Method for producing a moulded body having a foam structure at least in some portions

Abstract

The invention relates to a method for producing a moulded body (1) having a foam structure (2, 3) at least in some portions, said method comprising the following method steps: - building up (100) a first shaping structure (4) in an additive manufacturing method, wherein the first shaping structure (4) forms at least one cavity (6), - introducing (110) a foamable material (8) into the cavity (6) for at least partially forming a first foam structure (2), - building up (120) an element (9) in an additive manufacturing method while or after the foamable material (8) for at least partially forming the first foam structure (2) is being or has been introduced into the first cavity (6), wherein the element (9) is built up at or on the first shaping structure (4) and / or the first foam structure (2).

Description

[0001] 23-0427 DE

[0002] Method for producing a molded body having at least a foam structure in sections

[0003] The invention relates to a method for producing a molded body having a foam structure at least in sections.

[0004] Corresponding methods for producing molded bodies having a foam structure, at least in sections, are fundamentally known from the prior art. For example, it is known to produce molding agents provided with a cavity in an additive manufacturing process using an additive manufacturing device and, after completion of the additive construction, to remove the molding agent from the additive manufacturing device. A foamable material is then poured into the cavity of the molding agent removed from the additive manufacturing device, creating a molded body having a foamed structure. This foamed structure has a surface geometry or shape corresponding to the shaping surface of the molding agent. This process is time-consuming and requires a lot of space to carry out the process.

[0005] The invention is based on the object of specifying a method which, in particular with regard to a simple and cost-effective measure, increases the possibilities of the geometric and / or the strength and / or rigidity design of a shaped body having a foam structure.

[0006] The object is achieved by a method for producing molded bodies having a foam structure at least in sections, according to claim 1. The dependent claims relate to possible embodiments of the method. Furthermore, the object is achieved by a molded body according to claim 10.

[0007] The invention relates to a method for producing a molded body having a foam structure at least in sections, wherein a first shaping structure is first constructed using an additive manufacturing method, the first shaping structure forming at least one first cavity. During the additive manufacturing method, e.g. during 3D printing, a body is constructed which forms a first shaping structure. For this purpose, the first shaping structure can have a cavity. A foamable material is then introduced into the first cavity or into the cavity of the first shaping structure in order to form a first foam structure in the first cavity at least in sections using the introduced foamable material. For this purpose, the foamable material is poured into the cavity and / or introduced under pressure.The foamable material may already partially or entirely have a pourable foam-like structure, i.e., the foamable material is already foam-like while it is introduced into the cavity. The degree of foaminess, e.g., the ratio of gas to mass in a volume unit of the foamable material, may change after the foamable material has been introduced into the cavity or remain constant. Preferably, after the foamable material has been introduced into the cavity, the foamable material may harden. A foamable material is therefore understood to be a material that has a foam-like structure in its final state, i.e.,that the component of the molded body formed by the foamable material or the molded body formed by the foamable material, in the final state of the molded body, has a pore structure that forms at least partially, preferably predominantly, particularly preferably exclusively, open pores or at least partially, preferably predominantly, particularly preferably exclusively, closed pores. The pores or the gaseous bubbles are preferably surrounded or delimited by solid, in particular elastic, walls.

[0008] While or after the foamable material is or has been introduced into the first cavity for at least sectionally forming the first foam structure, an element is built up in an additive manufacturing process, wherein the element is built up on or at the first shaping structure and / or the first foam structure. The element is preferably built up in the same additive build job or in the same additive build process as the build up of the at least one first shaping structure. In other words, both the first shaping structure and the at least one element are built up in a process chamber of an additive manufacturing device, and between these two build steps, likewise while the built up first shaping structure is still in the process chamber of the additive manufacturing device, the foamable material is introduced into the first cavity.The process results in a molded body that has a foam structure, at least in sections. Because the element is additively built up only after the introduction of the foamable material, there is a greater degree of freedom in designing the geometry of the molded body, as there is no need to consider the ability to introduce foamable material in the molded body's final geometry. The foamable material can be introduced into the cavity during at least one intermediate step or simultaneously with the additive construction of an element or at least one molding structure. If - as in the prior art - the molding structure were to be completely built up and the foamable material were to be introduced last, this would have the disadvantage that the foamable material might not be able to reach desired, remote locations within the first cavity.This problem is solved with the present method and a higher degree of design freedom, particularly geometric freedom, is achieved for the molded body to be produced.

