DE4410046C1 - Method and material for producing a three-dimensional object by sintering - Google Patents

Method and material for producing a three-dimensional object by sintering

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Publication number
DE4410046C1
DE4410046C1 DE4410046A DE4410046A DE4410046C1 DE 4410046 C1 DE4410046 C1 DE 4410046C1 DE 4410046 A DE4410046 A DE 4410046A DE 4410046 A DE4410046 A DE 4410046A DE 4410046 C1 DE4410046 C1 DE 4410046C1
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component
powder
melting
melting point
powder material
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DE4410046A
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German (de)
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DE4410046C2 (en
Inventor
Hans J Dr Langer
Christian Wilkening
Peter Keller
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EOS GmbH
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EOS GmbH
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Priority to DE4410046A priority Critical patent/DE4410046C2/en
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Classifications

    • BPERFORMING OPERATIONS; TRANSPORTING
    • B22CASTING; POWDER METALLURGY
    • B22CFOUNDRY MOULDING
    • B22C7/00Patterns; Manufacture thereof so far as not provided for in other classes
    • B22C7/02Lost patterns
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B29WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29CSHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C64/00Additive manufacturing, i.e. manufacturing of three-dimensional [3D] objects by additive deposition, additive agglomeration or additive layering, e.g. by 3D printing, stereolithography or selective laser sintering
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B29WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29CSHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C64/00Additive manufacturing, i.e. manufacturing of three-dimensional [3D] objects by additive deposition, additive agglomeration or additive layering, e.g. by 3D printing, stereolithography or selective laser sintering
    • B29C64/10Processes of additive manufacturing
    • B29C64/141Processes of additive manufacturing using only solid materials
    • B29C64/153Processes of additive manufacturing using only solid materials using layers of powder being selectively joined, e.g. by selective laser sintering or melting
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B33ADDITIVE MANUFACTURING TECHNOLOGY
    • B33YADDITIVE MANUFACTURING, i.e. MANUFACTURING OF THREE-DIMENSIONAL [3-D] OBJECTS BY ADDITIVE DEPOSITION, ADDITIVE AGGLOMERATION OR ADDITIVE LAYERING, e.g. BY 3-D PRINTING, STEREOLITHOGRAPHY OR SELECTIVE LASER SINTERING
    • B33Y70/00Materials specially adapted for additive manufacturing
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B33ADDITIVE MANUFACTURING TECHNOLOGY
    • B33YADDITIVE MANUFACTURING, i.e. MANUFACTURING OF THREE-DIMENSIONAL [3-D] OBJECTS BY ADDITIVE DEPOSITION, ADDITIVE AGGLOMERATION OR ADDITIVE LAYERING, e.g. BY 3-D PRINTING, STEREOLITHOGRAPHY OR SELECTIVE LASER SINTERING
    • B33Y70/00Materials specially adapted for additive manufacturing
    • B33Y70/10Composites of different types of material, e.g. mixtures of ceramics and polymers or mixtures of metals and biomaterials
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B33ADDITIVE MANUFACTURING TECHNOLOGY
    • B33YADDITIVE MANUFACTURING, i.e. MANUFACTURING OF THREE-DIMENSIONAL [3-D] OBJECTS BY ADDITIVE DEPOSITION, ADDITIVE AGGLOMERATION OR ADDITIVE LAYERING, e.g. BY 3-D PRINTING, STEREOLITHOGRAPHY OR SELECTIVE LASER SINTERING
    • B33Y10/00Processes of additive manufacturing
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B33ADDITIVE MANUFACTURING TECHNOLOGY
    • B33YADDITIVE MANUFACTURING, i.e. MANUFACTURING OF THREE-DIMENSIONAL [3-D] OBJECTS BY ADDITIVE DEPOSITION, ADDITIVE AGGLOMERATION OR ADDITIVE LAYERING, e.g. BY 3-D PRINTING, STEREOLITHOGRAPHY OR SELECTIVE LASER SINTERING
    • B33Y30/00Apparatus for additive manufacturing; Details thereof or accessories therefor
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B33ADDITIVE MANUFACTURING TECHNOLOGY
    • B33YADDITIVE MANUFACTURING, i.e. MANUFACTURING OF THREE-DIMENSIONAL [3-D] OBJECTS BY ADDITIVE DEPOSITION, ADDITIVE AGGLOMERATION OR ADDITIVE LAYERING, e.g. BY 3-D PRINTING, STEREOLITHOGRAPHY OR SELECTIVE LASER SINTERING
    • B33Y80/00Products made by additive manufacturing

Abstract

The method concerns prodn. of a three-dimensional object (in particular, an initial pattern used in fine casting technology) by laser sintering, according to which layers of powder material are successively applied and hardened by electromagnetic radiation on the object at appropriate locations. The method is characterised by the fact that the material used is a mixture of two components with different melting points.

