Method for producing a three-dimensional moulded body by additive manufacturing

Abstract

The invention relates to a method for producing a three-dimensional metallic moulded body (1) by additive manufacturing and to a corresponding device. In order to simplify the production of a three-dimensional moulded body, a method is proposed which is characterised in that an introduction device (40) positioned in a bed (3) moves along a path (11) and in that introduction into the bed (3) takes place with the aid of the introduction device (40), as a result of which construction material (41) is provided in a working space (7) formed below the surface (6) of the bed (3), as a result of which the moulded body (1) is produced, wherein the bed (3) comprises metallic particles, and wherein introduction material (43) and / or energy (42) is introduced into the bed (3) with the aid of the introduction device (40).

Description

[0001] 25101T Patent Attorney Schneider, Neumarkt / Oberpfalz

[0002] 1

[0003] Description

[0004] Method for producing a three-dimensional shaped body by additive manufacturing

[0005] The invention relates to a method for producing a three-dimensional shaped body by additive manufacturing and a corresponding device.

[0006] Additive manufacturing processes, in particular layer-by-layer processes, are known from the prior art. Layer-by-layer processes are used to produce components from layer-by-layer, hardenable material. In this process, layers of a build-up material are successively applied one on top of the other. Before the application of each subsequent layer, the areas in the respective layers corresponding to the cross-section of the object to be manufactured are selectively hardened. This hardening is achieved, for example, by locally heating a powdered base material using a radiation source.

[0007] A disadvantage of these known powder bed processes is that the build-up material is applied in complete layers, even though it is only solidified at selected locations. Therefore, a large quantity of build-up material is always required.

[0008] Even if free-space processes are used instead, in which the build-up material for producing the molded part is melted or applied in liquid form and then solidified, the molded part to be produced is always built on a special, in particular height-adjustable, build-up platform. 25101T

[0009] 2

[0010] Furthermore, all free-space methods require the use of additional support structures in the case of undercuts or similar features.

[0011] Currently, an additive manufacturing process called "Submerged Arc Additive Manufacturing" (SAAM) is being developed. This process transforms classic submerged arc welding, an arc welding process in which the arc is generated between a molten electrode (e.g., wire, strip) and a workpiece under a layer of powder, into an additive manufacturing process. In SAAM, an arc operated under complete powder coverage, with a continuous supply of welding wire electrode material, is used to build a new component layer by layer by depositing material. In other words, an electric arc is generated between a molten electrode and the already molten material or a previously deposited layer.

[0012] A metal wire, serving as the starting material, is fed into the SAAM process via a controlled feeding mechanism. A suitable welding powder protects the liquid metallic melt pool, which is continuously reformed and solidified during the process. The melt pool is defined as the localized area beneath the arc where the metal has been melted by the arc. The melt pool, which lies completely beneath the powder layer, serves to locally remelt the previous layer and fuse it with new material. 25101T

[0013] 3

[0014] The selection of a suitable flux for the powder coating is a particularly crucial factor in the SAAM process, as the flux must ensure stable process conditions across many layers, since numerous layers are successively melted and solidified. The flux must simultaneously fulfill several functions. It protects the melting bath and the arc from oxygen, nitrogen, and atmospheric moisture. The flux provides electrical insulation for the arc from the environment. It stabilizes the arc. Even with multi-layer coatings, the flux must enable stable arc guidance and influence heat distribution and cooling in such a way that no undesirable stresses or cracking occur between layers.Due to the process-related heating of the component, sometimes lengthy interruptions of the build process are necessary to avoid compromising component quality. The flux serves to form the slag. During the SAAM process, parts of the flux melt and form a slag layer that thermally insulates the melting bath, regulates the cooling rate, and shapes and smooths the surface of the manufactured component. The resulting slag must be removed after the component is manufactured, a process that is quite complex. Because of the multilayer additive structure, it is important, with a view to the intended reuse of the flux, that it must not accumulate any undesirable reaction products. Therefore, SAAM fluxes are chemically stable systems.

[0015] To fulfill these functions, the flux is non-metallic. A mixture of silicates, oxides, and fluorides is regularly used as the flux, typically comprising about 90–98 wt.% of the flux composition. Some fluxes also deliberately contain small amounts of metallic components (always < 10 wt.%, typically < 5 wt.%) to control the chemical equilibrium in the melt bath and to influence the microstructure and chemical composition of the molten layers. These fluxes are also called reactive fluxes.

[0016] The use of SAAM aims at the particularly economical production of large and complex metal components, e.g., over 50 kg, with a high build rate and good material quality. However, as described, the process is comparatively complex and has several disadvantages. In particular, considering the relatively long waiting times for temperature control, the complex process management, and the limitations regarding the materials that can be processed, there is still a need for a simpler, better solution.

[0017] One object of the present invention is to simplify the production of a three-dimensional molded body.

[0018] This problem is solved by a method according to claim 1 or by a device according to claim 10.

[0019] The inventive method for producing a three-dimensional metallic shaped body by additive manufacturing is characterized in that a feeding device positioned in a bed moves along a path and that, with the aid of the feeding device, material is introduced into the bed, by which introduction into a working space formed below the surface of the bed, build-up material is provided, thereby creating the shaped body, wherein the bed comprises metallic particles and wherein, with the aid of the feeding device 25101T

[0020] 5

[0021] Material and / or energy is introduced into the fill.

[0022] The device according to the invention for producing a three-dimensional shaped body by additive manufacturing comprises a feeding device that can be positioned in a granular bed and a control unit, which is designed such that the feeding device is moved along a path and that, with the aid of the feeding device, material is introduced into the bed, thereby providing build-up material in a working space formed below the surface of the bed, whereby the shaped body is formed, wherein the bed comprises metallic particles and wherein, with the aid of the feeding device, feed material and / or energy are introduced into the bed. This device is particularly designed for carrying out the process according to the invention.

[0023] Advantageous embodiments of the invention are specified in the dependent claims or can be seen from the following description and / or the accompanying figures.

[0024] The advantages and features explained below in connection with the method also apply analogously to the device according to the invention and vice versa.

[0025] The invention makes it possible to simplify the production of a three-dimensional molded body.

[0026] In particular, a comparatively small amount of assembly material is required. According to one embodiment of the invention, this is achieved by providing assembly material only where it is actually needed for the 25101T.

[0027] 6

[0028] A solidification process is required, and thus the production of the molded body is necessary.

[0029] The invention relates to an additive manufacturing process, more precisely a process for the additive manufacturing of a molded body.

[0030] In particular, the invention relates to the three-dimensional shaping of a body within a bulk material, wherein both the introduction of material or energy and the solidification take place below the surface of the bulk material.

[0031] Essential to the invention is the use of a bulk material. Preferably, this bulk material serves to provide a working space within the bulk material necessary for the construction of the molded part. Preferably, this bulk material, by defining the working space on all sides, simultaneously supports the shaping of the molded part and / or enables this shaping in the first place. Preferably, the bulk material provides the material for the construction of the molded part or enables the provision or generation of this material.

[0032] Due to the use of fill material, a special assembly platform is unnecessary. Only a suitable support for the fill material is required. This support must be stable enough to bear the fill material and the molded part constructed within it. The support does not need to be perfectly flat. Since the manufactured molded part is completely enclosed within the fill material, no additional support structures attached to the molded part are necessary.

[0033] Essential to the invention is that the formation of the molded body takes place within a bulk material. In no case does the formation of the molded body take place within a liquid or gel; thus, no additional container is required to hold a 25101T.

[0034] 7

[0035] A liquid or gel is required. Regardless, the bulk material can be arranged in a container if this is advantageous from a process engineering point of view or for other reasons, for example with a view to possible reuse of the bulk material.

[0036] The following describes embodiments of the invention which relate to the production of a metallic molded part.

[0037] While in the SAAM process the flux consists essentially of non-metallic, ceramic-oxide material, is predominantly non-metallic in its composition, and metallic additives are technically controlled minimal amounts specifically intended for metallurgical purposes, i.e., they are not a main component of the flux and are not essential for its protective function, the particle bed used in the process according to the invention is a metallic bed. The bed material is therefore conductive, in particular electrically and thermally conductive.

[0038] According to one embodiment of the invention, the proportion of metallic particles in the bulk material is greater than 10 wt.%, preferably greater than 30 wt.%. Preferably, the bulk material comprises more than 90 wt.% metallic particles. It is particularly advantageous if the bulk material consists entirely or substantially entirely of metallic particles, especially with more than 98 wt.% metallic particles.

[0039] According to one embodiment of the invention, the bulk material comprises metallic powders, spheres, granules, chips, or mixtures thereof. According to one embodiment of the invention, the bulk material consists of flowable 25101T.

[0040] 8

[0041] Bulk material, i.e., material containing granular particles. Preferably, this is a dry, granular bulk material. According to one embodiment of the invention, the particles of the bulk material can have virtually any grain size and shape, as long as they functionally form a granular bulk material. The diameter of the particles is preferably between 0.05 mm and 5 mm, particularly preferably between 0.5 mm and 3 mm.

[0042] Preferably, the fill material comprises no components other than those mentioned. However, to save assembly time, the integration of semi-finished products, such as sheets or pipes, into the fill is possible. These are embedded in the fill and integrated into the structure of the molded body.

