Apparatus and method for forming a three-dimensional object

专利摘要:
Apparatus and method for forming a dimensionally stable, three-dimensional object by consecutive or continuous application and curing of a moldable printing material.
公开号:AT516839A4
申请号:T50366/2015
申请日:2015-05-06
公开日:2016-09-15
发明作者:Andrei Dr Neboian；Robert Dr Hein
申请人:Headlight Analytics E U；
IPC主号:

专利说明:

Apparatus and method for forming a three-dimensional object
The invention relates to an apparatus and a method for forming a dimensionally stable, three-dimensional object by consecutive or continuous application and curing of a moldable printing material.
In particular, the invention relates to a 3D printer which operates according to the FFF method, that is to say according to the so-called "fused filament fabrication" method. In this type of 3D printer, a fusible, in particular wire-shaped or filament-shaped printing material is melted in a print head and formed into a desired three-dimensional object by targeted, multi-layered, punctiform and / or strip-like application and curing.
Generic 3D printers are known and published in various embodiments. For example, filament printers are known in which a heated nozzle can be moved relative to a base in order to apply the melted printing material in the desired form. A disadvantage of these conventional devices is that during a continuous printing process only a single printing material can be applied. However, since more complex three-dimensional objects may require a support structure, or perhaps different print materials are required to construct the 3D object, there is a demand for 3D printers that can reshape at least two different print materials during a continuous printing operation. To solve this problem, so-called two-head printers are known in which two printheads are charged with two different printing materials, both printheads are permanently connected to the drive unit. A disadvantage of these systems is that the moving masses are greatly increased by the second print head. Due to the increased masses also stronger and thus larger drives are needed, which leads to a further increase in mass. In particular, according to the prior art, the linear drives for moving the print heads are arranged on moving components of the printer, whereby the masses to be moved are multiplied. This has a negative impact on the printing speed and printing accuracy of the 3D printer.
The object of the invention is therefore to overcome the disadvantages of the prior art. This includes in particular that the printer according to the invention is suitable for carrying out an efficient printing method.
The object of the invention is achieved in particular by the combination of features of the independent claims.
Optionally, the invention relates to an apparatus for forming a dimensionally stable, three-dimensional object by konsekutives or continuous jobs and curing a moldable printing material, in particular FFF-3D printer, comprising: - acting as a basis for the construction of the object base body, - at least one printhead for Jobs of the printing material, - a movement device for changing the relative position of the printhead relative to the base body, and - at least one printing material reservoir for receiving the printing material and for outputting the printing material to the printhead.
Optionally, the invention relates to a method for forming a dimensionally stable, three-dimensional object by consecutive or continuous application and curing of a moldable printing material, in particular for the formation of a dimensionally stable, three-dimensional object by consecutive or continuous
Jobs and curing two formable printing materials, and in particular method for printhead change, comprising the following steps: - moving the drive carriage and coupled to the drive carriage via a coupling device first printhead to a second print head, which is located in a arranged in the end of the first support member parking position and there is temporarily locked by a holding device, - coupling the second printhead to the drive carriage via the coupling device, so that the drive carriage is connected to both printheads, - release the holding device of the second printhead, so that the second printhead can be moved from its parking position, - moving the drive carriage and the two print heads coupled to the drive carriage via the coupling device to the parking position of the first print head at the opposite end region of the first support element, closing the Haltevorrichtu ng the first printhead and releasing the first printhead from the drive carriage by releasing the coupling device so that the first printhead is locked in its parked position, - moving the drive carriage and coupled to the drive carriage via the coupling device second printhead.
Optionally, the invention relates to a method for forming a dimensionally stable, three-dimensional object by consecutive or continuous application and curing of a moldable printing material, in particular to form a dimensionally stable, three-dimensional object by consecutive or continuous application and curing of two moldable printing materials, and more particularly to printhead change methods the steps of moving the drive carriage and the first printhead coupled to the drive carriage via a coupling device to the parking position of the first printhead at the end region of the first support element, closing the holding device of the first printhead, and releasing the first printhead from the drive carriage by releasing the coupling device, such that first printhead is locked in its park position, moving the drive carriage to a second printhead, which is in an opposite end region d it is first parking element arranged parking position and is temporarily locked there by a holding device, coupling the second print head with the drive carriage via the coupling device, releasing the holding device of the second print head, so that the second print head can be moved from its parking position, and moving the drive carriage and the with the drive carriage via the coupling device coupled second printhead.
Optionally, the invention relates to a method for forming a dimensionally stable, three-dimensional object by consecutive or continuous applications and curing a moldable printing material, in particular method for calibrating a device, wherein the device is arranged to form a dimensionally stable, three-dimensional object, wherein the object in particular by consecutive or continuous application and curing of a moldable printing material, and wherein the device comprises a base body acting as a base for the construction of the object, at least one print head for applying the printing material, and a moving device for changing the relative position of the print head relative to the base body following steps: - positioning a print head along the xy plane at a first calibration point, - reducing the distance between base body and print head until the base body calibrates touched reference element of the printhead, - and detecting the contact between the base body and the Kalibrierreferenzelement.
It may be advantageous if, during the calibration of the device by means of a print head, a further print head is arranged in its parking position, which is preferably outside the print area.
Optionally, the invention relates to a method for forming a dimensionally stable, three-dimensional object by consecutive or continuous application and curing of a moldable printing material, in particular methods for monitoring the printing material conveying, comprising the following steps: - actuating a drive wheel of a printing material drive for conveying the printing material, - measuring the retroactive Motor voltage of the printing material drive; comparing the retroactive motor voltage with a target value or range, in particular comparing a sliding standard deviation of the retroactive motor voltage with a target value or range, initiating an alternative operating mode or a cleaning mode when the value or the sliding standard deviation of the retroactive motor voltage deviates from the nominal value or from the nominal range.
Optionally, the invention relates to an apparatus for forming a dimensionally stable, three-dimensional object by konsekutives or continuous jobs and curing a moldable printing material, in particular FFF-3D printer, comprising: - acting as a basis for the construction of the object base body, - at least one printhead for Jobs of the print material, a movement device for changing the relative position of the print head relative to the base body, and at least one print material reservoir for receiving the print material and for outputting the print material to the print head, the motion device being at least one axis extending along an x axis, elongated first support element comprises, - wherein a connected to the print head or connectable drive carriage along the x-axis linearly guided on the first support member and in particular is parallel-guided, characterized in that - two printheads are provided sin d, - that the drive carriage has a coupling device, - and that the drive carriage via the coupling device with the printheads is coupled and detachable from the printheads, - wherein the drive carriage via the coupling device optionally with a printhead, with none of the printheads, or with both printheads is coupled.
Optionally, it is provided that the connection made by the coupling device of the drive carriage with the print head is a magnetic or a frictional connection, which is separable in particular by overcoming the holding force of the coupling device by moving the drive carriage along the x-axis.
Optionally, it is provided that the coupling device comprises a magnetic or magnetizable body which is coupled or coupled via magnetic forces with an element of the print head.
Optionally, it is provided that the print heads are guided linearly in each case via a print head carriage along the x-axis on the first carrier element. If appropriate, it is provided that the drive carriage is arranged along the path of the first carrier element between the two print head carriages of the two print heads.