Description

Die Erfindung betrifft ein Verfahren zum Herstellen eines dreidimensionalen Objekts nach dem Oberbegriff des Anspruchs 1 sowie ein Pulvermaterial zur Verwendung in einem derartigen Verfahren nach Anspruch 7.The invention relates to a method for producing a three-dimensional object according to the preamble of the claim 1 and a powder material for use in such Method according to claim 7.

Ein Verfahren der genannten Art ist beispielsweise aus der US-A-4 863 538 bekannt. Hier wird eine vorbestimmte Menge eines pulverförmigen Kunststoffmaterials auf eine Unterlage bzw. eine vorher erzeugte Schicht eines Objekts aufgebracht, dort verteilt und mittels eines Laserstrahls an den dem Objekt entsprechenden Stellen bestrahlt, so daß das Material dort zusammensintert (sogenanntes Lasersintern).A method of the type mentioned is for example from the US-A-4 863 538 known. Here is a predetermined amount a powdered plastic material on a base or applied a previously generated layer of an object, distributed there and by means of a laser beam to the Illuminated corresponding areas, so that the material sintered together there (so-called laser sintering).

Daneben ist es bekannt, ein Feinguß-Urmodell zunächst aus Wachs herzustellen und anschließend durch eine Tauchbeschichtung mit einer wenige Millimeter dicken Keramikschicht zu umhüllen. Durch Erhitzung wird die Keramikschicht zur fertigen Form gehärtet und gleichzeitig das Wachsmodell darin durch Ausschmelzen entfernt. Nachteil des Wachses ist jedoch dessen geringe mechanische Stabilität bzw. Sprödigkeit und thermische Beständigkeit. Ferner läßt sich Wachs nur schlecht maschinell bearbeiten. In addition, it is known to first make an investment casting master model Make wax and then by a Dip coating with a few millimeters thick To wrap the ceramic layer. By heating the Ceramic layer hardened to the finished shape and at the same time the wax model is removed by melting it out. disadvantage however, the wax has poor mechanical stability or brittleness and thermal resistance. Furthermore lets it is difficult to machine wax.  

Mit einem Verfahren nach der US-A-4 863 538 wäre es möglich, die Herstellung des Wachmodells zu erleichtern. Allerdings ist die Verwendung von Wachspulver im Lasersinterprozeß wegen der Überhitzungsgefahr des Pulverbettes schwierig und erfordert zusätzliche Maßnahmen wie Kühlung. Aus diesem Grund wurde bereits die Verwendung von Polycarbonat als Material in Betracht gezogen. Dieses Material verlangt aber bei der Sinterung eine sehr genaue Temperaturregelung der obersten Pulverschicht von etwa 2 bis 5°C unterhalb des Schmelzpunktes des Materials. Auch erlaubt die gegenüber dem Wachs erheblich höhere Schmelztemperatur kein einfaches übernehmen des üblichen Ausschmelzprozesses. Schließlich ist die Viskosität der Polycarbonat-Schmelze erheblich höher als die von geschmolzenem Wachs, so daß die Keramikhülle nicht durch einfaches Ausfließen der Schmelze entleert werden kann, sondern die Schmelze regelrecht ausgebrannt werden muß.With a method according to US-A-4 863 538 it would be possible to to facilitate the production of the guard model. Indeed is because of the use of wax powder in the laser sintering process the risk of overheating the powder bed difficult and requires additional measures such as cooling. For this reason was already the use of polycarbonate as a material in Considered. However, this material is required by Sintering a very precise temperature control of the top one Powder layer from about 2 to 5 ° C below the melting point of the material. It also allows a lot compared to the wax higher melting temperature not easy to take over usual melting process. Finally, the viscosity the polycarbonate melt significantly higher than that of melted wax so that the ceramic shell does not go through the melt can simply be emptied out, but the melt must be literally burned out.