[0043] According to the invention, material and / or energy are introduced into the bulk material with the aid of the introduction device. Preferably, the material and energy are introduced simultaneously. The introduction material is preferably build-up material, i.e., material that is melted to form the shaped body. The energy introduced into the bulk material is primarily or exclusively melting energy, i.e., energy that serves to melt the introduction material or the build-up material to produce the shaped body.

[0044] In this context, "introduction" by which a build-up material is provided means that the material is introduced into the bulk material and melted within the bulk material. The melted material then forms the build-up material used to create the molded part, or a portion thereof.

[0045] 9

[0046] The melting process serves to provide the build-up material, typically consisting of the input material – possibly supplemented by molten bulk material – and molten molding material, provided a layer or build-up track of the molded part is already present upon which the build-up is carried out. By providing the build-up material in the form of a melt bath, the molded body is created – after the melt has solidified.

[0047] According to one embodiment of the invention, the material used for the incorporation is a solid material, particularly in the form of a wire or rod. Preferably, metallic materials are used as the incorporation material, especially titanium, copper, nickel-based alloys, steel, stainless steel, or mixtures thereof. It is also possible to change the material used during the build-up process.

[0048] The material is introduced using an introduction device. According to one embodiment of the invention, this device can be connected to or is connected to a material reservoir which provides the required introduction material.

[0049] According to one embodiment of the invention, the insertion device is inserted into the bulk material in order to position itself at a defined location within the bulk material. In doing so, bulk material is displaced.

[0050] According to one embodiment of the invention, a working space is created within the bulk material by the insertion device penetrating it, optionally in conjunction with the penetration of a further functional device. A positioning device with several axes, controllable by means of a control unit, serves to position the insertion device in 10 of the bulk material. This control unit is also designed to perform all other described control functions.

[0051] According to the invention, the process is carried out without the use of a flux, which leads to a reduction in costs. Since it is a flux-free process, no slag is formed. Therefore, all slag handling, in particular slag removal, is eliminated. Because the use of a flux, which can lead to impurities, is completely avoided, even reactive metals such as titanium or aluminum can be processed.

[0052] According to one embodiment of the invention, solid material introduced into the bulk material is melted within the bulk material using an energy beam.

[0053] The energy beam introduced into the fill is preferably a concentrated and / or bundled energy beam, in particular a plasma, electron or laser beam.

[0054] According to one embodiment of the invention, a wire introduced into the bulk material is melted within the bulk material using an electric arc. The material introduced is therefore preferably in the form of welding wire or rod, or alternatively as a meltable material in another, defined feedable form. The wire or rod diameter is preferably in a range between 1 mm and 6 mm. The introduction device then comprises a wire feeder for the continuous, controlled feeding 11 of the wire into the bulk material.

[0055] According to one embodiment of the invention, a suitable arc source is provided for igniting the arc, which is also inserted into the bulk material. Preferably, the wire feed is combined with the arc source in a functional device and can be moved within the bulk material as a controlled moving unit. An insulating sleeve is provided at the wire outlet for defined position control of the arc.

[0056] According to one embodiment of the invention, the arc is ignited and maintained between the wire and the surrounding particle bed within the particle bed. Cold ignition within the particle bed is possible; a substrate is not required. The current is conducted away via the particle bed or via the shaped body. Multi-wire operation is possible, with the wire spacing preferably being less than 25 mm.

[0057] According to one embodiment of the invention, energy is introduced inductively. Preferably, energy is introduced such that electromagnetic fields within the packed bed, namely in the packing material and / or the material being introduced, generate eddy currents that cause local melting of material, in particular the material being introduced and / or the packed bed material. This type of energy introduction utilizes the principle of inductive coupling to melt material within the packed bed. Since the energy input is contactless, the creation of a free space is not required and preferably does not occur. 25101T

[0058] 12

[0059] If, according to one embodiment of the invention, energy is introduced into the bulk material by electromagnetic induction, coils or other suitable conductor structures are used to generate the eddy currents. These are arranged inside and / or outside the bulk material and, if necessary, moved inside and / or outside the bulk material with the aid of a suitable positioning device for the purpose of positioning relative to the working space.

[0060] According to one embodiment of the invention, different types of energy provision, in particular the types described above, are advantageously combined.

[0061] According to one embodiment of the invention, the energy introduced into the bulk material, in particular the energy beam or the induction field, fuses the introduced material and the material already present within the bulk material to form the shaped body. For this purpose, the energy input creates a locally confined melting zone by locally melting an area of ​​an existing surface of the shaped body within the bulk material. Simultaneously, introduced material, for example in the form of a wire or rod, is introduced into this melting zone from the outside. In other words, the energy beam or the induction field locally melts the material and an area of ​​the existing surface of the shaped part, so that the new material fuses with the existing layer.Preferably, only the portion of the existing molded body necessary for the adhesion of the new layer is melted. This allows for low thermal stresses and reduces distortion. As the energy beam or induction field is moved, the melt pool solidifies. By 25101T.

[0062] 13. By progressively moving the energy beam or the induction field and repeatedly, preferably continuously, adding material, the desired shaped body grows layer by layer. The geometry of the shaped body can be formed in almost any way imaginable.

[0063] According to one embodiment of the invention, the introduction comprises exclusively the introduction of the material into the bulk material. An additional introduction of energy is then not provided.

[0064] According to one embodiment of the invention, the input material, in particular the build-up material, is introduced into the working chamber as a liquid melt, especially from outside the bulk material, via a suitable supply line, a nozzle, or the like. Preferably, a metal melt that has already been melted outside the bulk material with the aid of suitable means is introduced into the working chamber. The melt solidifies within the bulk material and additively forms the molded body or a part thereof. The bulk material thereby assumes a shaping, supporting, and thermally damping function and acts as a heat sink.

[0065] According to one embodiment of the invention, as with other additive manufacturing processes, 3D data is used to control the deposition path and to determine the layer thickness. The build-up is additive, track by track, in particular layer by layer or in spatial tracks.

[0066] According to one embodiment of the invention, the bulk material is at least partially melted and integrated into the molded body. In this way, different material mixtures or alloys can be formed, particularly in conjunction with alternating layers of 25101T being incorporated into the bulk material.

[0067] 14 materials introduced.

[0068] According to one embodiment of the invention, the introduction comprises exclusively the introduction of energy into the bulk material, in particular in the form of a focused or concentrated energy beam or an induction field. In this case, the bulk material alone forms the build material and the shaped body is produced exclusively using the bulk material.

[0069] In one embodiment of the invention, when bulk material is consumed, it is provided that new bulk material is added to the bulk material to the extent of the bulk material consumed.

[0070] Insofar as the bulk material is not consumed, it is reusable according to one embodiment of the invention. For this purpose, the bulk material is preferably designed such that it can be reused at least ten times without losing its process-stabilizing effect.

[0071] According to one embodiment of the invention, at least a portion of the working space is designed as a free space into which input material and / or energy is introduced. Such a free space is characterized by the fact that it contains no material, in particular no bulk material. The free space preferably serves to provide a distance required for process-related reasons between the input material and / or the molded body on the one hand and the bulk material on the other, in particular to provide an insulating or spark gap for ignition or maintenance of the arc. 25101T

[0072] 15

[0073] According to one embodiment of the invention, the free space is formed with the aid of a functional device suitable for creating a free space, preferably as an insulating element projecting into the fill. Preferably, the formation of the free space by the free space device is supported by the supporting effect of the surrounding fill, the fill material of which has been displaced by the free space device. In particular, the supporting effect of the fill and / or the displacement resistance generated by the fill is a prerequisite for the creation of a stable free space by the free space device.

[0074] According to one embodiment of the invention, the insulating element, consisting of a suitable insulating material, for example ceramic, has a sleeve and / or bell shape and displaces fill material into other areas of the fill to form the free space, so that a preferably ring- or bell-shaped free space is created which ensures such a minimum distance to the fill and thus sufficient insulation that a short circuit can be excluded and a stable arc can be provided.

[0075] According to one embodiment of the invention, the material introduced is not a build-up material, but rather a material that supports the melting process or is necessary for carrying out the melting process, in particular a protective gas. Preferably, the melting takes place under the influence of a protective gas. The supply of protective gas, especially in the form of a protective gas stream, is necessary for some processes and is effected via a suitable introduction device. Preferably, the melting bath is subjected to controlled exposure to a suitable protective gas, such as argon or helium. 25101T

[0076] 16

[0077] According to one embodiment of the invention, the protective gas is supplied in a high concentration and therefore mixes only slowly with the atmosphere.

[0078] According to one embodiment of the invention, continuous exposure to a comparatively low gas flow of only 1 to 5 1 / min compared to other methods, such as SAAM, is carried out, resulting in low consumption and cost savings.

[0079] According to an alternative embodiment of the invention, because the working space is enclosed by the packing material, which serves as an atmospheric barrier, a continuous supply of protective gas is unnecessary. To provide the necessary quantity of protective gas for the process, the working space is then only partially or completely filled with the protective gas from time to time, as required, or at defined intervals.

[0080] According to one embodiment of the invention, the gas supply for protective gas application is combined with the provision of the free space. The protective gas forms a protective gas dome within the packing, which completely encloses the melting area.