[0009] It is possible for a second shaping structure to be constructed for forming an element to be produced in an additive manufacturing process while or after the foamable material is or has been introduced into the first cavity to form at least part of the first foam structure. The second shaping structure forms at least one second cavity and is constructed on or upon the first shaping structure and / or on or upon the first foam structure. Finally, a foamable material is introduced into the second cavity to form a second foam structure. This construction principle for the first and second shaping structures can be implemented for further shaping structures, so that a shaping structure is constructed alternately with an introduction of foamable material into at least one previously, in particular immediately previously, constructed cavity of a shaping structure.The molded body thus formed has, in the final production state, at least two, preferably three or more, foam structures that were formed in different introduction process steps into cavities of shaping structures constructed in different construction process steps. The introduction process steps and the shaping process steps can preferably have been carried out predominantly or entirely within the additive manufacturing device used to construct the shaping structure, in particular a process or construction chamber of the additive manufacturing device used. Optionally, the molded body can be formed from more than two foam structures, i.e., more than two shaping structures are formed during the additive construction, each of which provides cavities for receiving foamable material.

[0010] It may prove advantageous if a rotational and / or linear movement of the first shaping structure is carried out (a) before and / or during the construction of the second shaping structure or (b) before and / or during the introduction of the foamable material into the second cavity. By carrying out a defined rotational and / or linear movement of the first shaping structure, a targeted relative movement of the foamable material introduced into the first shaping structure to the shaping structure can be achieved through the action of gravity. This allows the foaming material introduced into the first cavity to be guided to predetermined locations within the cavity or its targeted, in particular homogeneous, distribution within a desired filling location in the first cavity to be achieved or supported.

[0011] The foamable material that is introduced at least partially, preferably predominantly, particularly preferably entirely, into the at least one first cavity, and the foaming material that is introduced at least partially, preferably predominantly, particularly preferably entirely, into the at least one second cavity, can, for example, be the same or similar material. Alternatively, different foamable materials can be used.

[0012] The construction of at least one element, in particular the second shaping structure, can, for example, only be carried out once the foaming material introduced into the first cavity has undergone a volume-increasing process to form a foam structure. Preferably, the element, in particular the second shaping structure, is only constructed once the foaming material introduced into the first cavity has reached at least 70 vol.%, preferably at least 85 vol.%, particularly preferably at least 95 vol.%, and most preferably at least 97 vol.%, of its final volume. In other words, the construction of the element, in particular the second shaping structure, is delayed until the foaming material introduced into the previously constructed first cavity of the first shaping structure has reached a minimum level of volume increase.This supports the aim of having a static, or rather, a no longer changing, or only slightly changing, basis for the construction of the element, in particular for the construction of the at least one second shaping structure, on which the at least one second shaping structure is constructed. The volume specifications mentioned in connection with the foamable material refer to the maximum volume of the foamable material delimited or circumscribed by the foamable material, i.e., its maximum extension volume.

[0013] In other words, it is possible for the foamable material to be introduced in a compact volume state into the at least one cavity of the first and / or second and / or at least one further shaping structure and to experience an increase in volume within the cavity after or during the introduction.

[0014] It is possible for the first shaping structure to be removed at least in sections, preferably predominantly, and particularly preferably entirely or completely, wherein this is carried out (a) before and / or during the construction of the second shaping structure and / or (b) before and / or during the introduction of the foaming material into the second cavity for the at least partial formation of the second foam structure. The at least one first and / or second shaping structure can, at least in sections, form a component of the finished molded body in its final state. However, components of the shaping structures can also be removed from the at least one foam structure, for example, so that these removed shaping structures do not form a component of the final molded body.For example, the molding structure can be completely separated from the foam structures so that the final molded body is formed only from the foam structures.

[0015] It can also be provided, for example, that an at least partial, preferably predominant, particularly preferably complete, removal of the first shaping structure is carried out (a) after the construction of the second shaping structure has been carried out and / or (b) after the introduction of the foaming material into the second cavity for at least partial formation of the second foam structure has been carried out. Thus, for example, removal of the first shaping structure can be carried out during additive construction and without the foam structures already produced in their geometric shape having to leave the process chamber of the additive manufacturing device. For this purpose, the additive manufacturing device can comprise at least one means that enables the removal of the first shaping structure.For example, the additive manufacturing device is equipped with a liquid and / or gas nozzle and / or with a heating device which is or are configured to apply a liquid and / or a gas and / or thermal energy to the first shaping structure in order to enable at least partial, preferably predominant, particularly preferably complete, removal or detachment of the first shaping structure from the first foam structure.

