Method for additional formation of 3D objects by layering basic blocks

Abstract

The method for additively forming a 3D object by layering solid base blocks (3) includes the steps of: (a) arranging at least one guide element (2) oriented in the direction of forming the 3D object; (b) depositing a first layer including at least one solid base block (3) on a horizontal line of the first layer; and (c) depositing at least one further layer including at least one solid base block (3) on a horizontal line spatially spaced apart from the horizontal line of the first layer in the direction of forming the 3D object, wherein at least one base block (3) of at least one layer is arranged using at least one cooperating means (4) arranged within the area of ​​the at least one guide element (2) and cooperating with the at least one guide element (2). The 3D object can also include various solid base blocks (3). It is advantageous if the first layer is arranged on a base plate (1). It is advantageous if the at least one base block (3) is arranged using a fastening means (5), for example, an adhesive. It is advantageous if after step c) the base plate (1) and / or the at least one inductive element (2) are removed. The 3D object can be strengthened by a thermal process.

Description

[Technical field]

[0001] The present invention relates to a method for additively forming 3D objects by layering basic blocks. The present invention belongs to the field of additive manufacturing of 3D objects. [Background technology]

[0002] Additive technologies for the fabrication of spatial objects using 3D printers are currently known and are based on the same basic principle: creating an object using digital design data by gradually solidifying a fusible material layer by layer. Additive technologies for the fabrication of spatial objects using 3D printers produce objects of various sizes, shapes, and structures. There are several 3D printing methods, each with advantages and disadvantages, depending on price, speed, accuracy, and the materials used. In fused deposition modeling, plastic fibers are fed into the printer, melted, and applied in layers that gradually solidify. A distinctive document describing this technology is WO 2018 / 223043 A1, which also uses a support beam. In selective laser sintering, a fine powder (metal or plastic) is applied and selectively fired by a moving laser, burning it into the underlying layers. This allows for the use of a wide variety of materials. A characteristic document describing this technique is Japanese Patent Publication No. 2019 / 147343A, in which a supporting object is also used. In stereolithography, a photosensitive liquid resin is irradiated with a laser or UV light, which hardens it. This process is fast and can create shapes with very high resolution. However, the result is an object with limited material strength.

[0003] Methods for the additive formation of 3D objects by depositing solid blocks are also known in the prior art, as described in Chinese Patent No. 109049687A, where solid base blocks of various shapes are first formed from a fiber-reinforced thermoplastic resin material, and then these blocks are deposited in layers, and the surfaces of the blocks are coated with an adhesive. Blocks within the same layer can have different heights. Document European Patent No. 3427869A1 is also known, where a method for manufacturing a 3D object is described based on joining prefabricated blocks to a layer. The solid material from which the blocks are prepared is selected from the group of metallic materials, polymeric materials, composite materials, and combinations thereof.

Summary of the Invention

Problems to be Solved by the Invention

[0004] None of the above-described techniques, especially the technique of laying blocks in layers, include an additional structure that guarantees the accuracy of block laying, the strength of the joined blocks, and the possibility of easily creating various overhangs and openings.

Means for Solving the Problems

[0005] The above drawbacks of the prior art are eliminated by a method for the additive formation of 3D objects by layering basic blocks according to the present invention. This solution is based on placing blocks of any shape, preferably on induction elements realized by rods or thin cables, and on the other hand, preferably, they are placed on top of each other. The induction elements are preferably embedded or fixed, for example, in a grid pattern on a base plate parallel to each other, thus filling the working space. The number and arrangement of the induction elements used are preferably determined according to the desired properties of the object to be formed, taking into account the materials used.

[0006] The basis of the method for the additive formation of 3D objects by layering solid base blocks lies in the following steps. First, an arrangement of at least one guiding element oriented in the formation direction of the 3D object is formed. Subsequently, a first layer containing at least one solid base block is deposited on the horizontal line of the first layer, and at least one further layer containing at least one solid base block is deposited on a horizontal line spatially separated from the horizontal line of the first layer in the formation direction of the 3D object. For the purposes of the present invention, the term "horizontal line" is intended to mean a virtual two-dimensional geometric shape within the space passing through the geometric centers of each base block of a given layer.