Optionally, it is provided that the first carrier element has a rail portion in which the print heads are movable and positionable along the x-axis, and that in each of the two end regions of the rail portion or the first support member a holding device for temporarily fixing a respective printhead and in particular a parking position is provided.
Optionally, it is provided that the first carrier element has a rail section in which the print heads are movable and positionable along the x-axis, and in that a holding device is provided in the two end regions of the rail section or the first carrier element for the temporary fixing of a respective print head. in that the holding devices each comprise a holding element, in particular a movable bar, and in that the holding elements of the two holding devices can be actuated simultaneously, synchronized or mechanically coupled to one another or that the holding elements of the two holding devices can be actuated independently of one another
Optionally, it is provided that the device for forming a dimensionally stable, three-dimensional object by consecutive or continuous melting, targeted, multi-layered dot-shaped or strip-shaped jobs and curing a fusible, wire-shaped or filament-shaped printing material is set up.
Optionally, it is provided that a machine frame is provided, which is optionally surrounded or formed by a housing, and that a space for forming the object is formed by the machine frame or by the housing.
Optionally, it is provided that the movement device comprises at least one, elongated first support element extending along the x-axis, that the movement device comprises at least one elongate second support element extending along the y-axis, that the first support element along the y axis Axially guided on the second support member and in particular guided in parallel, - that the second support member in particular stationary or rigidly connected to the machine frame, - and that connected to the printhead or connectable drive carriage along the x-axis linearly guided on the first support member and in particular guided in parallel is such that an xy kinematics for movement of the printhead is formed in an xy plane.
Optionally, it is provided that the movement device comprises a connected to the drive carriage first drive belt for moving the print head, at least a first belt drive with a Riemenantriebsrad for driving the drive belt and a plurality of pulleys for deflecting the drive belt, - that the first belt drive is mounted in particular stationary on the machine frame in that - at least one deflecting roller is mounted on the first carrier element and at least one deflecting roller is mounted on the machine frame, - and in that the first drive belt essentially extends in a first drive plane which runs parallel to the xy plane.
Optionally, it is provided that the movement device comprises a drive belt connected to the second drive belt for moving the print head, at least a second belt drive with a Riemenantriebsrad for driving the drive belt and a plurality of pulleys for deflecting the drive belt, - that the second belt drive is mounted in particular stationary on the machine frame in that - at least one deflecting roller is mounted on the first carrier element and at least one deflecting roller is mounted on the machine frame, - and in that the second drive belt essentially extends along a second
Drive plane extending parallel to and spaced from the first drive plane and / or parallel to the x-y plane.
Optionally, it is provided that the movement device per drive belt comprises two driven deflection rollers for driving the drive belt - or that the movement device per drive belt comprises two belt drives for driving the drive belt, - wherein the two driven pulleys or the two belt drives a drive belt in the course of the drive belt before and are arranged after the connection point or near the connection point (s) with the drive carriage, and that the two drives are in particular synchronized.
Optionally, it is provided that the movement device per drive belt comprises two belt drives or two driven pulleys for driving the drive belt, wherein the two belt drives or the two driven pulleys of a drive belt in the course of the drive belt in each corner position immediately before and after the connection point with the drive carriage on Machine frame are mounted.
Optionally, it is provided that the movement device comprises a base drive device for moving and in particular for parallel movement of the base body along the z-axis, wherein the base drive device comprises a base drive and at least one guide element, wherein the base drive as a linear drive and in particular as a stepper motor with a spindle and with a the ball screw in operative contact spindle nut is formed, and wherein the guide element is designed as a linear guide and in particular as guided along a rail socket.
Optionally, it is provided that the movement device comprises a base drive device for movement and in particular for parallel movement of the base body along the z-axis, wherein the base drive device comprises a base drive and at least one guide element, wherein the base drive as a linear drive and in particular as a stepping motor with a
The ball screw is formed and standing in operative contact with the ball screw spindle nut, wherein the guide element is designed as a linear guide and in particular guided along a rail bushing, and that designed as a cantilever pressure platform is provided for supporting the base body, which is substantially normal to the direction of movement of the Base body, in particular in a plane parallel to the xy plane, and which is displaceable and drivable via the base drive device along the z-axis. If appropriate, it is provided that the base body is designed as a removable pressure bed and is detachably connected or connectable to the pressure platform, and that the detachable connection is in particular a magnetic connection.
Optionally, it is provided that a Heizvorrichung is provided for heating the base body.
Optionally, it is provided that the print head comprises a printhead main body and a nozzle arrangement connected to the printhead main body for melting and protruding the printing material, wherein the nozzle arrangement, starting from the connection point, successively comprises a heat sink, a decoupling point and a heated or heated nozzle. Optionally, it is provided that the printhead comprises a printhead main body and a nozzle assembly connected to the printhead main body for melting and protruding the printing material, wherein the nozzle assembly from the junction successively a heat sink, a decoupling point and a heated or heated nozzle comprises, and that the decoupling point comprises a tube for the passage of the printing material, wherein the tube is at least partially formed from a solid, heat-resistant material with low thermal conductivity, so that a thermal separation between the heated nozzle and the heat sink is formed by the tube.
Optionally, it is provided that the printhead comprises a printhead main body and a nozzle assembly connected to the printhead main body for melting and protruding the printing material, wherein the nozzle assembly from the junction successively a heat sink, a decoupling point and a heated or heated nozzle comprises, and that the decoupling point comprises a tube for the passage of the printing material, wherein the tube is formed at least on the inside against the molten printing material with low friction or substantially non-adhesive.
Optionally, it is provided that the printhead comprises a printhead main body and a nozzle assembly connected to the printhead main body for melting and protruding the printing material, wherein the nozzle assembly from the junction successively a heat sink, a decoupling point and a heated or heated nozzle comprises, and that the decoupling point comprises a tube made of a metal alloy, a titanium alloy or a stainless steel alloy, and / or that the inside of the tube is polished, hardened, galvanized and / or coated, wherein the inside is in particular polished and nitrided or provided with a PTFE coating ,
Optionally, it is provided that the printhead comprises a printhead main body and a nozzle assembly connected to the printhead main body for melting and protruding the printing material, wherein the nozzle assembly from the junction successively a heat sink, a decoupling point and a heated or heated nozzle comprises, and that the nozzle assembly is separably connected or connectable to the printhead body.
Optionally, it is provided that the printing material reservoir is designed as a removable printing material reservoir, which is connected in a modular manner with the machine frame or connectable, wherein the connection is in particular via a fastening device and / or an insertion slot.
Optionally, it is provided that the printing material reservoir comprises a clamping device, that the clamping device has a clamping position in which a portion of the printing material is clamped between a resiliently biased spring element and a jaw, and in that the clamping device has a conveying position in which the clamping of the clamping device so is far removed, so that a promotion of the printing material can take place.