[0016] For at least partially, in particular completely, removing (separating and / or dissolving) the at least one first and / or second shaping structure from at least one first and / or second foam structure, water and / or acetone and / or limonene, for example, can be used as a solvent. In order to achieve at least partially removing the at least one shaping structure, water and / or acetone and / or limonene (1-methyl-4-prop-1-en-2-yl-cyclohexene), for example, can be used as a solvent. In this case, (a) the solvent can be water for a shaping structure comprising at least partially polyvinyl alcohol and / or salt and / or (b) the solvent can be limonene and / or acetone for a shaping structure comprising at least partially polystyrene, in particular high impact polystyrene (HIPS).In particular, at least one, preferably all, solvents can have a dissolving or decomposing effect on a binder of at least one section of the shaping structure, so that the shaping structure can be detached or separated from the cured and / or foamed material at least in sections, in particular completely. For example, the additive manufacturing device used to construct the at least one shaping structure has a device that enables the shaping structure to be separated. For example, the additive manufacturing device has a nozzle that enables a solvent to be detached, in particular selectively and depending on the area, at least in sections from a formed foam structure. The at least in section separation orDetachment of the shaping structure is possible within the process chamber in which the additive construction of at least one shaping structure also took place.

[0017] The at least one foamable material can, for example, experience a volume increase forming a foam structure by exposure to thermal energy and / or light, in particular UV light. In the case of a volume increase of the foaming material occurring by exposure to light, the shaping structure forming the cavity for this foamable material can be made of a translucent material, in particular a transparent material, so that the light, in particular the UV light, can penetrate at least partially through the walls of the shaping structure defining the cavity and impact the foamable material accommodated in the cavity.It is also possible for a heating element to be brought to the surface of the shaping structure from the outside, either in contact with or at a distance from the shaping structure, and / or to penetrate at least partially into a receiving space of the shaping structure, either in contact with the shaping structure from the outside or at a distance from the shaping structure, in order to achieve targeted and / or effective exposure to the foamable material received in the cavity of the shaping structure. Alternatively or additionally, a substance can be brought into contact with the foamable material located in the cavity in order to trigger a chemical reaction in the foamable material, which influences, in particular increases, the degree of formation of a foam-like structure of the foam structure.As a material for constructing at least one additively constructed shaping structure and / or at least one element, in particular at least one first and / or second shaping structure, plastic and / or synthetic resin and / or metal and / or concrete can be used, for example. A thermoplastic, particularly preferably polyvinyl alcohol and / or polyvinyl acetate and / or polystyrene, is preferably used. The additive manufacturing device can thus be set up to apply or process the aforementioned materials to form an additively manufactured shaped body, for example by selectively applying them layer by layer to a building board. It is also possible to form different shaping structures from different materials, so that, for example,a first shaping section of the shaping structure is formed from a thermoplastic material, and a further shaping section of the same shaping structure is formed from a synthetic resin. At least one material for forming the shaping structure can, for example, comprise a salt component or a mixture with salt. In this case, salt can, for example, be mixed with a thermoplastic material, so that during an optional, at least partial removal of the at least one shaping structure, water, for example, can be used as a solvent to dissolve the salt components and thus to at least partially dissolve the shaping structure.

