in the form of a conveyor belt, by means of which the detached three-dimensional object can be further transported in a particularly fast and simple manner to a post-processing device, for example in the form of a subsequent exposure device, which can fully harden the detached three-dimensional object if it has not yet been fully hardened.

[0051] It is further preferred if the device comprises a pivoting device for pivoting the three-dimensional object detached from the support device. For example, the pivoting device may be configured to pivot the three-dimensional object collected in the collection container, for example by 180°. The pivoting device may be configured to pivot the detached three-dimensional object collected on a transport device, in particular by 180°. For example, the pivoting device may be configured in the form of or include a pivoting flap onto which the detached three-dimensional object falls after detachment from the support device, and the pivoting flap is pivoted or folded by an angle of at least 90°, preferably at least 120°, in order to pivot the detached three-dimensional object about a pivot axis extending in a direction transverse to the direction of gravity.

[0052] For further explanation, preferred embodiments are described below in conjunction with the drawings. [Brief description of the drawings]

[0053] [Figure 1] 1 is a schematic perspective, partially cutaway, overall view of an embodiment of an apparatus for manufacturing a three-dimensional object; [Diagram 2] 2 is a perspective view of a portion of the apparatus of FIG. 1 with a support plate immersed in a container having material that can be solidified during formation of a three-dimensional object. [Diagram 3] 3 is a view similar to FIG. 2, but with the completed three-dimensional object held on a support plate. [Figure 4]2 and 3, a further perspective view of the portion of the apparatus of FIG. 1 during removal of the three-dimensional object from the support plate; [Diagram 5] FIG. 5 is a partial cutaway front view of the arrangement of FIGS. 2 to 4 before the three-dimensional object is removed from the support plate. [Figure 6] FIG. 6 is an enlarged cross-sectional view of area A in FIG. 5 . [Figure 7] 7 is a view similar to FIG. 6 of the three-dimensional object partially detached from the support plate. [Figure 8] 8 is a view similar to FIG. 7 after the three-dimensional object has been completely detached from the support plate. [Figure 9] 2 is a schematic perspective, partially cutaway overall view of a further embodiment of an apparatus for manufacturing a three-dimensional object; FIG. [Figure 10] FIG. 10 is a perspective view of a portion of the apparatus of FIG. [Figure 11] 11 is a view of the arrangement of FIG. 10 in the direction of arrow B. [Figure 12] 12 is a view of the arrangement of FIG. 11 in the direction of arrow C. [Figure 13] FIG. 10 is an enlarged cross-sectional view of region D in FIG. [Figure 14] 14 is a cutaway view taken along line 14-14 of FIG. 12. [Figure 15] FIG. 15 is a partial enlarged view of the arrangement of FIG. 14 prior to separation of the three-dimensional object held on the support plate. [Figure 16] 16 is a view similar to FIG. 15 during separation of the three-dimensional object from the support plate. [Figure 17a] FIG. 13 is a schematic partial cutaway view of an embodiment of a removal element cooperating with a support plate before removal of the three-dimensional object. [Figure 17b] A view in the direction of arrow E in FIG. 17a. [Figure 18a] FIG. 13 is a schematic partial cutaway view of a further embodiment of a removal element cooperating with the support plate before removal of the three-dimensional object. [Figure 18b] A view in the direction of arrow F in FIG. 18a. [Figure 19a] FIG. 13 is a schematic partial cutaway view of a further embodiment of a removal element cooperating with the support plate before removal of the three-dimensional object. [Figure 19b]A view in the direction of arrow G in FIG. 19a. [Figure 20a] FIG. 13 is a schematic partial cutaway view of a further embodiment of a removal element cooperating with the support plate before removal of the three-dimensional object. [Figure 20b] A view in the direction of arrow H in FIG. 20a. [Figure 21a] FIG. 13 is a schematic partial cutaway view of a further embodiment of a removal tool cooperating with the support plate, prior to removal of the three-dimensional object; [Figure 21b] A view in the direction of arrow H in FIG. 21a. [Figure 22] Schematic illustration of a further embodiment of an apparatus for manufacturing a three-dimensional object. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0054] FIG. 1 shows a first embodiment of an apparatus 10 for producing a three-dimensional object by solidifying, in particular layer-wise or successively, a material that can be solidified by radiation.