Optionally, it is provided that the printing material reservoir comprises a clamping device, that the clamping device has a clamping position in which a portion of the printed material is clamped between a resiliently biased spring element and a jaw that the clamping device has a conveying position in which the clamping of the clamping device so far is canceled, so that a promotion of the printing material can take place, and that the clamping device automatically changes from the clamping position to the conveying position when the printing material reservoir is connected to the device or is. Optionally, it is provided that a printing material drive with a drive wheel for conveying the printing material from the printing material reservoir to the print head is provided fixedly on the machine frame, and that the drive wheel, when the printing material reservoir is connected to the device, is in operative contact with a portion of the printing material or directly to a portion of the printing material is applied so that a promotion of the printing material is or is effected by actuation of the drive.
Optionally, it is provided that a printing material drive with a drive wheel for conveying the printing material from the printing material reservoir to the print head is provided fixedly on the machine frame, and that the drive wheel, when the printing material reservoir is connected to the device, is in operative contact with a portion of the printing material or directly to a portion of the printing material is applied, so that by actuation of the drive, a promotion of the printing material is effected, and that while the portion of the printing material between the drive wheel and the resiliently biased spring element is clamped, so that the friction between the drive wheel and printing material to improve the promotion increases is. Optionally, it is provided that a printing material drive with a drive wheel for conveying the printing material from the printing material reservoir to the print head is provided fixedly on the machine frame, and that the drive wheel, when the printing material reservoir is connected to the device, is in operative contact with a portion of the printing material or directly to a portion of the printing material is applied, so that by actuation of the drive, a conveyance of the printing material is or is effected, and that the printing material drive and the drive wheel remain in the machine frame when the printing material reservoir is removed.
Optionally, it is provided that the printing material reservoir is connectable or releasably connected to a fastening device, which is designed in particular as an insertion shaft provided on the machine frame, with the machine frame.
Optionally, it is provided that the printing material reservoir comprises a non-contact transmission device, in particular an RFID chip, which can be read and / or written in the inserted position of the printing material reservoir by a contactless transmission device, in particular an RFID unit, wherein a non-contact transmission device, in particular the RFID Unit, is connected to the data processing device, and wherein a non-contact transmission device, in particular the RFID unit, is attached to the fastening device, the insertion slot or the machine frame.
Optionally, it is provided that the printing material reservoir comprises a non-contact transmission device, in particular an RFID chip, which is readable and / or writable by a non-contact transmission device, in particular an RFID unit, and in that case data of the printing material reservoir such as serial number, type of material, date of flippability, security code , remaining amount of material that is updated in particular after each use, and / or material-dependent parameters such as the optimum printing temperature or the optimum printing speed are transmitted. Optionally, it is provided that two printing material reservoirs are provided which are each connected via a printing material line with a print head.
Optionally, the invention relates to a method for forming a dimensionally stable, three-dimensional object by consecutive or continuous application and curing of a moldable printing material, in particular to form a dimensionally stable, three-dimensional object by consecutive or continuous application and curing of two moldable printing materials, and more particularly to printhead change methods following steps: - Move the drive slide and the drive slide over one
Coupling device coupled first printhead, - moving the drive carriage to a second print head, which is located in a arranged in the end of the first support member parking position and is temporarily locked there by a holding device, - coupling the second print head with the drive carriage via the coupling device, - releasing the Holding device of the second printhead, so that the second printhead can be moved from its parking position, - before the coupling of the second printhead to the drive carriage or after the coupling of the second printhead to the drive carriage of the drive carriage and coupled to the drive carriage via a coupling device first Printhead is moved to the parking position of the first printhead, where the holding device of the first printhead is closed and the first printhead is released from the drive carriage, so that the first printhead is locked in its parked position, wob ei after printhead change, only the second printhead is connected to the drive carriage.
Optionally, the method comprises the following steps: moving the drive carriage and the first print head coupled to the drive carriage via a coupling device to a second print head which is located in a parking position arranged in the end area of the first support element and temporarily arrested there by a holding device, coupling the second printhead with the drive carriage via the coupling device, so that the drive carriage is connected to both printheads, - releasing the holding device of the second printhead, so that the second printhead can be moved from its parking position, - moving the drive carriage and the two with the drive carriage over the Coupling device coupled printheads to the parking position of the first printhead at the opposite end of the first support member, - closing the holding device of the first printhead and releasing the first printhead from the drive carriage dur releasing the coupling device so that the first printhead is locked in its parked position; moving the drive carriage and the second printhead coupled to the drive carriage via the coupling device.
Optionally, it is provided that the holding device of the first print head and the holding device of the second print head are simultaneously released, synchronized or coupled with each other or closed.
Optionally, it is contemplated that to lock a printhead in the park position, the printhead is displaced into the corresponding end region of the first support member, then the corresponding retainer is closed, and then the coupling device is separated by moving away the drive carriage and overcoming the holding force.
Optionally, the invention relates to a method, in particular a method for calibrating a device according to the invention, wherein the device is adapted to form a dimensionally stable, three-dimensional object, wherein the object is formed in particular by konsekutives or continuous jobs and curing a moldable printing material, and wherein the device a base body acting as a base for building the object, at least one print head for applying the print material, and a moving device for changing the relative position of the print head relative to the base body, comprising the steps of: positioning a print head along the xy plane at a first one Calibration Point, - reducing the distance between the base body and printhead until the base body contacts a calibration reference element of the printhead, - and detecting the contact between the base body and the calibration reference element ,
Optionally, it is provided that following the detection of the contact between the base body and the calibration reference element at the first calibration point, a distance is established between the base body and the calibration reference element.
Optionally, it is provided that after re-establishing a distance between the base body and the calibration reference the printhead is moved to a second calibration point, wherein the second calibration point in the xy plane has a distance from the first calibration point, then that the distance between the base body and is reduced to the printhead until the base body contacts the calibration reference element of the printhead and a detection of the contact between the base body and the Kalibrierreferenzelement, and in that following the detection of the contact between the base body and the Kalibrierreferenzelement at the second calibration point again a distance between the Base body and the calibration reference is made. Optionally, it is provided that, after the renewed establishment of a distance between the base body and the calibration reference element, the print head is moved to a further, in particular third, calibration point, wherein the further calibration point in the xy plane is at a distance from the already approached calibration points that subsequently the distance between the base body and the printhead is reduced until the base body contacts the calibration reference element of the printhead and a detection of the contact between the base body and the calibration reference element takes place, and following the detection of the contact between the base body and the calibration reference element at the other Calibration point, a distance between the base body and the calibration reference is made.
If appropriate, it is provided that at least three calibration points are approached one after the other until a contact between the base body and the calibration reference element is detected, and that relative or absolute position data, in particular x, y, and z values of the contact points or of the height differences of the contact points the z-axis are transmitted to a data processing device.
Optionally, it is provided that several successive, grid-like or checkerboard-like arranged along the base body calibration points are approached until each contact between the base body and the calibration reference is detected, and that relative or absolute position data, in particular x, y, and z values the contact points or the height differences of the points of contact along the z-axis are transmitted to a data processing device.
Optionally, it is provided that the x, y, and z values of the points of contact or the height differences of the points of contact along the z-axis to a
Data processing device are transmitted, and that the data processing device determines a calibration matrix or a calibration surface, which essentially corresponds to a mathematical image or an approximate mathematical image of the surface of the base body.