[0018] The foamable material used can be, for example, (a) plastic, in particular polyurethane (PUR) and / or silicones, and / or (b) synthetic resin, in particular casting resins, e.g., epoxy resin, and / or (c) metal, in particular iron or steel, and / or (d) concrete. The foamable material can, for example, be introduced into the cavity in flowable, in particular liquid and / or powder form. Due to its flowability, the foamable material can adhere to or act on the shaping surface of the shaping structure, at least in sections, preferably predominantly, particularly preferably almost completely (e.g., 55% to 99%, in particular 85% to 99%), most preferably completely, in a contour-contacting or contour-filling manner. A polyurethane foam, for example, can be used as the polyurethane. It is also possible to use synthetic polymers such as silicones or poly(organo)siloxanes.To produce at least one additively manufactured shaping structure, in particular to produce all of the additively manufactured shaping structures used in the course of producing the shaped body, at least one of the following processes can be used, for example: Selective Laser Sintering (SLS) and / or Multi-Jet Fusion (MJF) and / or Fused Deposition Modeling (FDM), also referred to as Fused Filament Fabrication (FFF) or melt layer formation, and / or Continuous Liquid Interface Production (CLIP) and / or Digital Light Synthesis (DLS) and / or Stereolithography (SLA) and / or . The introduction of foamable material can be carried out by means of introduction means which are arranged or assigned to the additive manufacturing devices which carry out the additive processes specified above.These means preferably form part of the components of an additive manufacturing device used and are provided, for example, in a process chamber, preferably in a build chamber, of this additive manufacturing device. If the additive manufacturing device comprises a protective gas atmosphere in its process chamber, the at least one means for introducing the foamable material is arranged within this protective gas atmosphere, at least during the introduction of the foamable material into the cavity. The introduction of the foamable material preferably takes place within the additive manufacturing device used, i.e., the foamable material is introduced during a build job into the shaping structure generated in this build job.

[0019] In a preferred embodiment, it can be provided that a software program product is configured to generate or suggest a process sequence for constructing the molded body and forming the at least one shaping structure, in particular all shaping structures, and / or for the quantity of foamable material that is introduced into the at least one cavity, based on data describing the target geometry and / or the target material properties of a molded body. In other words, based on the target geometry and / or target properties of the molded part - e.g., from the CAD data describing the molded part - the process time(s) for introducing the foamable material into the at least one then partially or completely constructed cavity of the molding structure(s) can be determined.Since the volume expansion behavior of the foamable material and the geometry of the cavities are known, the amount of foamable material introduced into the cavity created up to that point can be specifically determined or suggested by the computer program product.

[0020] In addition to the method for producing a molded body having a foam structure at least in sections, the invention also relates to a molded body, preferably a vehicle component, particularly preferably a motor vehicle component, which was produced according to a method described herein. For example, the molded body can be designed as a side panel component for installation in the interior of a vehicle. Due to its foam-like structure, the molded body can also have a defined, in particular area-dependent, stiffness or elasticity. Such a component can, for example, be optimized for specific crash requirements. Alternatively, the molded body can be designed as a bearing means, e.g. as a bushing bearing. For example, the bearing means is used in a stabilizer of a motor vehicle.In general, the molded body produced by the method described herein can form a dam body for a vehicle and / or for a building. If the molded body is designed as a building component, the at least one molding structure could be constructed from concrete using an additive manufacturing process.

[0021] All advantages, details, embodiments and / or features of the process according to the invention are transferable or applicable to the shaped body according to the invention and vice versa.

[0022] The invention is explained in more detail using exemplary embodiments in the drawings. In the drawings:

[0023] Fig. 1 is a perspective schematic diagram of a first shaping structure according to an embodiment;

[0024] Fig. 2 shows a perspective schematic representation of a first and a second shaping structure according to an exemplary embodiment; Fig. 3 shows a schematic representation of method steps of a method for producing a molded body having a foam structure at least in sections according to an exemplary embodiment.

[0025] Figure 1 shows an intermediate step or an intermediate stage of a molded body 1 to be produced and having a foam structure 2, 3 at least in sections. The essential method steps for producing the molded body 1 are evident from Figure 3. Figure 3 shows that, first, a first shaping structure 4 is built up 100 using an additive manufacturing process, wherein the first shaping structure 4 forms at least one first cavity 6. By way of example, the shaping structure 4 shown in Figure 1 is therefore the additively constructed molded body, which is designed or represented as a cuboid-shaped body, in particular as a cube-shaped body, due to the cavity 6 formed thereby and the walls defining the cavity 6. The shaping structure 4 can have almost any shape, in particular due to its additive construction process.

[0026] For example, a layered structure is achieved by applying building material layer by layer and selectively subjecting the building material to an agent that selectively solidifies it (e.g., an energy beam, in particular a laser beam, and / or a binder). Alternatively or additionally, the material forming the shaping structure 4, 5 can itself be applied selectively, i.e., applied at those locations intended to form the target geometry of the shaping structure 4, 5. Of course, an additional support structure (not shown) can be formed by the building material, wherein these support structures can be removed, at least in sections, in the final assembly state of the molded body 1.