[0055] The apparatus 10 includes a container 12 for the settable material. The container 12 is configured in the form of a flat tray 14.

[0056] The apparatus 10 further includes a support device 16 for holding the solidified three-dimensional object 18 .

[0057] The solidifiable material is not shown for clarity.

[0058] The apparatus 10 includes a radiation source 20, shown diagrammatically in Figure 1, for generating electromagnetic radiation that solidifies the solidifiable material. The radiation is imaged in a build plane by an imaging fixture 22, also shown diagrammatically in Figure 1. The build plane extends in a direction transverse to the direction of gravity, represented by arrow 24. The radiation source 20 and the imaging fixture 22 form part of an exposure apparatus for selectively exposing the build plane.

[0059] The bottom 26 of the container 12 is configured to be transparent to radiation, and a radiation source 20 positioned below the container 12 in the direction of gravity can solidify the solidifiable material contained in the tray 14 from below by exposure to radiation.

[0060] The support device 16 includes a support plate 28 that defines a planar support surface 30 that faces the tray 14 .

[0061] The apparatus 10 includes a drive device 32 for displacing the support device 16 on the holding frame to move the support device 16 in a direction parallel or substantially parallel to the direction of gravity, as well as in a direction opposite or substantially opposite to the direction of gravity.

[0062] The support device 16, movably arranged on the holding frame 34, comprises a sliding device 36 oriented transverse to the direction of gravity with a guide rail 38. The guide rail 38 extends transverse to the direction of gravity and serves to displaceably mount the support plate 28. A further drive device 40 allows a controlled relative movement of the support plate 28 in the direction transverse to the direction of gravity.

[0063] The apparatus 10 further includes a removal device 42 for automatically removing the three-dimensional object 18 held by the support device 16 .

[0064] For example, in the embodiment of the apparatus 10 shown in Figures 1 to 8, the removal tool 42 includes a removal element 44. The support tool 16, i.e. that portion thereof including the support plate 28, is arranged to be movable relative to the removal element 44. This is achieved by the removal element 44 being fixedly fixed to a frame 46 of the apparatus 10. The support plate 28, as described above, is arranged to be displaceable relative to the frame 46 in a direction transverse to the direction of gravity.

[0065] The removal element 44 includes a blade 48 with a cutter 50 facing toward the support plate 28 .

[0066] The construction of the blades 48 is described in more detail below in conjunction with Figures 17a to 20b.

[0067] In the embodiment of the device 10 shown in Figures 1 through 8, the removal element 44 is oriented and aligned with respect to the direction of gravity which is unalterable.

[0068] The removal tool 42 includes a retaining tool 52 for retaining the removal element 44. In a retaining position, as shown, for example, in Figures 1 to 8, the retention element 44 is retained on the retention tool 52. In a detached position, not shown, the removal element 44 is completely detached from the retention tool 52.

[0069] The removal element 44 is secured to the retainer 52 by a screw 54 .

[0070] The support device 16, of which the support plate 28 is a part, is arranged so as to be displaceable relative to the holding device 52, i.e. parallel to the support surface 30. To achieve this, the holding device 52 is arranged on the frame 46.

[0071] The apparatus 10 is configured such that the support device 16 is disengaged from the removal tool 42 with the removal element 44 in a build position where an object 18 is formed by solidifying a radiation-solidifiable material. Figures 1 to 3 show the build position as an example.

[0072] To remove the object 18 held on the support plate 28, the removal tool 42 with the removal element 44 in the removal position contacts the support plate 28. In this removal position, the object 18 is separated from the support tool 16, i.e., from the support surface 30 of the support plate 28. Figures 4 to 8 illustrate various removal positions, in which the removal element 44 engages the support plate 28 in different positions.

[0073] The apparatus 10 may optionally include a protective device 56, shown diagrammatically in Figure 1, which serves to protect the removal device 42. In particular, the protective device 56 may cover the removal element 44 in the modeling position, in particular to protect the cutter 50 from damage.

[0074] The protective device 56 comprises a protective element 57 for protecting the removal element 44 , in particular for protecting the blade 48 .