[0081] According to one embodiment of the invention, an insulating sleeve or bell projecting into the bulk material, with a recessed annular gas nozzle, is used as a combined free-space and insertion device. It is particularly advantageous if the nozzle unit has cooling and / or an integrated protective gas purge. 25101T

[0082] 17

[0083] Essential to the invention is that the bulk material, unlike in SAAM or other known similar processes, plays an active role in the production of the molded part; in other words, it is actively integrated into the manufacturing process. The bulk material does not merely serve as a particle bed. Preferably, it simultaneously serves as a molding medium and support for the melt bath and / or for the molded part to be produced, as a heat conductor for dissipating heat energy from the melt bath, and / or as an atmospheric barrier.

[0084] According to one embodiment of the invention, the packing material exerts a supporting and / or shaping effect on the working space and / or on the contents of the working space. Preferably, the packing material mechanically supports, stabilizes, and / or shapes the melt bath or the resulting molded part. Therefore, there are few limitations on the geometry of the molded part. In particular, layer heights greater than 8 mm per layer are possible despite low-viscosity melts, and self-supporting geometries can be produced without support structures.

[0085] According to one embodiment of the invention, the packing material conducts heat energy away from the working space, in particular from the melting bath. Due to the thermally conductive properties of the packing material, a targeted change in the temperature within the packing and thus in the ambient temperature of the working space or the melting bath is possible, in particular preheating or cooling during the build-up process.

[0086] Preferably, the packing material serves as an energy sink and thus for energy removal, in particular heat removal, from the molten bath. In this way, the molten bath can be cooled very quickly, so that the molten material solidifies rapidly. Overhangs and other 25101T

[0087] Eighteen complex structures can therefore be produced without any problems, without the need for a 5-axis control of the working head.

[0088] Furthermore, overheating damage can be avoided. In particular, copper and silver, nickel / cobalt alloys, as well as soft or ferritic steels can be used as construction materials. A low-stress construction and / or minimal distortion are achieved when using these materials.

[0089] According to one embodiment of the invention, the bulk material is actively cooled in order to further increase heat dissipation from the working space and / or the melting bath.

[0090] According to one embodiment of the invention, the packing acts as an atmospheric barrier, shielding the melting bath and / or the working space from the outside atmosphere. In other words, the packing prevents ambient air from entering the melting bath without requiring any additional structural or process-related measures.

[0091] Since the workspace acts as a kind of local inert chamber due to the shielding provided by the particle bed,

[0092] - especially when a stable energy supply for melting and very good heat dissipation are ensured

[0093] - also reactive metals and / or alloys, in particular titanium, aluminum, zirconium, tantalum, niobium and / or magnesium, are used as input material and melted on.

[0094] The above-described method for producing a metallic molded part is particularly suitable for the manufacture or repair of large metallic structures, especially large-volume metal components. Due to its simplicity and 19

[0095] Due to its robustness, the process can also be used in harsh environments, such as construction sites, field repairs, or marine environments. It is characterized by, among other things, the following advantageous properties: the ability to process difficult materials, high build rates, long application intervals without interruption, short waiting times, high process stability, distortion control through heat dissipation, no consumables, minimal gas supply, reusable process medium, and low operating costs.

[0096] Further embodiments of the invention are described below, the constructive and / or functional features of which can be advantageously combined with constructive and / or functional features of the previously described embodiments of the invention.

[0097] According to one embodiment of the invention, the bulk material consists of free-flowing bulk material (bulk material). This refers to material containing granular particles. In other words, it is a granular bulk material.

[0098] According to one embodiment of the invention, the fill is an inclined fill, i.e., there is an angle of repose (angle of friction) that depends on the type of granular fill material. The fill is preferably dimensionally stable enough that an additional container for receiving the fill material or limiting elements for confining the fill material are not required. Only a suitable support for the fill is needed, such as a base plate or other suitable substrate. Depending on the application, the ground is also suitable as a support for the fill. 25101T

[0099] 20

[0100] According to one embodiment of the invention, the support is stationary, i.e., it remains in one place and is not moved. This means that the fill material and thus the molded part being produced are also not moved. Preferably, the support is stationary throughout the entire build-up process, particularly until the solidification process is complete, i.e., until the molded part is completely or substantially completely solidified. After the build-up process is complete, the molded part can be removed from the fill material, cleaned of any remaining adhering material if necessary, and moved to another location for further use.

[0101] The flow properties of the bulk material are preferably such that the bulk material exhibits good flow behavior, i.e., it can be made to flow without effort. Fine and / or coarse-grained bulk material can be used.

[0102] According to one embodiment of the invention, the packing is a dry, granular packing, in particular a dry solid packing, for example a granular or powder packing. The packing can, for example, be formed by a bed of gravel or crushed stone. However, the packing can also be formed by a powder bed, in particular consisting of metal or ceramic powder.

[0103] A dry fill is preferably understood to mean that the fill material is functionally dry, i.e., structurally stable and purely mechanically displaceable, without elastic yielding and / or without viscoelastic or pasty flow behavior. The fill material behaves purely passively during displacement. 25101T

[0104] 21

[0105] According to another embodiment of the invention, the bulk material is moist bulk material. The bulk material can then be described as moist granular bulk material. In this case, too, the bulk material is preferably functionally dry.

[0106] According to one embodiment of the invention, the packing is formed from a single material. This means that the entire packing consists of one packing material.

[0107] According to one embodiment of the invention, the packing consists section by section, namely in the horizontal direction (along the x-axis and / or the y-axis) and / or in the vertical direction (i.e. along the z-axis, forming material planes), of different packing materials.

[0108] According to one embodiment of the invention, the fill is formed by a multi-component fill material, which is composed of a mixture of different fill materials. In other words, the fill does not need to be homogeneous. Different fill materials can be used for the fill. The different fill materials can be arranged in areas, layers, etc. In this way, the fill can be used for different functional purposes; for example, an upper layer of the fill can consist of fill material with a coarse grain, and a lower layer of the fill can consist of fill material with a fine grain.

[0109] If different bulk materials or multi-component bulk materials are used, the different materials or material components preferably exhibit 25101T.

[0110] 22 different particle sizes (granulations) to enable and / or simplify subsequent mechanical separation of the mixture.

[0111] According to one embodiment of the invention, the insertion device penetrates the bulk material in a penetration step that takes place prior to the actual assembly process, in order to position itself at a defined location within the bulk material. Positioning within the bulk material is achieved, in particular, by inserting, inserting, or immersing the device, whereby the insertion of the device displaces bulk material. The insertion of the device into the bulk material preferably occurs from above or from the side, in any case in such a way that the dimensional stability of the bulk material is not significantly impaired and its function for the assembly process is not affected.

[0112] The insertion device is advantageously designed in such a way that it is particularly well suited for displacing bulk material, and the bulk material used for the insertion is selected in such a way that it can be displaced by the insertion device.

[0113] Preferably, the insertion device is part of a working head which, in addition to the insertion device, includes other functional devices involved in the assembly process.

[0114] According to one embodiment of the invention, several insertion devices are provided which are used for staggered or simultaneous positioning in one and the same bulk material and / or for staggered or 25101T

[0115] 23 simultaneous use within this bulk material for the production of one and the same molded body are designed.

[0116] It is also possible to build up different shaped bodies one after the other or simultaneously in one and the same bulk material, for which purpose several insertion devices may also be provided.

[0117] According to one embodiment of the invention, a delivery device penetrates a bulk material, in particular a granular bulk material. According to one embodiment of the invention, the bulk material is configured such that its displacement or penetration resistance is dependent on the bulk height, and in particular directly and immediately on the bulk height. In other words, the bulk material used is preferably defined by the fact that it offers the delivery device a resistance that is dependent on the bulk height or penetration depth. In addition to this dependence on bulk height, the penetration resistance of the granular media preferably used as bulk material is also dependent on the grain size and shape as well as on the packing density (bulk density / porosity), since penetration into the bulk material requires work against the contact forces between the grains.This contrasts with gels, where the penetration resistance primarily depends on the material's modulus of elasticity, and a corresponding resistance results from elastic deformation and, if applicable, viscoelastic behavior of the material. It also contrasts with liquids, where the displacement resistance is primarily a dynamic flow problem and depends on velocity, viscosity, and flow rate. In summary, unlike liquids or gels, the displacement of the granular 25101T occurs...

[0118] 24

[0119] The flow properties of a packed bed material are determined by the rearrangement and friction of individual particles. The packed bed material does not exhibit continuous, plastic, viscoelastic, or thixotropic flow properties, but rather behaves as a discrete, granularly structured medium. In a packed bed, the resistance to penetration results from the depth-dependent increase in contact and frictional forces between the particles, whereas in liquids and gels, the resistance is determined by viscous or viscoelastic flow processes.

[0120] According to one embodiment of the invention, the bulk material is designed such that a working space can be provided or created within the bulk material. According to another embodiment of the invention, the bulk material is designed such that it supports the working space, allowing material to be introduced into the working space and / or ensuring that material (bulk material, introduction material, building material), in particular material contained in and / or introduced into the working space, remains within the working space. In other words, the bulk material provides support to the working space and / or its contents.

[0121] According to one embodiment of the invention, the supporting effect of the fill not only defines a lower boundary, base, or support for the workspace, but also acts in at least one further spatial direction (spatially partial supporting effect). If the workspace is located entirely within the fill, the supporting effect of the fill preferably extends in all directions (spatially omnidirectional supporting effect). 25

[0122] According to one embodiment of the invention, the bulk material serves as a forming device for the molded body to be produced, particularly in the sense of a formwork. If the working space moves along a build-up path through the bulk material, the bulk material preferably fulfills the function of a forming device moving along the build-up path.