[0027] A foamable material 8 is introduced into the first cavity 6 for at least partially forming a first foam structure 2 (introduction 110). For this purpose, the foamable material 8 can be introduced or filled into the cavity 6 through a filling opening 10 of the shaping structure 4. The foamable material 8 can be poured in via the filling opening 10 in liquid form and / or filled in powder form. Any excess (compared to a desired amount) of foamable building material 8 introduced into the cavity 6 can be drained out of the cavity 6, in particular laterally, via a drain opening. In this way, the overflow or protrusion of foamable material 8 over the exposed opening 12, at or on which a second foam structure 3 and / or a second shaping structure 5 is built up or formed, can be achieved.

[0028] It is optionally possible to close the filling opening 10 of the first shaping structure 4 at least in sections, preferably completely, during the additive construction of the second or a further shaping structure 5 and / or during the introduction of a foamable material 8 to form a second or a further foam structure 3.

[0029] In other words, the foamable material 8 introduced into the first cavity 6 can experience an increase in volume after introduction into the cavity 6, e.g., due to foaming. In order to prevent this foamable material 8, which has then increased in volume, from overflowing or protruding beyond an opening 12, which is subsequently adjoined at least in sections by the second foam structure 3 and / or the second shaping structure 5, any excess of the foamable material 8 introduced into the first cavity 6 can be drained off at the drain opening 11.

[0030] In the cavity 6, the foamable material 8 can reach locations in the cavity 6 predetermined for the arrangement of the foamable material 8, for example due to gravity and / or by applying compressive forces (not shown) to the foamable material 8.

[0031] While or after the foamable material 8 is or has been introduced into the first cavity 6 for at least partially forming the first foam structure 2, an element 9 is constructed 120 using an additive manufacturing process, wherein the element 9 is constructed on or upon the first shaping structure 4 and / or the first foam structure 2. In the embodiment shown in Figure 2, an element 9 is constructed which, at least in sections, fulfills the function of a further or second shaping structure 5 while forming a second cavity 7. In other words, for example, a construction 120 of a second shaping structure 5 can take place in an additive manufacturing process during or after the or a foamable material 8 is or has been introduced into the first cavity 6 for at least partially forming the first foam structure 2.The second shaping structure 5 can form at least one second cavity 7, and the second shaping structure 5 can be constructed on or upon the first shaping structure 4 and / or on or upon the first foam structure 2. Finally, an introduction 130 of a foamable material 8 into the second cavity 7 can be carried out to form a second foam structure 3. For this purpose, the second shaping structure 5 can, for example, have a filling opening 13 for introducing the foamable material 8. Alternatively or additionally, the second shaping structure 5 can have a drainage opening (not shown) or an overflow opening 14. The purpose of a drainage opening is to limit or prevent any protrusion or degree of protrusion of foamable material 8, which increases in volume after being introduced into the second cavity 7, beyond an opening (not shown) of the second shaping structure 5.An overflow opening 14 serves to ensure that, after the foamable material 8 has increased in volume, it completely fills a desired volume within the second cavity 7, since excess foamable material 8 is discharged via the overflow opening 14, whereby no further foam structure or further shaping structure is provided at or on the overflow opening 14. The overflow opening 14 can also be designed as a drain dome 15, see Figure 2, whereby the drain dome 15 can be or is removed from the sections of the molded body 1 forming the target molded body in order to achieve the target shape of the molded body 1. For this purpose, the drain dome 15 can be connected via a predetermined breaking point to the sections of the molded body 1 forming the target shape of the molded body, thus simplifying the separation of the drain dome 15.For example, at least one shaping structure 4, 5 can be provided with an overflow valve; preferably, the overflow valve is arranged or formed in or on the overflow opening 14 and / or the drain dome 15.

[0032] It is possible for the first and the at least one further or second shaping structure 4 and 5 to touch one another, i.e. for the molded body 1 to have at least two shaping structures 4, 5 in contact. Alternatively, the first and second shaping structures 4, 5 can be separated by a component of the first, additively produced shaping structure 4 and / or by a component of the additively constructed element 9, in particular the second, additively constructed shaping structure 5. By separating the first and second foam structures 2, 3 in this way, a defined floor or base can be achieved for the construction of the second foam structure 3, since there is no reliance on the first foam structure 2, which may develop a certain inaccuracy due to a possible increase in volume after its application into the first cavity 6.