[0075] As noted above, the driving tool 40 functions to move the removal tool 42 and the support tool 16, of which the support plate 28 is a part, relative to one another. In the embodiment of the apparatus 10 illustrated in Figures 1-8, the driving tool 40 is configured to cooperate with the support tool 16 to move the support tool 16, of which the support plate 28 is a part, relative to the apparatus 10, and in particular its frame 46, parallel to the support surface 30.

[0076] To form the three-dimensional object, as shown diagrammatically in FIG. 2, support plate 28 is moved into tray 14 by drive tool 32 until support surface 30 contacts the solidifiable material.

[0077] Here, the solidifiable material can be exposed by the radiation source 20 and the imaging device 22 in the desired manner, i.e., in a plane tangent to the support surface 30, i.e., in the build plane, and a first layer of solidifiable material is formed directly on the support surface 30 of the support plate 28.

[0078] Here, the support fixture 16 is moved, in a stepwise or continuous manner, from the tray 14 by the drive fixture 32 and radiation is applied to the solidifiable material, in a layered or continuous manner, to solidify the material and form the object 18.

[0079] When the object 18 is completed, the support device 16 with the support plate 28 is moved away from the tray 14 so that the support plate 28 can be displaced by the drive device 40 parallel to the support surface 30 towards the removal device 42 until the removal element 44 contacts the support plate 28.

[0080] As shown diagrammatically in FIGS. 6 and 7, the blade 48 is wedged between the object 18 and the support surface 30 while the support plate 28 is gradually displaced over the removal element 44 .

[0081] As soon as the removal element 44 completely scrapes the object 18 off the support surface 30 , the object 18 falls onto an impact surface 58 and from there can fall into a catch bin 60 , as shown diagrammatically in FIG.

[0082] Now, the support plate 28 from which the object 18 has been released as described above can be driven by the driving tool 40 back to a position from which it can be returned by the driving tool 32 back into the container 12 .

[0083] Thus, by means of the apparatus 10, three-dimensional objects of virtually any shape can be produced and automatically removed from the support fixture 16. This allows for a continuous production process: manual removal of the object 18 from the support plate 28 is not necessary.

[0084] A second embodiment of an apparatus 10 for producing a three-dimensional object 18 by solidifying a radiation-solidifiable material is shown diagrammatically in Figures 9 to 16. In the embodiment shown in Figures 9 to 16, components that are the same or functionally equivalent to those in the embodiment of the apparatus 10 shown in Figures 1 to 8 are provided with the same reference numerals.

[0085] Further embodiments of the device 10 are described in more detail below in conjunction with FIGS.

[0086] A driving tool 32 is disposed on the frame 16 for moving the support tool 16 with a support plate 28 including a support surface 30 facing towards the container 12 for containing the solidifiable material parallel and against the direction of gravity represented by the arrow 24. Here, the support plate 28 can be moved exclusively parallel or against the direction of gravity.

[0087] The apparatus 10 also includes a removal tool 42 having a removal element 44. The removal element 44 is configured in the form of a blade 48 having a cutter 50.

[0088] The removal element 44 is replaceably secured to the retainer 52 by a screw 54 .

[0089] The retaining device 52 includes two retaining elements 62 spaced apart from one another, each of which is secured by a screw 54 at one of two oppositely facing end regions 64 .

[0090] The retaining elements 62 are each retained on a bearing body 68 so as to be pivotable about a pivot axis 66 .

[0091] The retaining element 62 and the cooperating bearing body 68 together form a release angle setting device 70 for setting the orientation of the release element 44 relative to the direction of gravity.

[0092] The holding device 52 is configured to interact with the driving device 40. The driving device 40 drives a drive shaft 72 on which two gears 74 are held in a rotatably fixed manner at a distance from each other, so that they can be set to rotate synchronously with the driving device 40. The gears 74 serve to drive respective toothed belts 76. The toothed belts 76 are each tensioned by a further gear 78.

[0093] Each of the bearing bodies 68 is fixed to one of two toothed belts 76. Therefore, as a result of the rotation of the drive shaft 72, the toothed belts 76 move, which allows the bearing bodies 68 to be displaced in a direction crossing the direction of gravity. Thus, the blades 48 fixed to the holding devices 52 are also displaced in a direction crossing the direction of gravity.

[0094] To remove the three-dimensional object 18 from the support plate 28, the support device 16 is moved by the drive device 32 away from the container 12 in a direction opposite to the direction of gravity, i.e., until the support surface 30 is at the same height as the cutter 50 of the blade 48.