[0007] In this case, at least one base block of at least one layer is arranged within the region of at least one guiding element and is arranged using at least one cooperating means that cooperates with the aforementioned at least one guiding element. Preferably, at least one such base block is arranged within each layer, in which case the overall strength and dimensional accuracy of the finally formed object are increased. Advantageously, for example, holes in the volume of the base block or mechanical means known to those skilled in the art can be used as the cooperating means. It is also possible to arrange at least one solid base block of each layer in the regions of at least two guiding elements and arrange it using at least two cooperating means, each of which cooperates with at least one of these guiding elements. It is also possible to arrange at least one solid base block of each layer in the regions of at least two guiding elements and arrange it using at least one cooperating means that cooperates with these at least two guiding elements.

[0008] At least two different base blocks can advantageously be used in the method according to the present invention. In this case, the final object may advantageously be composed of different materials. Thanks to this, it is possible to create pre-designed objects with different qualitative and aesthetic characteristics of individual parts.

[0009] From the method, the first layer is preferably arranged on at least one base plate, and the horizontal lines of at least one further layer are preferably parallel to the horizontal lines of the first layer. When the horizontal lines of at least one layer, and preferably all subsequent layers, are parallel to the horizontal lines of the first layer, the overall formation method is considerably simplified and accelerated, regardless of the possible use of the base plate. The feature of this method is that at least one guiding element is oriented in a direction perpendicular to the horizontal lines of the first layer, or it is also possible that at least one guiding element is oriented in a direction not perpendicular to the horizontal lines of the first layer, for example, parallel or oblique. By using guiding elements oriented perpendicular to the horizontal lines of the first layer, the forming process is significantly simplified and accelerated. The perpendicular direction of the orientation of the guiding elements means that the angle between the longitudinal axis of the guiding elements and the horizontal lines of a given layer at their intersection is perpendicular. Other angles given in relation to the arrangement of the guiding elements related to the horizontal lines of a given layer must be understood in the same way. It is preferred that at least one base block is arranged using fastening means, or that all solid base blocks are arranged using fastening means. Preferably, the fastening means are an adhesive or other suitable fastening material. It is also possible to use mechanical fixing means such as screws and nuts. The fastening means can be a contact surface from a thermoplastic material on which the base block is made or on which the base block is at least partially coated. The strengthening occurs after the thermal process. For some uses of the 3D object, after step c), if used, it is advantageous for the base plate to be removed and / or at least one guiding element to be removed. To strengthen the 3D object, the 3D object is preferably reinforced by a thermal process. In this case, it is advantageous if at least one base block is made of a thermoplastic material.

[0010] The advantages of the method of additional formation of 3D objects by stratifying basic blocks are, for example, that when at least one base block is arranged within the regions of at least two guiding elements and is arranged using at least one alignment means cooperating with the at least two guiding elements, the proposed solution can advantageously store the zigzag blocks without the need to use fastening means. The guiding means also enables more accurate placement of the individual basic blocks and thus enables higher shape accuracy of the formed 3D object.

[0011] When fastening means are used, in order to achieve a good connection, the base blocks arranged using the fastening means can advantageously be pressed together at different levels by the guiding elements for a longer time. In this case, it is advantageous when at least one base plate is used. The guiding elements and the base plate mainly serve as a structure for ensuring the accuracy of production and also serve as a support structure for creating the pressure for the use of the fastening means. When the iterative process of depositing and curing the blocks is completed, advantageously, at least one guiding element and / or at least one base plate can be removed, and the resulting object is solid and can have any spatial shape.

[0012] By a suitable combination of the use of fastening means, guiding means, and preferably a base plate or plates, it is possible to create a self-supporting structure of the object in a very flexible way without other support structures.