[0123] According to one embodiment of the invention, the working space is formed at the position of the insertion device within the bulk material, in particular at the position of a discharge opening of the insertion device within the bulk material. In other words, the working space is formed below the surface of the bulk material, more precisely at a penetration depth of the insertion device. The working space is created by the penetration of the insertion device into the bulk material and is defined by the presence of the insertion device within the bulk material and the position of the discharge opening of the insertion device within the bulk material.

[0124] According to one embodiment of the invention, the working space has no fixed geometric boundaries. Therefore, the working space also does not have a specific, predetermined volume. Instead, the working space is preferably functionally defined as a spatial region moving along the build-up path in which material is displaced, and / or as a spatial region moving along the build-up path in which material is mixed, and / or as a spatial region moving along the build-up path in which material solidification takes place. Preferably, the working space is arranged completely within the fill, i.e., the working space is surrounded on all sides by the fill. The size of the working space can vary depending on the chosen embodiment 26 of the method.In particular, the size of the working space can be influenced by the cross-sectional area of ​​the discharge opening, the material properties of the input material, and / or the material properties of the bulk material. Preferably, the dimensions of the working space, especially its height, correspond essentially to the height of a layer of a layered molded body.

[0125] According to one embodiment of the invention, the penetration depth of the insertion device is greater than the height of the working space. Preferably, the penetration depth of the insertion device into the fill is 0.1 cm to 150 cm, in particular 0.5 cm to 30 cm.

[0126] According to one embodiment of the invention, the feeding device with its dispensing opening moves along a specific, predefined path within the bulk material. The path is preferably a three-dimensional path with components in all three spatial directions (x, y, z).

[0127] The fact that the feeding device is moved in this path direction means that the position of the feeding device's discharge opening, and thus the position of the working space within the bulk material, changes in a defined way (distance, time, speed). Due to this resulting movement of the working space, the molded body can be built up within the bulk material along the path or along the sum of the paths.

[0128] According to one embodiment of the invention, the path is a path consisting of a sum of individual paths into which a digital representation of the molded body to be produced is decomposed and which map the volume of the molded body to be produced. 25101T

[0129] 27

[0130] Preferably, the resulting shaped body corresponds essentially to the sum of the active path movements, i.e., those involving the introduction of material and / or energy.

[0131] According to one embodiment of the invention, the paths do not necessarily run in planar layers, i.e., the working space does not necessarily move in layers that lie in a plane, particularly in the xy-plane. In other words, the distance of the discharge opening of the insertion device from the surface of the fill material can change during insertion. This means that, in principle, the paths used can run arbitrarily in three-dimensional space. Nevertheless, the paths preferably run such that the molded body is built up layer by layer.

[0132] According to one embodiment of the invention, the paths do not intersect. In particular, the paths are selected such that the insertion device, during its movement within the bulk material, does not cross any paths along which material and / or energy has already been introduced into the bulk material.

[0133] According to one embodiment of the invention, the paths are configured such that the molded body is built up section by section or area by area. This means, in particular, that different parts of the molded body are built up successively, i.e., at intervals between each other. Preferably, the successively built molded body areas or sections touch each other, since they are built up along contacting individual paths, and are thus connected to one another. However, the molded body can also be built up along a single continuous path, with sections of the path touching during the build-up process, thereby connecting the individual 25101T

[0134] 28

[0135] Molded body areas or sections are connected to each other.

[0136] According to one embodiment of the invention, the formation of the molded body begins with the solidification of a first, initial molded body area within a region of a bulk material in which no molded body is yet present. Further molded body areas are then added to this first molded body area, following the course of at least one build-up path. Preferably, the build-up process taking place during the execution of the method does not merely serve to create a connection between existing components.If, during the execution of the process, a first molded body area is to be connected with a second molded body area, then this preferably involves the production of a connection between an already solidified first area of ​​the molded body and a second area of ​​this molded body that is yet to be solidified, wherein both areas are created successively by a build-up process along the build-up path and the connection of the two areas is effected by the solidification of the second area serving the build-up of the molded body.

[0137] According to one embodiment of the invention, the movement of the insertion device along the path is not manual, but motor-driven. For this purpose, the insertion device is connected to a suitable positioning device, which allows it to be positioned in space. The positioning device preferably comprises three or more controllable axes for this purpose.

[0138] According to one embodiment of the invention, the movement of the insertion device along the path is automatic, in particular controlled by a suitable control unit. 25101T

[0139] 29

[0140] According to one embodiment of the invention, the control unit controls both the movement of the insertion device through the bulk material and the insertion of material and / or energy into the bulk material, which depends on the position of the insertion device in the bulk material.

[0141] According to one embodiment of the invention, the control unit for this purpose comprises a processor for executing a computer program which contains computer program instructions corresponding to the method and / or is connected or connectable to a remotely arranged computer having such a processor.

[0142] According to one embodiment of the invention, material and / or energy, in particular thermal or radiant energy, e.g., by a laser to achieve solidification by radiation hardening, or by a plasma, is introduced into the bulk material with the aid of the introduction device. In other words, particularly during the movement of the introduction device within the bulk material, a material and / or non-material material is introduced into the bulk material with the aid of the introduction device. Material and energy can be introduced into the bulk material simultaneously or sequentially. If energy is introduced into the bulk material, it is in particular solidification energy, i.e., energy that serves to solidify build-up material for the production of the molded part.

[0143] According to one embodiment of the invention, this introduction initiates or triggers a solidification of the build-up material. That the introduction initiates or triggers a solidification of the build-up material means that 25101T

[0144] 30 years prior to this introduction, the consolidation of the building material had not yet begun, particularly because a component necessary for the consolidation process (material and / or energy) was still missing.

[0145] According to one embodiment of the invention, the bulk material is prepared before the introduction of the material in such a way that all components necessary for the solidification process are already present within the bulk material, except for at least one component (material and / or energy) which is introduced into the bulk material at a time determined by the user with the aid of the introduction device. The duration of the solidification process depends on the type of solidification.

[0146] According to one embodiment of the invention, the introduction is provided such that an introduction material is dispensed into the bulk material, whereby a chemical reaction occurs with a bulk material and / or a second introduction material already previously introduced into the bulk material, which chemical reaction and the subsequent solidification of material are still ongoing while the introduction device is already being moved further along the path through the bulk material.

[0147] According to one embodiment of the invention, the introduction is provided such that energy, in particular thermal energy, is introduced into the bulk material in order to solidify the bulk material and / or an introduction material already previously introduced into the bulk by the application of heat. For this purpose, the introduction device or the working head comprising the introduction device is moved into the interior of the bulk material. Preferably, the 25101T remains

[0148] 31

[0149] In such a case, the insertion device is positioned at the insertion position until the material has completely solidified or until a minimum degree of solidification is achieved that allows the insertion device to move further along the path.

[0150] The introduction of material and / or energy into the bulk material preferably occurs in such a way that the material and / or energy is introduced into the working space below the surface of the bulk material. In particular, material and / or energy is introduced essentially exclusively into the working space, i.e., the introduction of material and / or energy into an area outside the working space does not occur or only to an insignificant extent.

[0151] According to one embodiment of the invention, the method of introduction varies during the process. In particular, different materials and / or energies are introduced into the bulk material successively.

[0152] According to one embodiment of the invention, the introduction itself takes place in a defined manner, i.e., a certain quantity of material (weight, volume) and / or energy (joules) is introduced into the bulk material within a certain time by releasing this quantity from the introduction device into the working space.

[0153] According to one embodiment of the invention, the delivery of material and / or energy is suitably controlled within a specific period of time such that the speed and / or accuracy of the molded part production is influenced. 25101T

[0154] 32

[0155] According to one embodiment of the invention, the introduction of material and / or energy takes place automatically, in particular controlled by a suitable control unit, especially taking into account the position of the introduction device along the path, according to the amount of build-up material required for the production of the molded body or according to the amount of energy required for solidifying build-up material.

[0156] According to one embodiment of the invention, the material used is a build-up material, i.e., material which is solidified to form the shaped body.

[0157] According to one embodiment of the invention, the incorporation material is a solid material, in particular a granular material, e.g., granules or powder. However, in principle, any material can be used as the incorporation material; this includes solids, liquids, gases, and any mixtures thereof. Examples of incorporation materials are cement paste, clay, and the like.

[0158] According to one embodiment of the invention, the input material is material from which building material is created, for example with the help of further material and / or by adding energy, wherein the further material is material already present in the bulk material and / or additional input material introduced into the bulk material.

[0159] According to one embodiment of the invention, the input material is material that is required for the formation of build-up material, for example by mixing 25101T

[0160] 33 of materials and / or a chemical reaction of materials. In particular, the input material can either itself form the build-up material or contribute to the formation of the build-up material, especially as a component of the build-up material or as a reagent required for the formation of the build-up material.

[0161] According to one embodiment of the invention, the incorporation material comprises a first and at least one second material, the second material preferably being selectively mixed with the first material. The second material can, for example, be a material essential for the formation or solidification of the molded body. However, the second material can also be merely a non-essential additive, such as a colorant.

[0162] According to one embodiment of the invention, the incorporation material is one- or multi-component. Multi-component molded bodies can then be produced by selectively solidifying different bulk materials and / or incorporation materials, in particular build-up materials.