[0095] The removal element 44 is now moved by the drive tool 40, i.e. parallel to the support surface 30. In this way, the holding tool 52 moves relative to the device 10, for example its frame 46.

[0096] Starting from a build position, shown diagrammatically in Figures 9 to 12, in which the removal element 44 and the support device 16 are disengaged, the holding device 52 moves together with the removal element 44 to a removal position in which the object 18 is separated from the support device 16. There, the removal element 44 comes into contact with the support surface 30, as shown diagrammatically in Figures 15 and 16. Now, the blade 48 is forced successively between the object 18 and the support surface 30, chipping the object 18 from the support plate 28, as shown diagrammatically in Figure 16.

[0097] 9 to 16, the three-dimensional object can also be produced in a fully automated manner and automatically detached from the support device 16 by means of the removal device 42. This allows a continuous production process which can be carried out in a fully automated manner.

[0098] Various embodiments of the removal element 44 are described below in relation to Figures 17a to 20b.

[0099] An embodiment of a removal element 44 in the form of a blade 48 is shown in Figure 17a. The blade 48 includes a blade body 80 with a blade body leading side 82 and a blade body trailing side 84. The blade body 80 has a side 86 that is angled relative to the blade body leading side 82 to form a cutter 50 with a cutting edge 88.

[0100] The angled side 86 forms an oblique angle 90 with the blade body front side 82 .

[0101] The blade body 82 has a single angled side 86. The angled side 86 forms an acute angle 92 with the blade body rear side 84. The intersection of the angled side 86 and the blade body rear side 84 defines a cutting edge 88.

[0102] The blade body front side 82 and the blade body rear side 84 extend parallel to one another.

[0103] The cutting edge 88 is defined by cutting surfaces 94 and 96 that define the cutter 50 and meet at a cutting angle 98. The two cutting surfaces 94 and 96 are defined by the angled side surface 86 and the blade body rear side 84. Thus, the acute angle 92 defines the cutting angle 98.

[0104] Preferably, the cut angle 98 has a value in the range of 10° to about 50°.

[0105] To remove the object 18, the removal element 44 abuts the support surface 30 of the support device 16 with the cutting edge 88. Alternatively, the removal element 44 may be positioned at a small distance between the cutting edge 88 and the support device 16.

[0106] The detachment element 44 and the support surface 30 of the support device 16 form a detachment angle 100. This angle is defined by the cutting surface 94, which faces away from the support surface 30, and the support surface 30.

[0107] The embodiment of the blade 48 shown in FIGS. 17 a and 17 b is configured such that the angled side 86 and the support surface 30 form a removal angle 100 .

[0108] In both this embodiment and the three additional embodiments described below, the detachment angle 100 is preferably in the range of 0° to about 20°.

[0109] In the embodiment of the device 10 shown in Figures 9 to 16, the detachment angle 100 is configurable. In contrast, the detachment angle 100 in the embodiment of the device 10 shown in Figures 1 to 8 is non-variable.

[0110] The removal element 44 has a resilient configuration.

[0111] The release element 44 is made from a release element material having a modulus of elasticity ranging from about 100,000 MPa to 250,000 MPa.

[0112] The removal element 44, and thus the blade 48 contained therein, is made of metal. The metal is steel, i.e. spring steel.

[0113] In both of the above embodiments of the device 10, the removal tool 42 comprises a pressing tool 102 for pressing the removal element 44 against the support surface 30. In both cases, the pressing tool 102 comprises a drive tool 32 capable of pressing the support plate 28 against the removal element 44. The elastic removal element 44 is thus pressed by the cutting edge 88 against the support surface 30 under a slight pretension.

[0114] A further embodiment of a removal element 44 in the form of a blade 48 is shown in Figures 18a and 18b.

[0115] Here, the blade body 80 has two beveled sides 86 and 87. The two beveled sides 86 and 87 define cutting surfaces 94 and 96. The cutting surfaces 94 and 96 meet at the cutting edge 88.

[0116] Both side 86 and side 87 form acute angles 90 and 91 with blade body front side 82 and blade body rear side 84, respectively.

[0117] A removal angle 100 is then defined between the cutting surface 94 and the support surface 30 .