Aus der DE-OS 41 33 923 ist ein Verfahren zum Herstellen eines Feinguß-Urmodells mittels Stereolithographie bekannt, bei der jeweils eine Schicht eines flüssigen, UV-aushärtbaren Materials aufge­ bracht und durch Einwirkung eines Laserstrahls an den der Form entsprechenden Stellen verfestigt wird. Die Feingußmodelle werden zweckmäßig aus zwei Werkstoffen mit unterschiedlichen Schmelz­ punkten angefertigt, um Formschäden durch Schalensprengung beim Ausschmelzen der Modelle zu verhindern.DE-OS 41 33 923 describes a method for producing a Investment casting master model known by stereolithography, in each case applied a layer of a liquid, UV-curable material brings and by the action of a laser beam to the form appropriate places is solidified. The investment casting models are expediently from two materials with different enamel points made to prevent damage to the form due to shell blasting when To prevent melting of the models.

Aus der Druckschrift "konstruieren + gießen" 17, (1992), Nr. 4, Seiten 13 bis 19 ist ein Verfahren nach dem Oberbegriff des Pa­ tentanspruches 1 bekannt.From the publication "construct + cast" 17, (1992), No. 4, Pages 13 to 19 is a procedure according to the preamble of Pa tent Claim 1 known.

Es ist daher Aufgabe der Erfindung, ein Verfahren der eingangs genannten Art und ein dafür geeignetes Material zu schaffen, mit dem die genannten Probleme vermieden werden. Insbesondere soll die Herstellung des Modells in einfacher Weise und vorzugsweise bei Raumtemperatur und das Ausschmel­ zen ohne die Gefahr der Zerstörung der Überzugsschicht möglich sein.It is therefore an object of the invention to provide a method of type mentioned and a suitable material for it create, with which the mentioned problems are avoided. In particular, the manufacture of the model is said to be easier Way and preferably at room temperature and melting zen without the risk of destroying the coating layer to be possible.

Diese Aufgabe wird durch ein Verfahren mit den Merkmalen des Anspruchs 1 bzw. durch ein Material mit den Merkmalen des Anspruchs 7 gelöst.This task is accomplished by a process with the characteristics of Claim 1 or by a material with the features of Claim 7 solved.

Das erfindungsgemäße Verfahren basiert also auf dem aus der obengenannten US-A-4 863 538 bekannten Lasersinterverfahren, auf das hierinit zur weiteren Erläuterung verwiesen wird. Im Unterschied zum bekannten Verfahren wird jedoch bei der Erfindung kein einheitliches Pulvermaterial, sondern eine Mischung aus mindestens zwei Komponenten mit unterschiedlichem Schmelzpunkt verwendet. Eine erste Komponente besteht im wesentlichen aus einem Pulvermaterial mit hohem Schmelzpunkt, vorzugsweise über 150°C, und eine zweite Komponente weist ein Pulvermaterial mit demgegenüber niedrigerem Schmelzpunkt von beispielsweise 60 bis 130, vorzugsweise etwa 90°C auf. Die Verwendung der niedrig­ schmelzenden zweiten Komponente hat dabei auch den Vorteil, daß die Lasersinterung etwa bei Raumtemperatur durchgeführt werden kann, wodurch der Aufbau der Sintermaschine erheblich einfacher gehalten werden kann.The method according to the invention is therefore based on that from the US-A-4 863 538 known laser sintering method mentioned above, to which reference is hereby made for further explanation. in the Difference to the known method, however, in the Invention not a uniform powder material, but one Mixture of at least two components with different melting point used. A first one Component essentially consists of a powder material  with a high melting point, preferably above 150 ° C, and a second component has a powder material in contrast lower melting point of, for example, 60 to 130, preferably about 90 ° C. The use of the low melting second component also has the advantage that the laser sintering is carried out at about room temperature can be, whereby the structure of the sintering machine considerably can be kept easier.

Als erste Komponente wird entweder ein Kunststoffpulver wie Polyamid oder ein Metall- oder Keramikpulver verwendet. Als zweite Komponente kommt insbesondere ein thermoplastischer Kunststoff wie Copolyamid oder Copolyester in Frage. Die Korngröße der beiden Komponenten liegt vorzugsweise im Bereich von 50 bis 100 µm.The first component is either a plastic powder like Polyamide or a metal or ceramic powder used. When second component comes in particular a thermoplastic Plastic such as copolyamide or copolyester in question. The Grain size of the two components is preferably in Range from 50 to 100 µm.