[0163] If different materials are used as incorporation or build-up materials, these materials preferably have different compositions so that, through the targeted use of these materials, for example, sequentially or mixed together in a defined manner, specific areas of the molded body can be produced that exhibit different properties. 25101T

[0164] 34

[0165] According to one embodiment of the invention, the introduction material is a reactive material. In other words, the introduction material reacts with the bulk material and / or with a further, additional introduction material and / or with introduced energy.

[0166] According to one embodiment of the invention, the material used for incorporation is material that is required to solidify the building material.

[0167] According to one embodiment of the invention, the material introduced is not a material forming or representing a building material, but instead a material supporting the solidification process or a material necessary for carrying out the solidification process, in particular a protective gas or a solidification accelerator.

[0168] According to one embodiment of the invention, a first injection device serves to introduce a build-up material, and a second injection device serves to introduce a protective gas. The second injection device is preferably attached to the same working head as the first injection device, so that both injection devices perform the same movement along the build-up path. The introduction of the protective gas can occur simultaneously with or at a time delay from the introduction of the build-up material.

[0169] According to one embodiment of the invention, the introduction of the introduction material displaces the bulk material. For this to occur, the bulk material must pass through the 25101T.

[0170] 35

[0171] Allow the fill material to be displaced. If the fill material is completely displaced, it then serves, according to one embodiment of the invention, as a support material for the molded body and thus fulfills a protective and / or supporting function. Preferably, in this case, the fill material surrounds the space in which the molded body is formed by hardening, which is preferably the working space.

[0172] According to one embodiment of the invention, the material introduced into the bulk mixes with the bulk material instead of displacing it. In other words, the material to be solidified consists of material introduced into the bulk by the introduction device and / or bulk material already present in the bulk. According to one embodiment of the invention, the bulk material then serves as support material for the formed body and thus fulfills a protective and / or supporting function. Preferably, in this case, the bulk material surrounds the space in which the formed body is created by hardening, which is preferably the working space. Whether the bulk material is displaced or mixed with it depends essentially on the viscosity of the material introduced.

[0173] Mixing preferably takes place in such a way that the introduction material fills gaps and / or cavities in the bulk material. For example, the bulk material can have a coarse grain size and the introduction material a fine grain size. The introduction material can also be a pasty mass that is introduced into the bulk material under pressure.

[0174] 36. When the input material and the fill material mix, the fill material forms at least a portion of the molded body to be produced. In other words, according to one embodiment of the invention, the fill material becomes at least a partial component of the molded body.

[0175] According to one embodiment of the invention, the material to be introduced already comprises a proportion of bulk material. In this case, too, the bulk material becomes at least partially a component of the molded body, even if the bulk material already present in the bulk is completely displaced by the introduction of the material to be introduced.

[0176] According to one embodiment of the invention, the composition of the insertion material is not constant, but is changed depending on the penetration depth of the insertion device or the working head. In this way, the chemical composition of the materials involved in the formation of the molded part can be advantageously changed depending on or taking into account process parameters such as the speed of the working head, penetration depth, insertion pressure, grain size, particle shape, etc.

[0177] According to one embodiment of the invention, the insertion step does not include the insertion of material, but rather the introduction of energy exclusively into the bulk material. In this case, preferably only the bulk material forms the build-up material. In other words, the shaped body is produced exclusively using the bulk material. 25101T

[0178] 37

[0179] According to one embodiment of the invention, different materials are successively introduced to build up a plurality of shaped bodies, wherein these shaped bodies are connected to one another, preferably in such a way that one shaped body at least partially, but preferably completely or substantially completely encloses the other shaped body.

[0180] According to one embodiment of the invention, in a first insertion step, a first build-up material is introduced, preferably by displacing bulk material, i.e., using a high-viscosity material, to produce a shell component of defined shape and size located within the bulk material. Preferably, the shell component is designed as a thin-walled shell. In a subsequent second insertion step, a second build-up material is introduced into the interior of the shell component, preferably by mixing it with the bulk material, i.e., using a low-viscosity material, in particular such that the shell component is completely filled.Both the production of the shell component, especially in a form as a thin-walled formwork, and the filling of the formwork space formed by the shell component can be carried out without damaging or deforming the shell component, due to the supporting effect and the high local holding and resistance force of the fill.

[0181] According to one embodiment of the invention, bulk material is introduced into and / or applied to the bulk material using an introduction device. In particular, it can be advantageous that during the movement of the introduction device, during which a solidification in a 25101T

[0182] 38. The first working area is created, and simultaneously fill material is introduced into and / or applied to the fill. In this way, the height of the fill is increased. In particular, this fill material serves to form a fill area in which the insertion device will later move along a path to produce another part of the molded body.

[0183] To add this additional bulk material to the bulk material, the same feeding device can be used through which the material is introduced into the bulk material, or another feeding device can be used.

[0184] According to one embodiment of the invention, material is removed from the bulk material using a removal device. The removed material is either material involved in the manufacturing process and / or material not involved in the manufacturing process.

[0185] According to one embodiment of the invention, loose fill material not used for the construction of the molded body, in particular loose fill material (i.e., unsolidified fill material) remaining after the solidification process, is removed. The removed fill material is preferably reused.

[0186] According to one embodiment of the invention, material is removed from the bulk material in a targeted manner, i.e., the removal takes place at a defined position within the bulk material and / or the removal takes place at a defined time and / or a specific material is removed. 25101T

[0187] 39

[0188] According to one embodiment of the invention, particularly during the movement of the feeding device along the path within the bulk material, reaction products or intermediates arising in connection with the production of the molded part, especially in connection with the solidification of material, which interfere with the build-up process and / or inhibit bonding, are removed from the bulk material. This removal of reaction products or intermediates, which may settle in the working space or outgas, preferably takes place directly at the point of their formation and / or from the working space and / or from within the bulk material and / or from a solidification zone, wherein such a solidification zone is an area within the bulk material, not necessarily identical to the working space, in which solidification takes place.The removal of reaction products preferably takes place before further solidification of build-up material occurs along the build-up path or before the insertion device is moved further along the path.

[0189] According to one embodiment of the invention, material, for example reaction products, is removed by suction.

[0190] According to one embodiment of the invention, material is introduced and removed in such a way that a purposeful relationship results, in particular in the form of a material exchange. Preferably, material at a temperature T(1) is removed and replaced by material at a temperature T(2). <T ( 1 ) ersetzt . Mit Hil fe eines solchen Austausches von heißem Material durch kaltes Material kann eine schnelle Energieabfuhr verwirklicht werden . 25101T

[0191] 40

[0192] According to one embodiment of the invention, energy is extracted from the bulk material using a extraction device. This is preferably achieved by employing a functional element that reduces the temperature within the working chamber or within the bulk material. This element is preferably a suitable cooling element, a cold gas injection unit, or the like. Like all other functional elements, this functional element is also preferably moved along the build-up path, preferably in a defined spatial relationship to the insertion device. Advantageously, all functional devices involved in the build-up process are part of a single working head.

[0193] According to one embodiment of the invention, the packing is designed such that the entire molded body to be produced is located within the packing and below its surface. Alternatively, the packing can also be designed so that it merely encloses a volume in which the solidification process takes place, in particular the working area. In such a case, parts of the already produced molded body can be arranged outside the packing.

[0194] According to one embodiment of the invention, the fill is provided in a targeted and precise manner, in particular applied to a mounting platform or to a part of an already manufactured molded body, in order to provide a location within the fill where the working space can be formed by the penetration of the insertion device.

[0195] According to one embodiment of the invention, the position of the fill is changed as the construction process progresses, 25101T

[0196] 41 in particular such that the fill required for the provision of the work space is always located at the point in the assembly path where the production of the molded body is started or where production of the molded body that is already taking place is continued.

[0197] According to one embodiment of the invention, the incorporation material comprises one or more reinforcing elements. Preferably, a reinforcing element is understood to be an element distinct from the incorporation material, in particular a separate component provided in addition to the incorporation material, to be introduced into the bulk material, which preferably becomes part of the molded part in order to solidify the molded part. According to one embodiment of the invention, the reinforcing elements are contained in the incorporation material and are introduced into the bulk material together with the incorporation material. Alternatively, the reinforcing elements are introduced into the bulk material independently of any other incorporation material as a separate incorporation material.

[0198] According to one embodiment of the invention, the reinforcing element is a reinforcing fiber, particularly for achieving fiber reinforcement of the molded part to be manufactured. The fiber can, for example, be a carbon fiber, especially a pre-activated carbon fiber. Other suitable fibers include, for example, glass fibers, natural fibers, and metal fibers.

[0199] Preferably, the fiber is laid down in the working area or in the fill and remains at the laying location. For this purpose, the fill material must be displaceable, in particular, it must be able to be displaced by the fiber. The laid fiber extends 25101T

[0200] 42 after insertion along the path of the insertion device.

[0201] When reinforcing fibers are used as reinforcing elements, short, long, or continuous fibers are suitable. According to one embodiment of the invention, long fibers are used as reinforcing elements. These are defined as discontinuous reinforcing fibers incorporated into the component with a length exceeding the critical fiber length required for load transfer.

[0202] According to one embodiment of the invention, in connection with the insertion of the reinforcing fibers, which typically occurs in the direction of the path, or following this insertion, the reinforcing fibers are mechanically anchored to produce a fiber composite. The anchoring takes place within the material located in the working space and / or outside the material located in the working space, i.e., within the fill, in order to provide a reinforcing function similar to reinforcement or bracing, in particular to generate a load-bearing, crack-bridging, and / or strengthening effect.