[0118] The embodiment of the removal element 44 shown in Figures 19a and 19b includes a cutter 50 with a serrated cutting edge 88. The cutting edge 88 includes parallel offset cutting edge portions 104 and 106 that define a common cutting edge surface 108. The cutting edge surface 108 may extend parallel to the support surface 30 or may be inclined relative to the support surface. In the embodiment of the removal element 44 shown in Figures 19a and 19b, the cutting edge surface 108 is defined by the blade body rear side 84.

[0119] The cutting edge 88 has a leading cutting edge portion 104 and a recessed cutting edge portion 106 relative to the leading cutting edge portion 104. The cutting angle 98 of the leading cutting edge portion 104 is less than the cutting angle 99 of the recessed cutting edge portion 106.

[0120] To remove the object 18, as shown diagrammatically in Figure 19b, the serrated cutting edge 88 is preferably positioned such that the leading cutting edge portion 104 engages between the perforations 110 in the support plate 28. If the object 18 forms a protrusion that projects into the perforation 110, the object 18 is first lifted slightly by the cutting edge portion 104 and then further chipped away from the support surface 30 by the cutting edge portion 106 moving over the perforation 110.

[0121] The embodiment of the removal tool 42 shown diagrammatically in Figures 20a and 20b comprises two removal elements 44 arranged at a distance from each other, which may in particular be configured in the form of the embodiment of the removal element 44 shown diagrammatically in Figures 17a to 19b.

[0122] To remove the object 18, the cutting edges 88 abut the support surface 30. The two cutting edges 88 define a cutting edge surface 108. The cutting edge surface 108 is defined by the support surface 30.

[0123] Figures 21a and 21b show a schematic representation of an embodiment of a removal tool 42 with two removal elements 44. The removal elements 44 are configured like the removal element 44 shown in Figures 19a and 19b, which includes a cutter 50 with a serrated cutting edge 88. Thus, in Figures 21a and 21b, the same reference numbers are used to refer to the removal elements 44 as in Figures 19a and 19b.

[0124] The two removal elements 44 are arranged such that their front cutting edge portions 104 are arranged offset with respect to each other. The serrated cutting edge 88 of the front removal element 44 can preferably be arranged such that its front cutting edge portion 104 engages between the perforations 110 of the support plate 28, as shown diagrammatically in Fig. 21b. If the object 18 forms a protrusion protruding into the perforation 110, the object 18 is first slightly lifted by the cutting edge portion 104 and then further chipped away from the support surface 30 by the cutting edge portion 104 of the lagging removal element 44 which then moves over the perforation 110.

[0125] The blade 48 of the embodiment of the removal element 44 shown in Figures 18a to 21b is made from the removal element materials and has the properties described above.

[0126] A further embodiment of an apparatus 10 for manufacturing a three-dimensional object is shown diagrammatically in Figure 22. The embodiment of the apparatus 10 diagrammatically shown in Figure 22 corresponds substantially in its structure to the embodiment of the apparatus 10 shown in Figures 9 to 16. Therefore, the same reference numbers as in Figures 9 to 16 are used to refer to the elements shown in Figure 22.

[0127] 22 is further provided with a collection container 112 that is movable in a direction or plane transverse to the direction of gravity 24, represented by arrow 114, i.e., below the removal element 44. The removal element 44 is also movable in a direction transverse to the direction of gravity 24 in order to remove the solidified three-dimensional object 18 held on the support surface 30 from the support plate 28.

[0128] The collection container 112 has a bottom 116 that is inclined relative to the direction of gravity 24 and includes a plurality of perforations 120, as well as a container wall 118 that projects from the bottom 116 in a direction transverse to the direction of gravity 24. The perforations 120 allow unsolidified settable material to drip off of the objects 18 as said objects 18 are collected in the collection container 112 and to be drained from the collection container 112, for example into the tray 14.

[0129] The collection container 112 can be moved using a drive tool (not shown) like the removal element 44. For example, the collection container 112 can also be held on a toothed belt, which is shown in FIG. 22 and designated by reference number 76 for moving the removal element 44.

[0130] The device 10 may optionally further comprise a transport device 120 with a conveyor belt 122 capable of emptying the objects 18 collected in the collection bin 112, as shown diagrammatically in Fig. 22. For this purpose, the conveyor belt 122 is arranged below the collection bin 112, which is movable in the direction of gravity 24.