[0013] Another significant advantage of this solution is that it creates various overhangs and openings so that the stored support blocks are not placed, for example, without fastening means, and after the completion of the additional formation of the 3D object by layering, they are removed and can optionally be reused during the further formation of the 3D object. When forming a higher 3D object, the overhangs and inclined surfaces on the constructed higher layers can be created using guiding elements oriented in a direction other than the direction perpendicular to the horizontal line of the first layer, thus saving some basic blocks that only serve as support elements during construction and will finally be removed. This method of additional formation of 3D objects by layering enables the use of blocks of different materials, such as thermoplastic materials, colors, and dimensions, and thus has a wide range of applications. Also, depending on the size of the blocks and the grid, it is possible to generate devices for the additional formation of 3D objects of various sizes, regardless of whether they are small 3D objects such as vases, cups, flowerpots, or medium-sized objects such as cabinets, chairs, and furniture in general. It is also possible to manufacture human and animal figures at actual size. Finally, it is possible to manufacture an entire house.

[0014] The method of additional formation of a 3D object by layering the basic blocks according to the present invention is illustrated in the accompanying drawings.

Brief Description of the Drawings

[0015]

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DETAILED DESCRIPTION OF THE INVENTION

[0016] All figures show a preferred embodiment having fastening means used on the base block, indicated by double contour lines.

[0017] It should be understood that the individual embodiments of the present invention are presented as illustrative means, not as means of limitation. Those skilled in the art will be able to find or confirm many equivalents to a particular embodiment without using more than routine experimentation. Such equivalents will also fall within the scope of the claims. Since the optimal method design is not a problem for those skilled in the art, these features are not described in detail.

[0018] Figure 1 shows the range of elements required for the additive formation of a 3D object by layering base blocks. Thus, the range of elements consists of a base plate 1, guiding elements 2, i.e., rods, sticks or cables, wires, various rod profiles and the like. Further, they are one cooperating means 4, i.e., a block having a hole, an opening for the guiding element 2 and a basic block 3 in the shape of a cube. They are also two cooperating means 4, i.e., a block having a hole, an opening for the guiding element 2 and a basic block 3 in the shape of a cube. They are also one cooperating means 4, i.e., the base block 3 itself to which fastening means 5, such as glue, are applied, having a hole, an opening for the guiding element 2. They are also two cooperating means 4, i.e., the base block 3 itself to which fastening means 5, such as glue, are applied, having a hole, an opening for the guiding element 2. The basic block can generally be a block of any shape and material. A device for performing the additive formation of a 3D object by layering the basic blocks is not the subject of protection and is not shown in any image. Only the alignment means 6 that cooperate with one auxiliary element of the technology, i.e., the guiding element 2, of this device are referred to. The alignment means 6 is, for example, a robot arm or a sliding cat, or a special bar.

Example

[0019] Example 1 In this example of a particular embodiment, the implementation of a method for the additive formation of a 3D object by layering a base block according to the present invention is described, which is illustrated on the created 3D object, i.e., on a staircase having openings in the base and central portions shown in FIGS. 1-6. The method for the additive formation of a 3D object by layering a solid base block 3 consists of the following steps. First, the required number of guiding elements 2 are prepared and distributed. The number of guiding elements is determined according to the required properties of the object to be formed, taking into account the material used. Thereby, a linear working grid is created using parallel guiding elements 2 oriented axially in a direction perpendicular to the horizontal line of the first layer, and the guiding elements are oriented in the direction of forming the 3D object. This operation preferably precedes an auxiliary operation that is performed outside the space for the additive formation of the 3D object, which is the deposition of the first layer of the base block 3 onto the alignment means 6. Preferably, the auxiliary operation continues, which is the movement of the first layer of the base block 3 on the alignment means 6 that is just above a row of guiding elements 2 at the horizontal line of the first layer, and the cooperating means 4 on the base block 3 is above the guiding elements 2. The next step is to deposit the first layer of the individual base blocks 3 at the horizontal line of the first layer by the cooperating means 4 and screw them onto the guiding elements 2 by the alignment means 6 of the processing device. Alternatively, two or more alignment means 6 (not shown) may be used. The horizontal lines of all subsequent layers are parallel to the horizontal line of the first layer. The installation of the first layer of the base blocks 3 on the guiding elements 2 is performed by the vertical displacement of the first layer of the base blocks 3 placed on the alignment means 6 as shown in FIG. 2. Another advantageous auxiliary action is, as shown in FIG. 3, to extend the alignment means 6 from below the first layer outside the space for the additive formation of the 3D object and slide it onto the first layer of the already stored base blocks 3, and the alignment means 6 applies pressure on the first layer of the base blocks 3 to achieve placement accuracy. The horizontal line of the next layer is spatially separated from the horizontal line of the previous layer in the direction of forming the 3D object by the height of the solid base block 3.Subsequently, the step of depositing the second layer of the base block 3 on a horizontal line spatially separated from the horizontal line of the first layer in the direction of forming the 3D object continues, and this layer and subsequent layers preferably already include each base block 3 provided with fastening means 5 such as glue. This is done until the last layer of the base block 3 is deposited, and as shown in FIG. 4, pressure is applied for a sufficient time to solidify the adhesive and bond the base block 3 while achieving the accuracy of the arrangement. In the next step, as shown in FIG. 5, all the guiding elements 2 and some non-adhesive base blocks 3 are removed.