Optionally, it is provided that each calibration point is approached more often, in particular three times, that the position data of a calibration point recorded thereby are compared with one another, and that the calibration point is approached at least once, if the recorded position data, in particular the z-values of the position data to deviate from one another by a value exceeding a predetermined maximum deviation value.
Optionally, it is provided that two print heads are provided, that after starting the calibration points with the first printhead a printhead change is performed, so that only the second printhead is coupled to the drive carriage, that subsequently any, already approached with the first printhead calibration point, in particular a single arbitrary already approached with the first printhead calibration point, is approached with the second printhead, and that from the recorded position data of the second printhead a z-difference value is calculated to the corresponding value of the first printhead. Optionally, it is provided that the calibration area or the calibration matrix of the second print head is calculated by mathematical displacement of the calibration matrix of the first print head by the z-difference value, wherein the displacement of the calibration matrix is calculated in particular by vector addition.
Optionally, it is provided that, in order to form a three-dimensional object, the print head is moved along the calibration surface or parallel to the calibration surface during a movement in the x-y plane in order to keep the distance between the base body and the nozzle tip constant, in particular during the printing process.
Optionally, it is provided that in the formation of an object, the z-position of the base body is dynamically adjusted as a function of the x-y position of the print head, so that the nozzle of the print head in each print position the same distance from
Pressure surface or the print object has or the difference is compensated Schrittwese.
Optionally, it is provided that an inclination of the printing object is compensated as a result of an inclined base body in the printing process by a horizontal displacement of the individual layers.
Optionally, it is provided that the calibration takes place automatically or automatically, wherein the automation is carried out in particular program-controlled by a data processing device.
Optionally, it is provided that the calibration reference element is the tip of the nozzle of the print head, an element provided at the tip of the nozzle, or an element forming the tip of the nozzle.
Optionally, it is contemplated that for relative movement between the base body and the printhead, the base is moved along the z-axis, the movement being accomplished by actuating the base drive device.
Optionally, the invention relates to a method for forming a dimensionally stable, three-dimensional object by consecutive or continuous application and curing of a moldable printing material, in particular a method for monitoring the printing material conveying, comprising the following steps: - actuating a drive wheel of a printing material drive for conveying the printing material, - measuring the comparing the retroactive motor voltage with a desired value or range, in particular comparing a sliding standard deviation of the retroactive motor voltage with a desired value or range, - initiating an alternative operating mode or a cleaning mode when the value or the sliding standard deviation of the retroactive Motor voltage from the setpoint or the target range deviates.
It may be advantageous if, during the calibration of the device with the aid of a print head, a further print head is arranged in its parking position, wherein the parking position is preferably outside the print area.
Optionally, it is provided that a stationarily arranged or arranged machine frame and / or housing is provided. It is preferably provided that a movement device is provided which allows a relative movement of a print head relative to a base along several degrees of freedom, so that a three-dimensional object can be constructed. The degrees of freedom are preferably three linear degrees of freedom, in particular degrees of freedom along a Cartesian coordinate system with an x, y and a z axis. By definition, the x-y plane may be substantially horizontal in all embodiments. By definition, the z-axis in all embodiments may be a normal vector of the x-y plane.
For moving the print head along the x-axis, an elongated first support element is preferably provided, which extends in a profile shape along the x-axis. The print head can preferably be moved by displacement of a drive carriage guided along the longitudinal extension direction of a first carrier element. Optionally, it is provided that the drive carriage and / or the first carrier element comprise guide grooves and / or guide extensions, so that a rail-like guide, in particular a rail-like guide with an undercut and only a linear degree of freedom is formed.
Optionally, it is provided that the first carrier element is guided along the y-axis. Optionally, a second carrier element is provided for this purpose, which extends in a rail-like or profile-like manner along or parallel to the y-axis. Optionally, two second carrier elements are provided, which guide the first carrier element at its end portions or in the region of these end portions. Preferably, the second carrier element is in each case substantially rigidly or stationarily connected to the machine frame. It is preferably provided that the second carrier element extends substantially normal to the first carrier element, so that in particular an x-y kinematics is formed.
To drive the movement of the print head optionally at least one drive belt is provided, wherein preferably two drive belts are provided. More preferably, less than three drive belts are provided for driving the print head or the drive carriage along the x-y plane. Optionally, it is provided that the drive belt or belts is or are designed as revolving, optionally closed drive belts, wherein the drive belt or belts optionally has or have two mutually connected ends. For example, the two ends are connected to a drive carriage. Optionally, a drive belt or both drive belts are formed in all embodiments as a toothed belt.
The first drive belt is preferably connected or coupled to the drive carriage and extends in particular: from the drive carriage along the longitudinal extension direction of the first carrier element to a deflection roller arranged on the end region of the first carrier element; from this pulley further to a deflection roller which is provided in an end region of a second support member on the machine frame; from there further to a deflection roller which is provided in an end region of the other second support member; from there along this second support member on the first support member over to another pulley on which the belt is deflected substantially 180 °; from there along the second carrier element to a deflection roller, which is provided at the nearer end portion of the first support member; and from there again to the drive carriage, so that a closed, circumferential drive belt is formed. The axes of rotation of the pulleys are substantially parallel to each other. At least one of the deflection rollers is designed in particular as a belt drive wheel of a belt drive. It is preferably provided that a guide roller attached to the machine frame is designed as a belt drive roller. It is preferably provided that along the drive belt next to the drive carriage on the machine frame arranged deflection rollers are designed as belt drive wheels. Optionally, therefore, two pulleys are designed as a belt drive pulley each of a belt drive. The drives are preferably fixedly mounted on the machine frame.
It is preferably provided that the first drive belt extends substantially along a plane parallel to the x-y plane.
Preferably, a second drive belt is provided. Preferably, the configuration of the second drive belt and its drives and / or pulleys are the same design as the configuration of the first drive belt, wherein the configuration is a mirrored with respect to the first drive belt configuration. In particular, the configuration of the second drive belt relative to the configuration of the first drive belt is mirrored about a plane in which the z-axis lies. In particular, the mirror plane is a center-running y-z plane. Preferably, the second drive belt extends in a direction parallel to the plane of the first drive belt by a certain distance along the z-axis parallel plane.
It is preferably provided that, by actuating the belt drive of the first drive belt and actuating the belt drive of the second drive belt, the drive carriage can be moved into an arbitrary position along the x-axis and / or along the first carrier element. In addition, by actuation of the two belt drives, the first carrier element can be displaced along the second carrier element, whereby the drive carriage and optionally the print head can be moved along an arbitrary contour in the x-y plane to any position along the kinematics. An advantage of this configuration is that the drives for moving the print head can be arranged stationary on the machine frame, and only comparatively light components, such as a pulley or a belt as moving masses exist.
Optionally, two print heads are provided, wherein the two print heads are preferably arranged displaceably on the first carrier element along the x-axis. Optionally, it is provided that a drive slide which can be displaced and driven along the first carrier element has a coupling device, wherein the coupling device can preferably be coupled to one of the print heads or with both print heads and / or can be detached from the print heads. Optionally, the printheads themselves are each guided linearly on a separate printhead carriage along the x-axis on the first carrier element. Optionally, the leadership of one or both printheads on the drive carriage is done. In this case, the print heads can be arranged away from the first carrier element, wherein the coupling and guide on the first carrier element takes place exclusively via the drive carriage.