[0131] To orient the object 18 in a desired direction, the apparatus 10 may further optionally include a pivoting device 124, as shown diagrammatically in Fig. 22, for example to rotate the object 18 by 180°. In particular, the pivoting device 124 may include a pivoting flap around which the object 18 falls after being removed from the support device 16, and which may be pivoted or folded about a pivot axis extending transverse to the direction of gravity 24 by a pivot angle of at least 90°, preferably at least 120°, in order to pivot the object 18.

[0132] As already mentioned, the removal element 44 of the device 10, as described in relation to Figures 1 to 16 and 22, may optionally be configured in the form of one of the embodiments of the removal element 44 described in relation to Figures 17a to 22. [Explanation of symbols]

[0133] 10...device 12…Container 14…Tray 16...Support equipment 18…object 20…Radiation source 22...Imaging equipment 24…Arrow 26...bottom 28…Support plate 30...support surface 32...Drive equipment 34…Retaining frame 36...Slide device 38…Guide rail 40...Drive equipment 42…Removal tool 44…Removable element 46…Frame 48…Blade 50…Cutter 52...Holding device 54…Screw 56...Protective equipment 57…Protection elements 58…Collision surface 60…Capture container 62...Holding element 64...End area 66...Pivot shaft 68...Bearing body 70…Removable angle setting tool 72…Drive shaft 74…Gear 76…Toothed belt 78…Gear 80…Blade body 82…Front side of blade body 84…Rear side of blade body 86…Side 87…Side 88…Cutting edge 90...Angle 91...Angle 92...Angle 94…Cut surface 96...Cut surface 98...Cutting angle 99...Cutting angle 100…Removal angle 102...Pressing device 104…Tip of blade 106…Tip of blade 108…Cutting edge 110…perforation 112…Collection container 114…Arrow 116...Bottom 118…Container wall 120…perforation 122...Transportation equipment 124...Conveyor belt 126...Rotating device

Claims

1. 1. An apparatus (10) for producing a three-dimensional object (18) by solidifying a radiation solidifiable material, the apparatus (10) comprising a support device (16) for holding the solidified three-dimensional object (18), the apparatus comprising: the apparatus (10) including a removal device (42) for automatically removing the three-dimensional object (18) held on the support device (16); the removal tool (42) includes at least one removal element (44), and the at least one removal element (44) and the support tool (16) are arranged or configured to be movable relative to one another; said at least one detachment element (44) comprises a blade (48) equipped with a cutter (50) or said at least one detachment element (44) is configured in the form of a blade (48) equipped with at least one cutter (50); the blade (48) having a blade body (80) with a blade body leading side (82) and a blade body trailing side (84), the blade body (80) having at least one inclined side (86) that is inclined relative to the blade body leading side (82) and / or the blade body trailing side to form the cutter (50) with a cutting edge (88); the at least one detachment element (44) having a resilient configuration; said at least one detachment element (44) being made from a detachment element material, said detachment element material having a modulus of elasticity having a value in the range of 100,000 MPa to 250,000 MPa; said at least one detachment element (44) being at least partially made of metal; and At least one of the following a) and b): a) the blade body front side (82) and the blade body rear side (84) extend parallel to one another; b) said cutting edge (88) is defined by two cutting surfaces (94, 96) that define said blade (50) and that meet at a cutting angle (98), said cutting angle (98) having a value in the range of 10° to 50°; An apparatus comprising:

2. 2. The apparatus of claim 1, wherein said at least one beveled side (86) forms an obtuse angle (90) with said blade body front side (82).

3. 3. The device according to claim 1 or 2, a) the blade body (80) has two inclined sides (86, 87) to form the cutter (50), and the intersection of the two inclined sides (86, 87) defines the cutting edge (88); or b) the blade body (80) has a single beveled side (86) that forms an acute angle (92) with the blade body rear side (84), and the intersection of the beveled side (86) with the blade body rear side (84) defines the cutting edge (88); An apparatus comprising:

4. 4. The apparatus according to claim 1, wherein the at least one detachment element (44) and a support surface (30) defined by the support device (16), on which the three-dimensional object (18) is held, form a detachment angle (100).