Der Anteil der ersten bzw. zweiten Komponente an der Gesamtmenge des Materials kann entsprechend den gewünschten mechanischen Eigenschaften des fertigen Objekts eingestellt werden; beispielsweise führt ein hoher Anteil der niedrigschmelzenden Komponente, also von Copolyester oder Copolyamid, zu flexiblen Objekten, während bei einem niedrigeren Anteil eine erhöhte Härte und Steifigkeit erreicht wird. Auch wird von dem Mischungsverhältnis ebenso wie durch die Auswahl der beiden Komponenten die für das Ausschmelzen erforderliche Temperatur bestimmt. Günstige Mischungsverhältnisse liegen etwa im Bereich von 50 bis 90 Vol.-% und vorzugsweise 75 bis 85 Vol.-% der ersten Komponente und dem entsprechenden Rest der zweiten Komponente.The share of the first or second component in the Total amount of material can be according to the one you want mechanical properties of the finished object become; for example, a high percentage of low-melting component, i.e. copolyester or Copolyamide, to flexible objects, while one lower proportion increased hardness and rigidity is achieved. Also, the mixing ratio is the same as by selecting the two components for that Melting required temperature determined. Cheap Mixing ratios are in the range of 50 to 90 Vol .-% and preferably 75 to 85 vol .-% of the first Component and the corresponding rest of the second Component.

Nach der schichtweisen Verfestigung des Objekts durch Lasersinterung und gegebenenfalls einer Nachbehandlung wird das Objekt durch eine Tauchbeschichtung mit einer wenige Millimeter dicken Keramikschicht umhüllt. In einem weiteren Verarbeitungsschritt wird das Objekt zusammen mit der Keramikschicht auf eine Temperatur erhitzt, die über der Schmelztemperatur der zweiten Komponente, aber unter der Schmelztemperatur der ersten Komponente liegt. Diese Temperatur liegt je nach verwendetem Material bei etwa 60 bis 130°C. Es schmilzt also nur die niedrigschmelzende zweite Komponente, wodurch aber das Gefüge des in gewissem Umfang porösen Sintermaterials des Objekts, das im Vergleich zum Vollmaterial nur eine Dichte von 50 bis 75% aufweist, in sich zusammenbricht und die Viskosität des Gesamtmaterials auf Werte vergleichbar derjenigen von ausschmelzendem Wachs absinkt, so daß das Material aus der Keramikhülle durch entsprechende geeignete Löcher ausfließen kann. Wegen des Aufschmelzens lediglich der niedrigschmelzenden zweiten Komponente treten beim Schmelzen nur geringe innere Spannungen und damit geringe Verzugserscheinungen auf, so daß die Gefahr, daß die Keramikhülle, die gleichzeitig bei der Erhitzungstemperatur gehärtet wird, beschädigt oder zerstört wird, durch das erfindungsgemäße Verfahren reduziert wird.After the layer has solidified through Laser sintering and, if necessary, an aftertreatment the object through a dip coating with a few Millimeter thick ceramic layer encased. In another Processing step is the object together with the Ceramic layer heated to a temperature above the  Melting temperature of the second component, but below that Melting temperature of the first component is. These Depending on the material used, the temperature is around 60 to 130 ° C. So it only melts the low-melting second Component, but thereby the structure of the to a certain extent porous sintered material of the object, which compared to the Solid material only has a density of 50 to 75% breaks down and the viscosity of the entire material Values comparable to those of melting wax drops, so that the material from the ceramic casing through appropriate suitable holes can flow out. Because of the Melting only the low-melting second Components occur only slightly when melting Tensions and thus slight signs of delay, so that the danger that the ceramic casing, which is used at the same time Heating temperature is hardened, damaged or destroyed is reduced by the method according to the invention.