[0203] According to one embodiment of the invention, other suitable elements, such as rods, fibers, nets, fabrics or comparable inserts, are used as reinforcing elements.

[0204] According to one embodiment of the invention, the introduction of material into the fill comprises the combined introduction of a building material and a reinforcing element. 25101T

[0205] 43

[0206] According to one embodiment of the invention, a boundary element is provided that limits the working space in the path direction. The boundary element is preferably designed such that it limits the working space and / or the molded part to be produced, thereby influencing the contour and / or the surface of the molded part. Preferably, the boundary element is either designed as part of the insertion device that moves with the insertion device, or the boundary element is designed as a component fixed in the material bed, in particular such that it either becomes part of the molded part or is detached from it after the molded part has been produced.

[0207] According to one embodiment of the invention, a movement element is provided which is designed as part of the insertion device or a working head and moves along with the insertion device in the direction of the build path. The movement element comprises a profile with a contour that shapes the body to be produced in the path direction, so that the volume of the body is at least partially formed by the movement of the movement element.

[0208] According to one embodiment of the invention, the moving element is designed and its temperature can be controlled so that it can be used as a heating and / or cooling element. In this way, the solidification process can be supported, depending on the principle on which it is based.

[0209] According to one embodiment of the invention, it is provided that the fill material and / or the material to be introduced, in particular the building material, is compacted. 25101T

[0210] 44

[0211] Preferably, this compaction is carried out selectively. Preferably, this compaction takes place during the movement of the feeding device along the path within the fill. In particular, the compaction is carried out with the aid of a suitable compaction device, which is preferably positioned with an offset to the path, for example, attached to the feeding device.

[0212] According to one embodiment of the invention, the fill material is selected such that the fill material surrounding the molded body during the solidification of the molded body improves the shape retention of the surface of the molded body.

[0213] According to one embodiment of the invention, the packing material itself serves as a shaping element for the molded part to be produced. The greater the penetration depth of the insertion device into the packing material, i.e., the deeper the working space lies below the surface of the packing material, the greater the displacement resistance that the packing material offers to the working head, and the greater the pressure exerted by the packing material on the build-up material, which is primarily due to the compaction of the packing material, dependent on the distance to the packing surface. In this way, the packing material at least partially determines the shape of the molded part. The packing material preferably completely encloses the build-up material or the molded part. In other words, the packing material preferably serves as a shaping casing for the molded body.

[0214] According to one embodiment of the invention, the fill is not formed exclusively from fill material. Preferably, support material 45 is provided to limit the fill. In this way, the required amount of fill material can be minimized.

[0215] According to one embodiment of the invention, preferably during the movement of the insertion device, support material limiting the fill is selectively removed and replaced with fill material. In this way, the composition of the fill, in particular with regard to the required fill material, can be specifically influenced, especially along the path.

[0216] According to one embodiment of the invention, fill material and / or support material is applied to a construction surface, e.g. a base plate or the like, and / or to an existing fill during the movement of the placement device.

[0217] According to one embodiment of the invention, the at least one injection device is designed for the point-by-point or substantially point-by-point injection of material into the bulk material. This means that the material is not injected into the bulk material over a surface area, but rather at a specific point along the build-up path. Preferably, no surface solidification or solidification as a volume reaction occurs within the bulk material; instead, solidification also takes place at specific points or substantially at specific points. In other words, material and / or energy is preferably injected into the bulk material only at those locations where the molded body to be produced is to be formed.

[0218] According to one embodiment of the invention, material and / or energy are exclusively directed into such volume ranges of the 25101T

[0219] 46

[0220] The fill material is introduced, which, after completion of the assembly process, will contain the formed body.

[0221] According to one embodiment of the invention, the at least one feeding device comprises at least one hollow profile with a dispensing opening. The hollow profile, in particular in the form of a tube or cone, is preferably conical and has a dispensing opening, which is preferably located at the end and through which material and / or energy is dispensed into the bulk material. It can be advantageous for the dispensing of material if the hollow profile or the dispensing opening is designed as a nozzle.

[0222] According to one embodiment of the invention, the insertion device comprises two or more hollow profiles designed for the simultaneous or staggered insertion of material and / or energy, and arranged in a defined manner relative to each other, this arrangement preferably being unchanging, so that all hollow profiles of an insertion device fully perform the same movement of the insertion device along the path.

[0223] According to one embodiment of the invention, a material reservoir connected or connectable to the insertion device is provided for supplying insertion material.

[0224] If at least one dispensing device is provided, according to one embodiment of the invention, this device is also designed as a hollow profile, in particular in the form of a tube or pipe, which has a dispensing opening. The dispensing device can be positioned in the bulk material by means of the dispensing opening, which is preferably located at the end. 25101T

[0225] 47

[0226] If several insertion devices are provided and / or at least one insertion device and another functional device that can be inserted into the bulk material, such as a removal device, are provided, then, according to a preferred embodiment of the invention, these functional devices are moved in a coordinated manner, i.e., in a synchronized fashion. Preferably, these functional devices are moved along the same path or along paths that are offset from each other only vertically. In particular, two insertion devices can be moved parallel to each other vertically through the bulk material, with one insertion device inserting material, especially building material, into the bulk material, while another insertion device inserts bulk material into or onto the bulk material.

[0227] According to one embodiment of the invention, two hollow profiles are arranged relative to each other such that a first hollow profile is positioned inside a second hollow profile at a distance from it, in particular such that the central longitudinal axes of the hollow profiles coincide. In this way, different materials can be introduced simultaneously to a common destination within the bulk material with particular ease. This embodiment is especially advantageous for the simultaneous introduction of different materials and for the combined introduction of material and energy.

[0228] According to one embodiment of the invention, in addition to the insertion device, at least one further functional device is provided, each of these functional devices being characterized by the fact that it has 25101T

[0229] 48. It has at least one functional element that can be introduced into the bulk material. An example of a functional device is the previously described dispensing device.

[0230] According to one embodiment of the invention, at least a portion of the working space is designed as a free space containing no material, in particular no bulk material. Preferably, material and / or energy, in particular building material, is introduced into the free space at a later time. Preferably, this free space can be created solely due to the supporting effect of the surrounding bulk material.

[0231] According to one embodiment of the invention, a voiding device is provided as the functional unit, the functional element of which is designed to create a void within the bulk material. In other words, the functional element serves to create a cavity within the bulk material that is free of material, in particular free of bulk material. The functional element is preferably an element that displaces material into other areas of the bulk material to form the void, preferably a bell-shaped displacement element, or an element that removes material from the bulk material to form the void. The creation of a void within the bulk material is particularly advantageous in conjunction with the introduction of energy, for example, when using a plasma or to ensure sufficient insulation when welding metal powder within the working area.

[0232] According to one embodiment of the invention, all functional devices involved in the method, including the insertion device, are parts of a single 25101T

[0233] 49

[0234] The working head is moved by the control unit in a manner defined by the hopper. Alternatively, the functional devices involved are distributed across several working heads that can be used simultaneously or sequentially.

[0235] According to one embodiment of the invention, the working head, which can be inserted into the bulk material, is designed to be multifunctional for the production of the molded body, in order to enable or support the build-up process, in particular to initiate the solidification of the build-up material. For this purpose, the working head has, in addition to a supply or insertion function for material and / or energy, which is present in every case, preferably a removal or extraction function for material and / or energy, a temperature-changing function (i.e., heating or cooling), and / or a shaping function.

[0236] According to one embodiment of the invention, the hollow profiles of the insertion devices or other functional elements of functional devices inserted into the bulk material, such as hollow profiles of intake devices, limiting elements, and the like, are used as tools within the bulk material. These tools serve to produce the shaped body or support this production. Preferably, these functional elements are designed such that, although they are moved along a common build-up path, they can have different directions of action.

[0237] According to one embodiment of the invention, the at least one insertion device and / or another functional device is mechanically actuated to produce additional, in particular, movements that deviate from the movement along the path and / or do not primarily serve the movement along the path.

[0238] 50

[0239] To fully execute movements. These additional movements serve in particular to selectively influence the desired effect of a functional device introduced into the bulk material, especially if it is designed in the form of a hollow profile. Preferably, this mechanical action is such that it causes a rotation about the longitudinal axis of the hollow profile and / or a vibration of the hollow profile.

[0240] According to one embodiment of the invention, the mechanical action of a functional device serves to support the movement of the hollow profile or another functional element introduced into the bulk material. In such a case, for example, vibration serves to reduce the force required to move the insertion device through the bulk material.

[0241] According to one embodiment of the invention, the mechanical action of a functional device serves to create the flowability of an input material or to support the transport of the input material into the bulk material. For this purpose, for example, a vibration caused by an ultrasonic signal transmitter is suitable.

[0242] According to one embodiment of the invention, the mechanical action of a functional device serves to support a mixing and / or combination of input material and bulk material and / or a compaction of material.

[0243] According to one embodiment of the invention, the mechanical action of a functional device serves to smooth the surface of the build-up material. 51

[0244] According to one embodiment of the invention, a functional device is used which mechanically acts upon the input material, in particular reinforcing elements, especially reinforcing fibers, such that the reinforcing elements, preferably deviating from their input direction, are completely or partially moved into a space outside the working space. Preferably, the mechanical treatment of the reinforcing elements is carried out such that the reinforcing elements are positioned across layers, forming a layered composite. Preferably, a plurality of reinforcing elements are introduced into the working space and / or into the bulk material and subsequently mechanically treated with the aid of the functional device such that the reinforcing elements form a composite not only with the input and / or bulk material, but also with each other.