Optionally, the coupling device comprises a magnetic and / or magnetizable body. In particular, the print head can be temporarily attached to the drive carriage via magnetic forces. Optionally, both printheads can be coupled to the drive carriage or the coupling device via at least one magnet or magnetizable body.
If appropriate, it is provided that in each of the two end regions of the first carrier element a parking position is set up for a print head. The parking positions preferably each comprise a holding device for the temporary fixing of the respective print head. In particular, the holding device comprises a holding element, such as a movable latch, an extendable bolt, a magnetic element or the like, by means of which the print head can be locked or held in the parking position. Optionally, it is provided that the holding force of the holding device is greater than the holding force of the coupling device, whereby the coupling device and thus the print head separates from the drive carriage when the drive carriage is moved away from the parking position with the holding device closed. In particular, the coupling device may be or include a frictional clamping connection or a magnetic connection, wherein optionally the holding device can produce a positive connection.
For example, for undocking, a device could be used on the back wall of the print area which is approached at a printhead change, separating the magnets between the printhead from the drive carriage and pushing the printhead toward a slightly weaker magnet which fixes it in its parked position. When re-docking, the two stronger magnets between printhead and drive carriage connect and the two weaker magnets between printhead and parking position are pulled apart as soon as the drive carriage moves back in the direction of the print area.
The component referred to in the description as a fastening device or locking unit optionally performs two tasks that need not necessarily be fulfilled by the same component, namely - locking the material cassette in the correct position to release the printing material from the clamping position and the correct back pressure for the material feed - Lock the media cassette in the insertion slot until it is rewound and released to prevent part of the media from breaking off and remaining in the printer if removed prematurely. Optionally, there is a spring-loaded latch on the front of the media cassette, which snaps when the media cassette is loaded and must be pressed down to remove the media cassette. In order to prevent premature removal, a locking unit can be used, which in this case, however, does not have the task of applying the counterforce for the clamping position and the material feed, so that a significantly weaker pull magnet can be used due to the lower friction occurring when the lock is opened can.
Optionally, it is provided that the two holding devices can be opened or closed simultaneously, synchronized or coupled.
In particular, the procedure for changing the printhead can be as follows:
A first print head is connected to the drive carriage via the coupling device. Subsequently, the drive carriage moves together with the first print head to the parking position of the second print head, where the second print head is held by the holding device and / or locked. Subsequently, there is a coupling of the second print head with the drive carriage via the coupling device. Subsequently, the holding device of the second print head is opened. Optionally, both holding devices of both parking positions are opened. Subsequently, the drive carriage, which is coupled to both printheads, moves toward the parking position of the first printhead. If the first print head is in its parking position, the holding device of the first print head is closed, whereby the first print head is locked in its parking position. Optionally, the holding device of the second print head is thereby closed. However, since the second printhead is not in its park position in the present position, the second printhead is not locked. Subsequently, the coupling device between the drive carriage and the first print head is disconnected, and the drive carriage is only coupled to the second print head. To re-printhead change this process is logically repeated for the other printhead.
Optionally, it is provided that the drive carriage along the x-axis can be coupled on both sides, each with a print head. As a result of the exchangeability, it is advantageously possible to construct an object during the printing process, optionally with the first print head or with the second print head, without the moving mass being increased during the printing process.
Optionally, in all embodiments, a parking position may be provided rigidly or stationarily on the machine frame. Optionally, two printheads can be provided, each with a parking position, preferably both parking positions are rigid or stationary provided on the machine frame, the parking position can be arranged for example in the region of the rear wall of the housing.
Optionally, in all embodiments, a parking position may be provided on a carrier element, preferably on the first carrier element and particularly preferably in an end region of the first carrier element. Optionally, two print heads can be provided, each with a parking position, wherein preferably both parking positions are provided on a carrier element, preferably on the first carrier element and particularly preferably in each case in an end region of the first carrier element.
For the construction of three-dimensional objects, a printing material is applied consecutively or continuously and hardened, in addition to the displaceability of the print head in the x-y plane and a relative movement along the z-axis, in particular to allow a structure of the object along the z-axis.
Optionally, it is provided that the movement device comprises a base drive device for moving and in particular for parallel movement of the base along the z-axis.
The base preferably comprises a straight, flat surface which runs substantially parallel to the x-y plane and on which the object can be constructed. However, if necessary, the base has some structure or a curved or complex surface. The base drive device comprises, for example, guide elements that are set up for parallel displacement of the base. Preferably, the base drive device comprises a drive, in particular a linear drive, by means of which the base can be moved along the z-axis.
According to a preferred embodiment, the three-dimensional body to be formed is built up in layers. The first layer substantially follows the surface of the base body and in particular that surface of the base body which faces the print head. Since the surface of the base body is optionally curved or due to tolerances not exactly parallel to the xy plane, there is a risk that with a displacement of the print head along the xy direction, the distance between the nozzle tip and the base body varies and in particular too large or too is small, whereby the accuracy in the formation of the object is impaired. For this reason, a calibration is preferably performed.
Optionally, it is provided in all embodiments that this calibration takes place automatically or automatically. For example, the automation can be program-controlled, in particular program-controlled by a data processing device. Optionally, it is provided that the print head is provided with a calibration reference. This calibration reference allows the exact determination of the surface of the base body relative to the nozzle tip. Preferably, the calibration reference element is the tip of the nozzle of the printhead, an element provided at the tip of the nozzle, or an element forming the tip of the nozzle. By using the nozzle tip as a calibration reference element an exact calibration of the position relative to the base body is possible.
For calibration, preference is given to approaching a plurality of calibration points along the x-y plane, wherein the individual calibration points are spaced apart from one another and are preferably distributed over the course of the base body in a planar and / or grid-shaped manner. Each of the calibration points is approached for calibration individually. This means that in a first step, the print head is moved away from the base body to the desired x-y position of the calibration point. In a next step, the distance between the print head or the calibration reference element and the base body is reduced until it comes to a touch of these components. This contact is detected, for example, by an acceleration sensor and / or by detecting an increased engine load of the base body drive. Subsequently, the movement is stopped, and the base body brought back to a certain distance from the calibration reference. Subsequently, the printhead and thereby also the calibration reference element are brought to a second calibration position where the previous steps are repeated. These steps can be carried out on a plurality of calibration points, preferably on more than two and in particular on a plurality of grid-shaped distributed along the base body. At each calibration point, on the one hand, the x-y position data and position data, which allow conclusions to be drawn about the differences in the tumes of the points of contact along the z-axis, are transmitted to a data processing device. In this data processing device, a calibration matrix or a calibration surface can then be calculated via the individual coordinates and their z-positions, which substantially corresponds to a mathematical mapping of the surface of the base body.