Claims (11)

1. Verfahren zum Herstellen eines dreidimensionalen Objekts, insbesondere eines Feinguß-Urmodells durch Lasersintern, dem jeweils eine Schicht eines pulverförmigen Materials aufgebracht und durch Einwirkung elektromagnetischer Strahlung an den dem Objekt entsprechenden Stellen verfestigt wird, dadurch gekennzeichnet, daß als Material eine Mischung von zwei Komponenten mit verschiedenem Schmelzpunkt verwendet wird. 1. A method for producing a three-dimensional object, in particular an investment casting master model by laser sintering, to each of which a layer of a powdery material is applied and solidified by the action of electromagnetic radiation at the locations corresponding to the object, characterized in that a mixture of two components is used as the material with different melting point is used. 2. Verfahren nach Anspruch 1, dadurch gekennzeichnet, daß das Objekt nach der Verfestigung und nach Beschichtung mit einer Überzugsschicht auf eine vorzugsweise zwischen den Schmelzpunkten der beiden Komponenten liegende Temperatur erhitzt wird und dadurch eine Komponente ausgeschmolzen wird.2. The method according to claim 1, characterized in that the object after the Consolidation and after coating with a Coating layer on a preferably between the Melting points of the two components Temperature is heated and thereby a component is melted out. 3. Verfahren nach Anspruch 1 oder 2, dadurch gekennzeichnet, daß als erste Komponente ein Kunststoff mit einem Schmelzpunkt von mindestens 150°C, beispielsweise Polyamid, und als zweite Komponente ein thermoplastischer Kunststoff verwendet wird.3. The method according to claim 1 or 2, characterized in that as a first component Plastic with a melting point of at least 150 ° C, for example polyamide, and as a second component thermoplastic is used. 4. Verfahren nach Anspruch 1 oder 2, dadurch gekennzeichnet, daß als erste Komponente ein Metall- oder Keramikpulver und als zweite Komponente ein thermoplastischer Kunststoff verwendet wird.4. The method according to claim 1 or 2, characterized in that as a first component Metal or ceramic powder and as a second component thermoplastic is used. 5. Verfahren nach einem der Ansprüche 2 bis 4, dadurch gekennzeichnet, daß auf eine im Bereich von 60°C bis 130°C liegende Temperatur erhitzt wird. 5. The method according to any one of claims 2 to 4, characterized in that in the range of 60 ° C temperature up to 130 ° C is heated.   6. Verfahren nach einem der vorhergehenden Ansprüche, dadurch gekennzeichnet, daß die Verfestigung durch Bestrahlung der Schicht des Materials mittels eines La­ serstrahls und vorzugsweise bei Raumtemperatur erfolgt. 6. The method according to any one of the preceding claims, characterized in that the solidification by Irradiation of the layer of the material by means of a La serstrahls and preferably at room temperature.   7. Pulvermaterial zur Verwendung bei der Herstellung von dreidimensionalen Objekten mittels Lasersintern, bestehend aus einer ersten Komponente mit einem Schmelzpunkt von mindestens 150°C und einer zweiten Komponente mit einem niedrigeren Schmelzpunkt.7. Powder material for use in the manufacture of three-dimensional objects using laser sintering, consisting of a first component with a Melting point of at least 150 ° C and a second Component with a lower melting point. 8. Pulvermaterial nach Anspruch 7, dadurch gekennzeichnet, daß die zweite Komponente ein niedrigschmelzendes, vorzugsweise thermoplastisches Kunststoffpulver wie z. B. Copolyamid oder Copolyester ist.8. powder material according to claim 7, characterized in that the second component low-melting, preferably thermoplastic Plastic powder such as B. copolyamide or copolyester is. 9. Pulvermaterial nach Anspruch 7 oder 8, dadurch gekennzeichnet, daß die erste Komponente ein hochschmelzendes Kunststoffpulver, z. B. Polyamid, ein Metall- oder Keramikpulver ist.9. powder material according to claim 7 or 8, characterized in that the first component high-melting plastic powder, e.g. B. polyamide Is metal or ceramic powder. 10. Pulvermaterial nach einem der Ansprüche 7 bis 9, dadurch gekennzeichnet, daß die Korngröße des Pulvers zwischen 50 µm und 100 µm beträgt.10. powder material according to one of claims 7 to 9, characterized in that the grain size of the powder is between 50 µm and 100 µm. 11. Pulvermaterial nach einem der Ansprüche 7 bis 10, dadurch gekennzeichnet, daß der Schmelzpunkt der zweiten Komponente bei etwa 60 bis 130°C, vorzugsweise bei etwa 90°C bis 100°C liegt.11. Powder material according to one of claims 7 to 10, characterized in that the melting point of the second Component at about 60 to 130 ° C, preferably at about 90 ° C to 100 ° C.
DE4410046A 1994-03-23 1994-03-23 Method and material for producing a three-dimensional object by sintering Expired - Fee Related DE4410046C2 (en)

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