5. 5. The apparatus according to claim 4, At least one of the following a) to d): a) one of the two cutting surfaces (94, 96) faces away from the support surface (30) and the one cutting surface (94) and the support surface (30) form the detachment angle (100) between the one cutting surface (94) and the support surface (30); b) said inclined side (86) facing away from said support surface (30) and said support surface (30) form said removal angle (100); c) said detachment angle (100) has a value ranging from 0° to 20°; d) the device (10) includes a detachment angle setting tool for setting the detachment angle (100) or the detachment angle (100) is not alterable; An apparatus comprising:

6. 6. The device according to claim 1, wherein the removal tool (42) comprises two removal elements (44) arranged at a distance from each other.

7. 7. The apparatus according to claim 6, the two cutting edges (88) of the two removal elements (44) are spaced apart from each other; and the two cutting edges (88) defining cutting edge surfaces (108) extending parallel or substantially parallel to a support surface (30) defined by the support device (16) on which the three-dimensional object (18) is held; An apparatus comprising:

8. 8. The apparatus according to claim 1 , the cutter (50) includes a serrated cutting edge (88) with a plurality of cutting edge portions (104, 106) arranged parallel to one another and offset from one another, and the serrated cutting edge (88) defines a common cutting edge surface (108) that extends parallel to or is inclined relative to a support surface (30) defined by the support device (16) on which the three-dimensional object (18) is held; An apparatus comprising:

9. 9. The apparatus of claim 8, the cutting edge (88) having a leading cutting edge portion (104) and a cutting edge portion (106) that is recessed relative to the leading cutting edge portion (104); and the cutting angle (98) of the leading cutting edge portion (104) is less than the cutting angle (99) of the recessed cutting edge portion (106); An apparatus comprising:

10. 10. The device according to any one of claims 1 to 9, characterized in that the at least one removal element (44) abuts with its cutting edge (88) against the support device (16) or is positioned at a distance from the support device (16) when removing the three-dimensional object (18) in order to remove the three-dimensional object (18).

11. 11. The apparatus according to claim 1, wherein the removal tool (42) comprises a pressing tool (102) for pressing the at least one removal element (44) against a support surface (30) defined by the support tool (16) on which the three-dimensional object (18) is held.

12. 12. The device according to claim 11, characterized in that the pressing tool (102) comprises at least one pressing element for pressing the at least one detachment element (44) against the support surface (30).

13. 13. The device according to any one of the preceding claims, characterized in that the removal tool (42) comprises a holding tool (52) for holding the at least one removal element (44).

14. 14. The apparatus of claim 13, At least one of the following a) and b): a) the at least one detachment element (44) is held on the holding device (52) in a holding position and detached from the holding device (52) in a detaching position; b) the holding device (52) and the support device (16) are arranged so as to be displaceable relative to each other; An apparatus comprising:

15. 15. An apparatus according to any one of claims 1 to 14, At least one of the following a) and b): a) the removal tool (42) and the support tool (16) are disengaged at a building position, where at least one three-dimensional object (18) is formed by solidifying the radiation solidifiable material, and are in contact with each other at a removal position, where the at least one three-dimensional object (18) is separated from the support tool (16); b) the device (10) includes a protective device (56) for protecting the removal device (42); An apparatus comprising:

16. 16. The apparatus according to claim 1, wherein the apparatus (10) includes at least one driving tool (40) for moving the removal tool (42) and the support tool (16) relative to each other.

17. 17. An apparatus according to any one of claims 1 to 16, At least one of the following a) and b): a) the apparatus (10) comprises a container (12) for the solidifiable material and the support device (16) is arranged so as to be movable in a direction parallel or substantially parallel to the direction of gravity (24) as well as in a direction opposed or substantially opposed to the direction of gravity (24); b) the apparatus (10) includes a collection container (112) for the three-dimensional object (18) that is detached from the support device (16); An apparatus comprising:

18. 18. An apparatus according to any one of claims 1 to 17, a) the at least one detachment element (44) is arranged or formed on the device (10) so as to be immobile, and the support device (16) is arranged on the device (10) so as to be movable in a direction or plane intersecting with the direction of gravity (24); or b) the at least one removal element (44) is arranged on the device (10) so as to be movable in a plane or direction extending transversely to the direction of gravity (24); An apparatus comprising:

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