[0245] According to one embodiment of the invention, the functional device for mechanically applying pressure to the reinforcing elements comprises a preferably actively controlled mechanical plunger mechanism, with the aid of which reinforcing elements introduced in the path direction are introduced in a direction-changing manner into underlying areas of the working space, underlying layers of a layered molded body, and / or underlying areas of the fill material. Preferably, the plunger mechanism is designed to apply pressure to the reinforcing elements in different directions. In this way, material areas with particularly strongly bonded reinforcing elements can be produced. Preferably, the plunger mechanism is operated simultaneously with the layer application. Preferably, the 52

[0246] The penetration depth of the plunger is adjustable, in particular such that the plunger penetrates one or more underlying layers. Preferably, the thrust direction of the plunger is controllable in order to selectively introduce reinforcing elements into underlying layers at an angle, the angle preferably being adjustable within a range of up to ± 60° relative to the vertical or the path direction.

[0247] According to one embodiment of the invention, gravel or other aggregate (crushed stone, crushed stone) is used as the fill material, and a suitable polymer is used as a binder to produce a polymer concrete component. A suitable device, in particular a mixing device, is used to ensure sufficient wetting of the fill material with the binder. In this way, a polymer concrete component with advantageously high porosity can be produced with a comparatively small amount of polymer binder. Reinforcing elements can also be incorporated to increase strength.

[0248] The advantages of the invention are based directly or indirectly on the creation of a working space, which may optionally be designed – partially or completely – as a free space, within a bulk of granular bulk material, wherein the bulk material preferably has a displacement resistance that depends on the bulk height or penetration depth and supports the working space and / or the molded body or parts thereof.

[0249] Using this process, a wide variety of materials can be used to produce shaped bodies, such as metals, non-metals, minerals, plastics, etc. These materials can be formed into virtually any shape.

[0250] 53, provided that this form is suitable for use as bulk material and / or material for incorporation in accordance with the invention. The method is therefore universally applicable.

[0251] The process is also virtually infinitely scalable and therefore universally applicable. The resulting molded part can have a volume of just a few cubic millimeters or several cubic meters. The process can thus be used both for manufacturing large components, especially from concrete or similar materials, as used in building construction, and for manufacturing small and very small components, for example, by melting metal or ceramic powder.

[0252] Exemplary embodiments of the invention are explained in more detail below with reference to the drawings. These show:

[0253] Fig. 1 shows a section running in the direction of the path through a fill with a material injection (displacement of the fill material by the injection material).

[0254] Fig. 2 shows a section running in the direction of the path through a fill with a material input (mixing of the input material with the fill material).

[0255] Fig. 3 shows a section through a fill material with an energy input, 25101T, running in the direction of the path.

[0256] 54

[0257] Fig. 4 shows a section running in the path direction through a fill with a material introduction according to Fig. 1 and additional introduction of a long fiber as a reinforcing element.

[0258] Fig. 5 shows a section through a fill running transversely to the path direction with a material input according to Fig. 1 and additional use of a boundary element.

[0259] Fig. 6 shows a section running in the path direction through a packed bed with an energy input according to Fig. 3 and additional introduction of a protective gas.

[0260] Fig. 7 is a schematic illustration of a device for producing a molded body.

[0261] Fig. 8 shows a section through a fill in which a concrete component is produced, consisting of a filled formwork structure.

[0262] Fig. 9 shows a section through a fill in which a thin-walled, fiber-reinforced concrete component is produced.

[0263] Fig. 10 shows a section running in the path direction through a metallic particle bed with a wire as material introduction and an electric arc.

[0264] All figures do not show the invention to scale, only schematically and with its essential components. Identical reference symbols correspond to elements of the same or comparable function. 25101T

[0265] 55

[0266] As outlined in Fig. 1, a placement device is positioned at a defined position in a dry, granular fill 3 by immersing the placement device in the fill 3. The fill 3 was previously poured onto a base plate 4.

[0267] The insertion device comprises a hollow profile 2 with an end-end discharge opening 5. A working space 7 is formed at the position of the discharge opening 5 below the surface 6 of the bulk material 3.

[0268] The hollow profile 2 is connected via a supply device 8, which serves for the transport of material and includes, for example, pipelines and pumps, to a material container 9 in which construction material is located, see Fig. 7.

[0269] A digital representation of the molded body 1 to be produced is decomposed into paths that map the volume of the molded body 1 to be produced. These build paths are stored in a data memory of a control unit 10, see Fig. 7.

[0270] The hollow profile 2 is moved along a continuous path 11 in the direction of path 22. In the example shown here, the path 11 runs in layers through the fill 2. Simultaneously, during defined periods, i.e., either continuously or at specific intervals, pasty build-up material 12 is introduced through the hollow profile 2 into the fill 3. Gravel, for example, is used as the fill material 13. Cement paste, clay, or a geopolymer is used as the build-up material 12. 25101T

[0271] 56

[0272] The introduction of the build-up material 12 displaces the fill material 13. This provides build-up material 12 in layers within the working space 7, from which the molded body 1 is formed. In the depicted section, a first layer NI of the molded body 1 is already completed, and the working space 7 formed at the discharge opening 5 is being moved by the fill material 3 to form a second layer N2 of the molded body 1. The first layer NI can rest on the base plate 4 or be arranged within the fill material 3 at a distance from the base plate 4. The displacement of fill material 13 changes the surface 6 of the fill material 3.

[0273] After completion of the solidification process, the molded body 1 can be removed from the fill 3. No further processing of the molded body 1, such as the removal of support structures or the like, is required.

[0274] The positioning of the hollow profile 2 in the fill 3 and the movement of the hollow profile 2 through the fill 3 along the construction path 11 is carried out with the aid of a positioning device 14, see Fig. 7.

[0275] The control unit 10 serves to control the positioning device 14 for positioning the hollow profile 2 in the fill 3 and for moving the hollow profile 2 along the path 11, as well as for controlling the supply device 8 for introducing the construction material 12 into the fill 3, see Fig. 7.

[0276] The example shown in Fig. 2 differs from the example in Fig. 1 in that a different material is introduced into the fill 3. In this case, mortar is used as 25101T.

[0277] 57

[0278] The fine-grained material 15 is used. It mixes with the coarse-grained fill material 13 (gravel) by filling the voids present in the fill material 13. In this way, a building material for the molded body 1 is provided, and the molded body 1 is formed.

[0279] A different insertion device is used for the example shown in Fig. 3. Again, a hollow profile 16 is used. This one, however, serves to introduce thermal energy 22 for solidifying a build-up material 17 in the area of ​​the working chamber 7, which is located within the bulk material 3. The introduced thermal energy 22 is symbolized in Fig. 3 by an indicated laser beam. A correspondingly designed supply device is provided for supplying the energy. By moving the hollow profile 16 along a defined build-up path 11, the energy is introduced into the areas of the build-up material 17 to be solidified, and the build-up material 17 is solidified layer by layer, thereby producing the molded body 1.

[0280] A variant of the example shown in Fig. 1 is illustrated in Fig. 4. In this case, a reinforcing element in the form of a continuous long fiber 18 is introduced into the fill 3 through the hollow profile 2 together with the building material 12. After insertion, the fiber 18 extends along the path 11 and remains at the installation site.

[0281] A further variation of the example shown in Fig. 1 is illustrated in Fig. 5. A plate-shaped limiting element 19, which delimits the working space 7 in the path direction 22, is attached to the hollow profile 2 and, together with the hollow profile 2, extends along the construction path 11 through the fill 3 25101T

[0282] 58 is moved. The boundary element 19 supports the contouring of the shaped body 1.

[0283] Fig. 6 shows a modified example of energy input compared to Fig. 3. The first hollow profile 16, which serves to introduce thermal energy into the fill 3 to solidify the build-up material 17, is spaced apart within a second hollow profile 20 such that the annular space between the two hollow profiles 16, 20 can be used for the simultaneous introduction of a protective gas into the fill 3 using a further discharge opening 24. The protective gas is symbolized by arrows 21.

[0284] Figure 8 illustrates the production of a concrete structure 1 within a dry, granular fill 3 made of coarse-grained fill material 13, which consists of two successively produced, mechanically connected individual precast parts. First, a highly viscous first build-up material 17, in particular a suitable cement / sand mixture, or a comparable, suitable material, is introduced along a three-dimensional build-up path within the fill 3 using an introduction device in the form of a hollow profile 2. During introduction, the fill material 13 is locally mechanically displaced by the first build-up material 27, creating a geometrically defined, thin-walled formwork structure 27 that is completely surrounded and supported by the fill 3. The formwork structure 27 forms a substantially closed shell.The shell structure 27 preferably consists of only a single layer of construction material 25 and preferably contains a high proportion of long fibers (not shown) as reinforcing elements. In this way, the 25101T.

[0285] 59

[0286] The formwork structure 27 can be erected quickly, hardens quickly and is nevertheless sufficiently stable, especially in combination with the supporting fill 3 that completely surrounds the formwork structure 27.