Optionally, two or more printheads are provided on the device. To perform a calibration relative to the second or further printhead, a printhead change is performed so that only the second printhead is coupled to the drive carriage. As a consequence, any calibration point already approached with the first print head is also approached by the second print head. From the data contained, a z-difference of the calibration between the first and the second print head can be calculated. For example, the nozzle of the second print head is slightly shorter than the nozzle of the first print head, which would result in a difference in the distance between nozzle tip and base body. By reading this z-difference can be calculated by a single calibration point, the entire calibration matrix for the second printhead, for example by vectorially adding the z-difference. Optionally, however, a further calibration point is approached by the second or further print head in order to verify the displacement of the calibration surface, if necessary.
To form a three-dimensional object, the print head can now be moved along the x-y plane along the desired contour. In order to keep the distance between the base body and the nozzle tip constant, a constant distance can be maintained during an x-y movement of the print head via the base body drive and the stored mathematical image of the calibration surface. The subsequent layers can likewise be applied along the calibration surface or along a surface offset by the layer thickness from the calibration surface.
Optionally, in an inclined position of the surface of the base body, the entire object along the normal vector of this inclined surface are constructed, this normal vector then differs from the direction of the z-axis usually.
Optionally, an unevenness and / or an inclination of the surface of the base body can also be compensated or leveled by applying a printing material or a supporting structure. This leveling can be built up, for example, by the first printing layers. The leveling may in particular be part of the printing process. In this case, even if the surface of the base body inclines along the z-axis, the object can be built up.
The invention optionally relates to a printhead for forming a dimensionally stable, three-dimensional object by consecutive or continuous application and curing of a moldable printing material. In particular, a wire or filamentary printing material is fed to the print head. Optionally, the printhead includes a printhead body and a nozzle assembly. Optionally, it is provided that a drive with a drive wheel for conveying the printing material is provided on the printhead main body. The printing material is preferably conducted via a tubular connecting line from the printing material in the print head. Optionally, it is provided that the print head comprises at least one fan. The fan is preferably connected to one or more ventilation channels or fluidly connected. The exits of the ventilation duct are preferably directed to the pressure point, so that the printed material applied in the molten state is cooled by the air cooling and thereby cured. Optionally, a fan is provided, the parts of a nozzle assembly, in particular a cooling body of the nozzle assembly by artificial convection cools or dissipates the heat. Optionally, the fan for cooling the nozzle assembly and the fan for cooling the applied printing material, the same fan.
Optionally, it is provided that, starting from a connection point of the nozzle arrangement with the printhead base body, a heat sink, a decoupling point and a heated or heatable nozzle are successively provided. Optionally, these three elements protrude freely from the junction with the printhead body. In particular, it is advantageous if the hot nozzle of the remaining components of the print head is largely thermally insulated or insulated. For this purpose, a thermal decoupling point can be provided between the heat sink and the nozzle. This thermal decoupling point can be formed for example by a body having a low coefficient of thermal conductivity, whereby insulation or insulation is given. In particular, the heat conduction between the hot nozzle and the heat sink should be reduced or minimized. At the same time, if appropriate, the transition zone in which the printing material changes from the solid to a moldable, molten state should be kept as short as possible. For this reason, it is advantageous to provide sufficient thermal decoupling. The heat sink is in particular configured to emit the heat coming from the heated nozzle to the environment, so that the connection point and the printhead body and other components of the printhead remain largely thermally unloaded and the print material is not heated in the upper region.
Optionally, according to an embodiment, not shown, the melting unit or a nozzle arrangement is formed as follows: The melting unit comprises, for example, a heat sink made of aluminum, a connector made of stainless steel, an annular heater and a nozzle unit, a nozzle, two sleeves, for example, two brass sleeves and a Tube, for example, a Teflon tube or a metal tube. Through the tube, the print material passes through the heat sink into the nozzle, where it is liquefied and pushed out by the incoming print material down.
For example, the tube has a flange at the lower end which is clamped between the nozzle and the two sleeves. For this purpose, the inner sleeve, which has both inside and outside a thread, first screwed onto the nozzle to increase the bearing surface. Together with the tube these are then screwed into the outer sleeve, which also has an inner and outer thread and has a constriction at the top. The nozzle unit is screwed from below into the connector, which is attached to the heat sink and is enclosed by the radiator. During printing, the connector is heated by the radiator and heat is transferred to the nozzle via the two sleeves. It has an internal thread at both ends and several recesses in the middle to reduce the cross-section and thus the heat flow upwards.
Since there is an air gap between the lower edge of the heat sink and the upper edge of the nozzle unit and the connector has no direct contact with the pipe, high temperature gradients can be achieved in the printing material. This shortens the transition area in which the printing material is in viscous form, which has a positive effect on the printing result. In contrast to other designs, the direct attachment of the guide tube to the nozzle has the advantage on the one hand that there is no gap between the guide tube and the nozzle, in which pressure material can deposit, which can gradually lead to blockage. On the other hand, the maintenance is simplified because the nozzle unit as a whole can be replaced easily.
Subsequently, the invention and its optional individual components will be further described with reference to FIGS.
Fig. 1 shows a schematic oblique view of an embodiment of a printer according to the invention.
Fig. 2 shows an oblique view of a detail of the movement device.
3 shows a schematic view of a movement device, wherein the image plane substantially corresponds to the x-y plane.
Fig. 4 shows two schematic views of a configuration of two drive belts for driving the print head along the x-y plane, wherein preferably the two illustrated belt guides are arranged in two parallel planes.
Fig. 5 shows a schematic oblique view of the docking system or the coupling device.
Fig. 6 shows two schematic views of a print head, the left view being a schematic oblique view. In the right view, the viewing axis essentially follows the x-axis.
Fig. 7 shows a schematic view of the steps of a printhead change.
Fig. 8 shows a part of the movement device, in particular the base drive device.
Fig. 9 shows the printing bed and the printing platform, and the base body and parts of the base drive device.
10 shows a schematic representation of the steps for calibrating the device.
11 shows a schematic representation of a possibly recorded calibration curve, or a calibration matrix or a calibration surface.
FIG. 12 shows an embodiment of a print head in an oblique view from the front or from the back in an external view.
Fig. 13 shows details of a print head, in particular of the print head of Fig. 12, wherein internal details are also shown.
14 shows the nozzle unit of a printhead, in particular a nozzle arrangement in an oblique view, in a central sectional view, in a detail view of the nozzle and in a sectional view of the nozzle.
15 shows an exemplary measurement of the retroactive motor voltage under motor load, in particular from 3 phases: 50-70: normal operation, 70-75: increased load, 75-90: standstill.
16 shows a supply unit and material cassette, in particular a printing material reservoir.
Fig. 17 shows a counter-pressure element or a spring plate and a feed unit or details of the printing material reservoir and its clamping device.
The figures show concrete embodiments of individual, optionally independent components, wherein features of these or other components can also be taken from the general description part. For example, the mover, the docking system, the vertical positioning system, the printhead, the nozzle assembly of the printhead, and the media reservoir may be independently varied. The illustrated and described embodiments of the components and the assembly of the components are each an optionally possible embodiment. The invention results in particular from the features of the claims and from the features of the description.
In no way is the invention limited to the embodiments shown in the figures. For example, the movement device can also be set up to move a printhead that deviates from the illustrated or described printhead. For example, the described printhead change can also be performed with another movement device. For example, the calibration can also be carried out only with one print head, with two or more print heads, and in particular also with another movement device. For example, the movement device can also be used without exchangeable printheads. For example, the print material reservoir can also be used with other print heads or other movement devices.