[0033] A build-up 120 of at least one element 9, in particular of the second shaping structure 5, can, for example, only take place or be carried out when the foaming material 8 introduced into the first cavity 6 has carried out a volume-increasing process to form a foam structure 2 and the foaming material 8 introduced into the first cavity 6 has reached or is present at least 70 vol.%, preferably at least 85 vol.%, particularly preferably at least 95 vol.%, most preferably at least 97 vol.%, of its final volume.In other words, the construction 100 of the element 9, in particular of the second shaping structure 5, is delayed until there is no longer any or no significant change in the volume of the foaming material 8 introduced into the first cavity 6, so that the construction 120 of the element 9, in particular of the second shaping structure 5, can take place on a basis that does not change or no longer changes significantly, namely the first shaping structure 4 and / or the first foam structure 2.

[0034] An at least partial, preferably predominant, particularly preferably complete, removal 140 of the first shaping structure 4 can be carried out, for example, (a) before and / or during the construction 120 of the second shaping structure 5 and / or (b) before and / or during the introduction 130 of the foaming material 8 into the second cavity 7 for at least partial formation of the second foam structure 3. This makes it possible for interfaces of the first shaping structure 4 to be exposed and used for direct contact with the second shaping structure 5 and / or for direct contact with the second foam structure 3. In other words, surface sections of the first foam structure 3 shaped by the first shaping structure 4, for example, can be used as a construction base for the subsequently applied or constructed second foam structure 5 and / or second shaping structure 5.For this purpose, the first shaping structure 4 is removed beforehand, at least in sections.

[0035] An at least partial, preferably predominant, particularly preferably complete, removal 140 of the first shaping structure 4 can be carried out, for example, (a) after the construction 100 of the second shaping structure 5 has been carried out and / or (b) after the introduction 130 of the foaming material 8 into the second cavity 6 for at least partial formation of the second foam structure 3 has been carried out.

[0036] The at least one foamable material 8 can, for example, by exposure to thermal energy and / or exposure to light, in particular UV light, form a foam structure 2, 3.

[0037] Experience an increase in volume. In other words, activation of foam formation and / or reinforcement of the formation of a foam-like structure of the foam structure 2, 3 can be initiated by exposing the foamable material 8 to thermal energy and / or light. Preferably, the additive manufacturing device is equipped with a means (not shown) that enables at least partial exposure to the first and / or second foam structure 2, 3, in particular located within the additive manufacturing device.

[0038] As material 8 for the construction of at least one additively constructed shaping structure 4, 5 and / or at least one element 9, in particular at least one first and / or second shaping structure 4, 5, plastic and / or synthetic resin and / or metal, aluminum and / or iron and / or steel, and / or concrete can be used, for example. A thermoplastic material, particularly preferably polyvinyl alcohol and / or polyvinyl acetate and / or polystyrene, can be used. In principle, mixtures of the aforementioned elements and alloys are also possible.

[0039] As foamable material 8, for example, plastic, in particular polyurethane (PUR), and / or silicone and / or synthetic resin, in particular casting resins, and / or metal, in particular iron or steel or aluminum, and / or concrete can be used. In principle, mixtures of the aforementioned elements or alloys are also possible.

[0040] For producing at least one additively manufactured shaping structure 2, 3, at least one of the following methods can be used:

[0041] Selective Laser Sintering (SLS) and / or Multi-Jet Fusion (MJF) and / or Fused Deposition Modeling (FDM) and / or Continuous Liquid Interface Production (CLIP) and / or Digital Light Synthesis (DLS) and / or Stereolithography (SLA). The respective method can, for example, comprise means configured to enable the introduction 110 of the foamable material 8. Preferably, the foamable material 8 is introduced into the at least one cavity 6, 7 by these means, while the at least one shaping structure 4, 5 delimiting this cavity 6, 7 is located within the process chamber of the additive manufacturing device in which the corresponding shaping structure 4, 5 was also additively constructed.

[0042] The invention also relates to a shaped body 1, preferably a vehicle component, particularly preferably a motor vehicle component, which was produced according to a method described herein.