[0287] Following the complete formation of the formwork structure 27, a low-viscosity, second building material 26, in particular a binder mixture, especially a suitable cement paste mixture or a comparable, suitable material, is introduced into the interior 28 of the formwork structure 27 through an introduction opening provided for this purpose in the formwork structure 27 using the hollow profile 2 (alternatively using a second insertion device, not shown). The formwork structure 27 is thereby completely filled. The second building material 26 mixes with the fill material 13 by penetrating the spaces within the fill material 13, filling the voids there, and hardening together with the formwork structure 27 to form a solid concrete structure 1. The introduction of the second building material 26 can also be carried out along a building path.After hardening, the molded part produced in this way, the concrete structure 1, is removed from the fill 3.

[0288] Figure 9 illustrates the production of a thin-walled, multidimensionally fiber-reinforced concrete structure 1 within a dry, granular fill 3 made of coarse-grained fill material 13. A build-up material 30, in particular a cement / sand mixture, containing a high proportion of long fibers 29, is introduced layer by layer into the fill 3 using an insertion device, again in the form of a hollow profile 2. Each individual layer NI, N2, ... is formed by local mechanical displacement of the fill material 13. Simultaneously with the insertion of each new 25101T

[0289] 60

[0290] In layer N, targeted impacts with a defined frequency and penetration depth are performed by means of an actively controlled, mechanical plunger mechanism 31 to locally and controllably push long fibers 29 of the currently inserted layer N2 into previously inserted layers NI below, in order to create a layer composite. The penetration depth of the plunger is controllable and adjustable between one and five underlying layers. Likewise, the thrust direction 32 is controllable, so that the long fibers 29 are inserted into underlying layers at an angle of up to ± 60° relative to the vertical.

[0291] Figure 10 illustrates an additive manufacturing process for producing a metallic component 1 by arc welding within a metallic particle bed 3, suitable for various metals including reactive alloys. In this process, a welding wire 44 is melted within a bed 3 of metal particles 13 under a protective gas 21. The particle bed 3 supports and mechanically stabilizes the molten pool, dissipates heat in a controlled manner, and prevents oxidation through the protective gas. The particle bed material serves as the process-guiding medium. The process is robust, cost-effective, and field-compatible, requiring no flux and no complex protective gas or vacuum systems.

[0292] The process medium 13 is an electrically conductive granulate of metal spheres. The metallic bulk medium consists of metal spheres made of steel or stainless steel with a diameter of 1 to 2 mm. The metallic sphere bulk is contained in a suitable container (not shown). 25101T

[0293] 61

[0294] The sphere pack 3 serves simultaneously as a mechanical form support, thermal buffer, and atmospheric arc shield. An electric arc 42 is ignited and maintained between the wire 44 and the surrounding sphere pack 3. A suitable electric welding power source 45 with adjustable current is used for this purpose.

[0295] As part of a welding wire feed system, a controlled wire feed unit 46 ensures the required wire feed rate. The wire is fed into the sphere bed 3 via a gas-carrying nozzle unit 40, which, as a combined insertion and clearance device, locally displaces the spheres 13, thereby creating a clearance space and simultaneously supplying the working area 7 locally with a controlled, low flow of shielding gas (0.5 to 2 l / min). A controlled mechanical motion device (not shown) guides the nozzle unit 40 within the space. The nozzle unit 40 is moved along a continuous path 11 in the direction of path 22. The nozzle unit 40 combines a bell-shaped ceramic insulating sleeve 47 with a recessed annular gas nozzle 48.

[0296] A solid wire 44 (e.g., made of steel, titanium, or copper) is inserted into the bed 3 as the build-up material. The wire 44 is melted by the electric arc 42 below the bed surface 6. The build-up material 28 is fused with a melted layer of the existing molded body 1. In this way, material is built up layer by layer below the bed surface 6. The build-up track is between 5 and 20 mm wide. The height of the build-up layer is between 2 and 10 mm. Depending on the strength of the electric arc 42 used, the build-up rate is between 5 and 40 kg / h. A cooling break is only necessary when the bed or interlayer temperature reaches approximately 500 °C.

[0297] 62 required. This allows for continuous operation of approximately 3 to 4 hours at a build-up rate of 30 kg / h, before a break of approximately 10 to 20 minutes is necessary.

[0298] Regarding the devices used in carrying out all the described methods, reference is made to Fig. 7.

[0299] All features described in the text, the following claims, and the drawings can be essential to the invention, either individually or in any combination. Each of these features or combinations of features can constitute an independent invention, the right to claim which is expressly reserved.

[0300] When specifying a combination of features defining an invention, individual features from the description of an exemplary embodiment do not necessarily have to be combined with one or more or all other features specified in the description of that exemplary embodiment; in this respect, every subcombination of features of one or more exemplary embodiments is expressly disclosed.

[0301] Furthermore, tangible features of the device can be reformulated and used as process features, and vice versa. Features reformulated in this way are implicitly disclosed.

[0302] Reference character list

[0303] 1 Molded body

[0304] 2 Hollow profile

[0305] 3 Bulk 25101T

[0306] 4 Base plate

[0307] 5. Delivery opening

[0308] 6 Surface area of ​​the fill

[0309] 7 Workroom

[0310] 8 Provisioning facility

[0311] 9 material containers

[0312] 10 Control unit

[0313] Path 11

[0314] 12 Assembly material

[0315] 13. Fill material

[0316] 14 Positioning device

[0317] 15 Introduction material

[0318] 16 Hollow profile

[0319] 17 Assembly material

[0320] 18 reinforcing fibers

[0321] 19 Boundary element

[0322] 20 hollow profile

[0323] 21 Shielding gas

[0324] 22 Path direction

[0325] 23 thermal energy

[0326] 24 Delivery opening

[0327] 25 first assembly material

[0328] 26 second assembly material

[0329] 27 Shell structure

[0330] 28 Interior of the formwork structure

[0331] 29 Long fiber

[0332] 30 assembly material

[0333] 31. Plunger mechanism

[0334] 32 Direction of thrust

[0335] 40 Insertion and clearance device, nozzle unit

[0336] 41 metallic construction material

[0337] 42 Energy beam 25101T

[0338] 64

[0339] 43 Introduction material

[0340] 44 welding wire

[0341] 45 Welding power source

[0342] 46 Wire feed unit

[0343] 47 I insulating sleeve

[0344] 48 ring gas nozzle

Claims

1. 25101T 65 Claims 1. Method for producing a three-dimensional metallic shaped body (1) by additive manufacturing, characterized in that a placement device (40) positioned in a bulk (3) moves along a path (11) is moved and that, with the aid of the introduction device (40), an introduction into the bulk (3) takes place, whereby build-up material (41) is provided in a working space (7) formed below the surface (6) of the bulk (3), whereby the formed body (1) is created, wherein the bulk (3) comprises metallic particles and wherein, with the aid of the introduction device (40), introduction material (43) and / or energy (42) is introduced into the bulk (3).

2. Method according to claim 1, characterized in that the proportion of metallic particles in the bulk material (3) is greater than 10 wt.%, preferably greater than 30 wt.%, particularly preferably greater than 90 wt.%.

3. Method according to claim 1 or 2, characterized in that the bulk material (13) comprises metallic powders, spheres, granules, chips or mixtures thereof.

4. Method according to one of claims 1 to 3, characterized in that solid input material (43) introduced into the bulk (3) is melted within the bulk (3) using an energy beam (42).

5. Method according to claim 4, characterized in that a wire (44) introduced into the bulk (3) is melted within the bulk (3) using an electric arc (42). 25101T 66 6. Method according to one of claims 1 to 3, characterized in that the energy input is inductive, in particular such that electromagnetic fields generate eddy currents inside the packing, which cause local melting.

7. Method according to one of claims 4 to 6, characterized in that the energy introduced into the bulk material (42) for the formation of the molded body (1) the input material (43) and the material already contained within the fill (3) merges together.

8. Method according to one of claims 1 to 6, characterized in that the input material, in particular the build-up material, is introduced into the working space as a liquid melt.

9. Method according to one of claims 4 to 8, characterized in that the bulk material (13) is at least partially melted and integrated into the molded body (1).

10. Method according to one of claims 1 to 9, characterized in that at least a part of the working space (7) is designed as a free space into which input material (43) and / or energy (42) is introduced.

11. Method according to one of claims 4 to 10, characterized in that the melting takes place under the influence of a protective gas.

12. Method according to any one of claims 1 to 11, characterized in that the fill (3) forms a support and / or 25101T 67 exerts a form effect towards the workspace (7) and / or towards the content of the workspace (7).

13. Method according to one of claims 1 to 12, characterized in that the packing (3) removes heat energy from the working space, in particular from the melting bath.

14. Method according to one of claims 1 to 13, characterized in that the packing (3) serves as an atmospheric barrier and shields the melt bath and / or the working space (7) from the outside.

15. Device for producing a three-dimensional metallic shaped body (1) by additive manufacturing, in particular designed for carrying out the method according to one of claims 1 to 14, with a placement device (40) positionable in a bulk (3) and with a control unit (10) which is designed such that the placement device (40) is moved along a path (11) and that placement into the bulk (3) is carried out with the aid of the placement device (40), whereby build-up material (41) is provided in a working space (7) formed below the surface (6) of the bulk (3), whereby the shaped body (1) is formed, wherein the bulk (3) comprises metallic particles and wherein placement material (43) and / or energy (42) is introduced into the bulk (3) with the aid of the placement device (40).

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