Unless indicated otherwise, the reference numerals correspond to the following components: housing 1, installation space 2, control unit 3, first printing material reservoir (for model material or support material) 4, second printing material reservoir (for model material or support material) 5, first supply hose 6, second Supply hose 7, first print head 8, second print head 9, x-axis 10, y-axis 11, print object 12, support structure 13, print bed or base body 14, z-axis 15, docking unit 16, toothed belt 17, guide carriage (in the X direction ) 18, guide rail (in X direction) 19, cross bar 20, guide slide or linear bearing (in Y direction) 21, guide rail (in Y direction) 22, belt drive or drive unit 23, light barrier (for Y axis) 24, frame 25, pulley 26, belt tensioner 27, side plate 28, light barrier (for Y-axis) 29, locking unit 30, pulley 31, nozzle wiper 32, light bar 33, connecting plate 34, docking magnet 35, docking platform e 36 Bolt (to fix the timing belt) 37, Hole (to lock the bolt) 38, Front support profile 39, Rear support profile 40, Guide carriage or linear bearing (in Z direction) 41, Guide rail (in Z direction) 42, Spindle nut 43 , Spindle or ballscrew 44, spindle coupling 45, stepping motor (for Z-axis) 46, thrust bearing 47, spring steel plate 48, pressure surface 49, plastic plate 50, rivets (for fixing the plastic plates) 51, support plate 52, spacer plate 53, heat-resistant magnet 54 , Heating mat 55, insulating mat 56, spacing bolt 57, countersunk screw (for fixing the support plate) 58, printhead front 59, printhead center 60, printhead cover 61, recess (for timing belt passage) 62, stepper motor (for material extrusion) 63, Ribbon cable 64, melting unit 65, axial fan 66,
Radial fan 67, air duct 68, guide groove 70, back pressure unit 71, drive roller 72, heat sink 73, nozzle unit 74, heat sink 75, temperature barrier 76, heating element 77, guide tube or guide tube 78, connection sleeve 79, nozzle 80, insertion slot 81, guide rails 82, ejection unit 83, locking unit 84, contactless transmission device such as RFID or NFC unit or contactless data transmission unit 85, feed unit 86, adapter unit 87, material cassette 88, printing material (model material or support material) 89, printing material coil 90, outer shell 91, spring plate or counter-pressure element (optionally plastic plate) 92, non-contact data transmission chip or non-contact transmission device such as RFID or NFC chip 93, moving device 94, printing material line 95, data processing device 96, first support member 97, drive carriage 98, coupling device 99, Druckko 100, rail section 101, end section 102, second support element 103, holding device 104, parking position 105, holding element 106, movable latch 107, machine frame 108, xy kinematics 109, xy plane 110, first drive belt 111, first belt drive 112, belt drive wheel 113, first drive level 114, second belt drive 115, second drive belt 116, second drive level 117, junction 118, corner position 119, base drive device 120, base drive 121, guide element 122, linear drive 123, linear guide 124, bush 125, pressure platform 126, heater 127, printhead body 128, nozzle arrangement 129, decoupling point 130, inner side 131, clamping device 132, clamping position 133, insertion shaft 134, clamping jaw 135, conveying position 136, printing material drive 137, drive wheel 138, fastening device 139, reference plane 140, surface (of the base body) 141, first printing layer 142, second printing layer 143, Joint (the nozzle at order with the printhead body) 144.
Schematic external view (FIG. 1):
The present extrusion-based 3D printer comprises a housing (1) with a construction space (2), a control unit (3) and a respective supply unit for thermoplastic modeling or support material (4/5), which in the form of filaments via supply hoses (6 / 7) is conveyed to the two print heads (8/9) inside the installation space (2).
The print heads (8/9), which can be horizontally positioned along the X / Y axis (10/11), apply the print object (12) and the support structures (13) layer by layer to the print bed (14), the along the Z-axis (15) can be moved vertically. The positioning of the print heads (8/9) and the print bed (14) as well as the selective material extrusion are coordinated by the control unit (3).
Housing and installation space (Fig. 1)
The space (2) is enclosed on the sides and at the back and bottom of the housing (1). A transparent sliding door - not shown - forms the front and top, so that the print object (12) during printing is protected from external influences (eg draft) and the risk of injury from moving or hot parts inside the installation space (2) is minimized. Fans in the rear wall - not shown - provide a continuous exchange of air to protect the electronic components inside the installation space (2) from overheating.
Since the housing (1) has no cross bracing at the front upper edge, the access to the interior of the installation space (2) is substantially facilitated. The resulting stability disadvantages are compensated by appropriate reinforcements elsewhere. For structural reasons, the housing (1) has in each case double side walls and a partition, which delimits the space (2) of the control and supply units (3, 4, 5) on the left side.
The transparent sliding door (not shown), which extends from the front lower edge to the rear upper edge of the housing (1), allows unobstructed view of the printed object (12) from different angles even during the printing process. The sliding door can be slid to the left via telescopic rails at the bottom and at the back of the housing (1), concealing the control and supply units (3, 4, 5) so that the available space is used optimally and the printing process for safety reasons can only be started when the door is closed. If the door is opened during the printing process, this is detected by a sensor and the pressure is interrupted immediately.
Horizontal positioning system (FIGS. 2 and 3)
Both print heads (8, 9) and the docking unit (16) located therebetween, which can be moved by means of two toothed belts (17), are connected to the same guide rail (19) via guide carriages (18). While one print head (8) is connected to the docking unit (16) and thus can be positioned in the X direction (10) ("print position"), the other print head (9) waits at the end of the guide rail (19) outside the print area ( "parking position").
The transverse bar (20) to which the guide rail (19) is fastened is connected via linear bearings (21) at the ends to the lateral guide rails (22) and thus freely movable in the Y direction (11). About the two toothed belt (17) of the crossbar (20) and thus the active printhead (8) in the Y direction (11) can be positioned. The two toothed belts (17) are moved by in each case two drive units (23) which consist of a stepping motor and a drive roller and are installed on the housing (1).
The two guide rails (22), the four drive units (23), a light barrier (24) for referencing the Y-axis, and a plurality of pulleys and parts of the vertical positioning system (see FIG. 8) are in a frame (25) of U-axis. mounted on shaped steel profiles. This provides additional stability and allows pre-assembly of the horizontal positioning system as a whole. Spacers between frame (25) and drive units (23) facilitate the assembly of the pulleys and reduce the transmission of vibrations. Since the screws with which the shaft holders are attached to the frame (25) are accessible from the outside, the guide rails (22) can still be aligned after the final assembly.
Timing belt system (FIG. 4)
Each of the two toothed belts (17) is fastened with both ends to the docking unit (16) and initially runs outward until it is deflected forwards at the end of the transverse bar (20). After passing through the front drive unit (23), it runs in the opposite direction to the rear deflection roller (26) and from there to the belt tensioner (27) and to the rear drive unit (23) on the opposite side. After passing through the rear drive unit (23) it runs forward again and is at the end of the crossbar (20) deflected back to the docking unit (16).