[0020] In a preferred alternative, the preparation and layout of the base plate 1 are first arranged, and a virtual two-dimensional geometric shape within the space passing through the geometric center of each base layer is arranged to be parallel to the horizontal line of the first layer in principle, while one guiding element 2 is arranged at the center of each base plate 1 as shown in FIG. 1. The number of base plates 1 is determined according to the required properties of the formed object considering the material used. Then, the first layer of the base block is deposited as described above.

[0021] Finally, the remaining non-reinforced non-adhesive base blocks 3 and all the base plates 1 are removed, thus creating openings in the base and central part of the 3D object as shown in FIG. 6.

[0022] This method of additional formation of a 3D object by layering the basic blocks according to the present invention is optionally complemented by a strengthening heat process for strengthening the formed 3D object. In such a case, it is preferred that at least a part of the base blocks used contains a thermoplastic material.

[0023] Example 2 In this example of a particular embodiment, an implementation of a method for the additive formation of a 3D object by layering a base block according to the present invention is described, which is illustrated by a terraced structure having openings on the 3D object, i.e., within the base and central portions shown in FIGS. 7 and 8. The method for the additive formation of a 3D object by layering a solid base block 3 consists of the following steps. First, the preparation and layout of the base plate 1 in this case are preferably carried out such that a virtual two-dimensional geometric shape within the space passing through the geometric center of each base layer is arranged to be parallel to the horizontal line of the first layer in principle. One guiding element 2 is oriented within the center of each grid, i.e., within the base plate 1, in a direction perpendicular to the horizontal line of the first layer, and thus, when arranged in an orientation in the direction of forming the 3D object, a planar working grid is formed. Similarly, it is possible to create this planar working grid without disassembling the base plate 1, for example, as described in Example 1. The next step is to deposit the first layer of the solid base block 3 on the base plate 1 by means of the cooperating means 4 and to screw it onto the guiding element 2 by the alignment means 6 of the generating device through it. Then, it continues with the further steps already described in Example 1.

[0024] Example 3 In this example of a specific embodiment, the implementation of a method for the additive formation of a 3D object by layering a base block according to the present invention is described, which is illustrated on the created 3D object, i.e., by a pillar and shown in FIG. 9. The method for the additive formation of a 3D object by layering a solid base block 3 consists of the following steps. First, it is preferably carried out the preparation and decomposition of one base plate 1, where one guiding element 2 oriented in the direction of forming the 3D object is arranged at its center. Alternatively, as described in Example 1, it is possible to proceed without decomposing the base plate 1. The next step is to deposit a first layer of one solid base block 3 on the base plate 1 by means of cooperating means 4 and to screw it onto the guiding element 2 by means of the alignment means 6 of the generating device through it. Then, it follows the further steps already described in Example 1.

[0025] Example 4 In this example of a specific embodiment, the implementation of a method for the additive formation of a 3D object by layering a base block according to the present invention is described, which is illustrated on the created 3D object, i.e., by a high wall having a niche shown in FIG. 10 and basically described in Example 1. In addition, on the last layer of the wall, a horizontal niche is formed such that the guiding element 2 for constructing the niche is oriented in a direction other than perpendicular to the horizontal line of the first layer of the constructed wall.