[0043] List of reference symbols

[0044] 1 molded body

[0045] 2 first foam structure

[0046] 3 second foam structure

[0047] 4 first shaping structure

[0048] 5 second shaping structure

[0049] 6 first cavity of 4

[0050] 7 second cavity of 5

[0051] 8 foamable material

[0052] 9 Element

[0053] 10 Filling opening

[0054] 11 Drain opening

[0055] 12 opening of 4

[0056] 13 Filling opening

[0057] 14 Overflow opening

[0058] 15 Drain dome

[0059] 100 Building from 4

[0060] 110 Inserting 8 into 6

[0061] 120 Building of 5 or 9

[0062] 130 Inserting 8 into 7

[0063] 140 Remove 4

[0064] 150 Remove from 5

Claims

CLAIMS 1. A method for producing a molded body (1) having at least a foam structure (2, 3) in sections, comprising the following method steps: - constructing (100) a first shaping structure (4) in an additive manufacturing process, wherein the first shaping structure (4) forms at least one first cavity (6), - introducing (110) a foamable material (8) into the first cavity (6) for at least partially forming a first foam structure (2), - Building (120) an element (9) in an additive manufacturing process during or after the foamable material (8) is or has been introduced into the first cavity (6) for at least partially forming the first foam structure (2), wherein the element (9) is built up on or on the first shaping structure (4) and / or the first foam structure (2).

2. Method according to claim 1, characterized by - constructing (120) a second shaping structure (5) in an additive manufacturing process during or after the or a foamable material (8) is or has been introduced into the first cavity (6) for at least partially forming the first foam structure (2), wherein the second shaping structure (5) forms at least one second cavity (7) and the second shaping structure (5) is constructed on or onto the first shaping structure (4) and / or on or onto the first foam structure (2), - introducing (130) a foamable material (8) into the second cavity (7) to form a second foam structure (3).

3. Method according to claim 1 or 2, characterized in that a construction (100) of at least one element (9), in particular the second Shaping structure (5), only takes place when the foaming material (8) introduced into the first cavity (6) has carried out a volume-increasing process to form a foam structure (2) and the foaming material (8) introduced into the first cavity (6) has reached or is present at least 70 vol.%, preferably at least 85 vol.%, particularly preferably at least 95 vol.%, most preferably at least 97 vol.%, of its final volume.

4. Method according to claim 2 or 3, characterized in that an at least partially, preferably predominantly, particularly preferably complete, removal (140) of the first shaping structure (4) is carried out before and / or during the construction (120) of the second shaping structure (5) is carried out and / or - before and / or during the introduction (130) of the foaming material (8) into the second cavity (7) for at least partially forming the second foam structure (3).

5. Method according to one of claims 2 to 4, characterized in that an at least partially, preferably predominantly, particularly preferably completely, removal (140) of the first shaping structure (4) is carried out, - after the construction (100) of the second shaping structure (5) has been carried out and / or - after the introduction (130) of the foaming material (8) into the second cavity (6) has been carried out for at least partially forming the second foam structure (3).

6. Method according to one of the preceding claims, characterized in that the at least one foamable material (8) is subjected to thermal energy and / or to Light, in particular UV light, experiences an increase in volume forming a foam structure (2, 3).

7. Method according to one of the preceding claims, characterized in that plastic and / or synthetic resin and / or metal and / or concrete is used as material (8) for the construction of at least one additively constructed shaping structure (4, 5) and / or at least one element (9), in particular at least one first and / or second shaping structure (4, 5), preferably a thermoplastic plastic, particularly preferably polyvinyl alcohol and / or polyvinyl acetate and / or polystyrene, is used.

8. Method according to one of the preceding claims, characterized in that plastic, in particular polyurethane (PUR), and / or silicone and / or synthetic resin, in particular casting resins, and / or metal, in particular iron or steel or aluminum, and / or concrete is used as the foamable material (8).

9. Method according to one of the preceding claims, characterized in that at least one of the following methods is used to produce at least one additively manufactured shaping structure (2, 3): Selective Laser Sintering (SLS) and / or Multi-Jet Fusion (MJF) and / or Fused Deposition Modeling (FDM) and / or Continuous Liquid Interface Production (CLIP) and / or Digital Light Synthesis (DLS) and / or Stereolithography (SLA).

10. Shaped body (1), preferably a vehicle component, particularly preferably a motor vehicle component, produced by a process according to one of the preceding claims.

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