[0026] Example 5 In this example of a specific embodiment, the implementation of a method for the additive formation of a 3D object by layering a base block according to the present invention is described, which is illustrated on the created 3D object, i.e., by a farmhouse having an inclined roof shown in FIG. 11 and basically described in Example 1. In addition, on the last layer of the wall, an inclined roof is formed in such a way that the guiding element 2 for constructing the roof is oriented in a direction other than perpendicular to the horizontal line of the first layer of the constructed wall.

[0027] Example 6 In this example of a particular embodiment, an embodiment of a method for additive formation of a 3D object by layering a base block according to the present invention is described, which is illustrated in the shape of a branched triangular prism in the bottom view, side view and top view shown in FIGS. 12, 13 and 14, i.e., on the created 3D object. First, three base plates 1 are prepared and distributed into a triangular configuration as shown in FIG. 12. The guiding elements 2 are adapted to each base plate in such a way that, as shown in FIG. 13, their vertices are directed outwards from the object, rather than being arranged in parallel. FIG. 14 shows a 3D object constructed from a monolithic base block 3.

[0028] Industrial utility The method for additive formation of a 3D object by layering a solid base block according to the present invention can be used in the construction industry, the furniture industry, and the manufacture of toys and small utility items.

Claims

A method for the additive formation of a 3D object by layering a solid base block (3) by means of at least one alignment means (6), wherein at least one said alignment means (6) a. arranging at least one guiding element (2) oriented in the formation direction of the 3D object; b. depositing a first layer comprising at least one solid base block (3) on the horizontal line of the first layer; c. depositing at least one further layer comprising at least one solid base block (3) on a horizontal line spatially separated from the horizontal line of the first layer in the direction of forming the 3D object, wherein at least one solid base block (3) of the at least one layer is arranged within the region of the at least one guiding element (2) and is arranged using at least one cooperating means (4) that cooperates with the at least one guiding element (2), and the at least one solid base block (3) is arranged using fastening means (5); a depositing step; d. removing the at least one guiding element (2). A method characterized by performing the above steps. The method according to claim 1, wherein at least one said alignment means (6) arranges at least one solid base block (3) of each layer within the region of the at least one guiding element (2) and arranges it using at least one cooperating means (4) that cooperates with the at least one guiding element (2). The method according to claim 1 or 2, wherein at least one said alignment means (6) arranges at least one solid base block (3) of the at least one layer within the regions of at least two guiding elements (2) and arranges it using at least two cooperating means (4), each of the cooperating means (4) cooperating with at least one of the at least two guiding elements (2). The method according to claim 1 or 2, wherein at least one said alignment means (6) arranges at least one solid base block (3) of the at least one layer within the regions of at least two guiding elements (2) and arranges it using at least one cooperating means (4) that cooperates with the at least two guiding elements (2).

5. The method according to any one of claims 1 to 4, characterized in that there are at least two solid base blocks (3), and the at least two solid base blocks (3) are different.

6. The method according to any one of claims 1 to 5, characterized in that the first layer is arranged on at least one base plate (1).

7. The method according to any one of claims 1 to 6, characterized in that the horizontal lines of the at least one further layer are parallel to the horizontal lines of the first layer.

8. The method according to any one of claims 1 to 7, characterized in that the at least one induction element (2) is oriented in a direction perpendicular to the horizontal lines of the first layer.

9. The method according to any one of claims 1 to 8, characterized in that the at least one induction element (2) is oriented in a direction not perpendicular to the horizontal lines of the first layer.

10. The method according to claim 1, characterized in that at least one of the alignment means (6) arranges all the solid base blocks (3) using fastening means (5).

11. The method according to claim 1 or 10, characterized in that the fastening means (5) is an adhesive.

12. The method according to claim 6, characterized in that at least one of the alignment means (6) removes the base plate (1) after step c).

13. The method according to any one of claims 1 to 12, characterized in that the 3D object is reinforced by a thermal process.

14. After step (c) but before step (d), at least one of the alignment means (6) presses at least one solid base block (3) arranged using fastening means (5) together with at least one other solid base block (3) in cooperation with at least one induction element (2). The method according to any one of claims 1 to 13.

15. The method according to any one of claims 1 to 14, characterized in that after the additional formation of the 3D object is completed, at least one of the alignment means (6) removes at least one solid base block.

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