The second toothed belt, which has a mirrored course, is located on a second vertical plane in order to avoid overlapping with the first toothed belt. In contrast to a conventional toothed belt system, where at least one drive motor is located on the moveable crossbeam, all drive motors in the system used are fastened to the housing so that higher accelerations and traversing speeds can be achieved due to the lower moving masses. In contrast to a conventional system, the double timing belt guide prevents tilting of the crossbar, which would have negative effects on the positioning accuracy of the printhead and on the wear of the guide elements.
The front pulleys are used to increase the wrap angle of the belt (17) to the front drive units (23) for better power transmission and reduce the run distance before and after rotation of the drive unit (23). As a result, the toothed belt passage in the crossbar (20) can be reduced, which has a positive effect on its rigidity and on the utilization of space. The rear pulleys both increase the angle of wrap of the toothed belt (17) about the rear drive units (23) and the distance between the toothed belt (17) and frame (25) to increase the assembly of the belt tensioners (27) and the vertical positioning system (see FIG. 8).
The synchronous use of two drive motors per toothed belt not only higher acceleration forces but also higher positioning accuracies can be achieved because the run length between the drive motor and print head is shortened and the elasticity of the toothed belt system is reduced.
Linear guiding and docking system (FIGS. 5 and 6)
The two ends of the crossbar (20) are connected via U-shaped side plates (28) with the linear bearings (21), which can move freely on the lateral guide rails (22) in the Y direction. On the side plate (28) are also a light barrier (29) for referencing the X-axis, a locking unit (30), two pulleys (31) and a nozzle wiper (32). A light bar (33) on the
Bottom of the crossbar (20) illuminates the print bed (14) with the print object (12) from above.
The guide rail (19) with the three guide slides (18) is mounted on the back of the crossbar (20). The two outer slides are each connected via a connecting plate (34) with a print head (8 or 9). In between there is a passage for the two toothed belts (17) and for the docking magnet (35). The middle carriage is connected to the docking unit (16), which consists of a U-shaped mounting plate (36) with two screws (37) for fixing the toothed belt (17) and a respective docking magnet (35) on both sides. During printing, the active printhead (8) is connected to the docking unit (16) via the docking magnets (35) mounted on the link plate (34) and thus can be positioned while the inactive printhead (9) is locked by the latch unit (30) his parking position at the end of the guide rail (19) is held.
In order to park the active printhead (8), it is moved by the docking unit (16) into its parking position and held there by the locking unit (30) by the latch - not visible - in a corresponding hole (38) in the connecting plate ( 34) is extended. If the docking unit (16) now moves again to the middle of the printing area, the two docking magnets (35) are pulled apart by the force of the toothed belts (17) and thus the print head (8) is separated from the docking unit (16).
To activate the parked printhead (9), the docking unit (16) moves to its parking position until the docking magnets (35) connect before the printhead (9) is released by opening the latch unit (30). Subsequently, the docking unit (16) moves together with the print head (9) back into the printing area and passes through the nozzle scraper (32) to remove previously drained and possibly trailing printing material before printing with the new printhead (9) is continued ,
Since the parked printhead (9) is outside the printing area, there is no risk that the printing object (12) is contaminated by uncontrolled trailing printing material. To avoid this, the inactive nozzle would have to be completely cooled in a two-nozzle printhead before a change of material and reheated before a new material change, which would take significantly more time. Alternatively, the inactive nozzle would have to be lifted and covered mechanically, which would be very complicated to implement, especially against the background of tight tolerances in the distance to the printing bed (14).
Since only the active print head (8) must be moved in the X direction while the inactive print head (9) remains in its park position, higher accelerations and thus higher print speeds can be achieved with the same toothed belt force due to the lower moving mass. In addition, the automatic calibration (see Fig. 10) is greatly facilitated because the print bed (14) can be scanned separately from both printheads while the other printhead is out of print area in its parked position. Otherwise, the vertical distance between the two nozzles would have to be set manually with great effort.
In addition, it is possible to simultaneously remove both print heads from the print area so that the print bed (14) can be raised to the bottom of the crossbar (20). This makes it possible to eject the print object (12) automatically after completion of the printing process by being pushed forwards or backwards from the print bed (14) by means of the crossbeam (20).
Automatic printhead change (Fig.7)
The automatic printhead change, for example, proceeds as follows: 1) First, the docking unit (16) is moved together with the first printhead (8) to the parking position of the second printhead (9). 2) Next, the lock units (30) are opened on both sides so that the second print head (9) is released. 3) Subsequently, the docking unit (16) is moved together with both print heads (8/9) to the parking position of the first print head. 4) Arrived there, the two locking units (30) are closed again, so that the first print head (8) is held in its parking position. 5) Finally, the docking unit (16) is moved back together with the second print head (9) back into the printing area. 6) Now the second print head (9) is in printing position.
Unlike a printhead switch in which the active printhead (8) is parked before the parked printhead (9) is reactivated, the two latch units (30) can be connected in parallel for ease of control. If the locking units (30) before the docking of the second print head (9) are opened, this z. B. solve by vibrations from its parking position and uncontrolled with the approach of the docking unit (16) with these collisions and thus damage the docking magnets (35). In addition, this ensures that the automatic referencing of the X-axis is still possible after a system restart during the printhead change, since at any time at least one of the two light barriers (29) is uncovered.
Vertical positioning system (Fig. 8)
The printing platform - not shown - is supported by a support structure, which here consists of three U-shaped support profiles (39) and an L-shaped rear wall (40). On the latter two linear bearings (41) are mounted, which can move vertically on two guide rails (42) in the Z direction. The guide rails (42) are fixed to the frame (25) and to the underside of the housing (not shown), so that they can be aligned even after final assembly.
The vertical positioning via a spindle nut (43), which is also attached to the rear wall of the support structure (40) and with the aid of a ball screw (44) can be moved vertically. The latter is connected via a coupling (45) with a stepping motor (46) which is fixed to the top of the frame (25). Between the coupling (45) and underside of the frame (25) is a thrust bearing (47) to relieve the stepper motor (46) of the axial forces occurring.
Printing bed and printing platform (Fig. 9)
The removable pressure bed (14) consists for example of a ferromagnetic spring steel plate (48) with a special pressure surface (49) and two plastic plates (50) on both sides, which are held by rivets (51) and when removing the print bed (14) as Handles are used to prevent injury from sharp edges or burns from hot surfaces. In addition, the upper plastic plates (50) can be used to fix the pressure surface (49) on the spring steel plate (48), while the lower plastic plates (50) help to center the print bed (14) on the underlying printing platform.
The printing platform also consists of several layers. Under the carrier plate (52) made of ferromagnetic steel is a spacer plate (53) with recesses for heat-resistant magnets (54) which magnetize the carrier plate (52) from below so that the ferromagnetic printing bed (14) adheres to it. Below the spacer plate (53), which may be aluminum for thermal conduction and weight saving, is attached a fleece mat (55) which heats the print bed (14) from below during printing to reduce the pressure of the print object (12) on the print surface (Fig. 49). An insulating mat (56) below Fleizmatte (55) reduces heat loss occurring down.
Since the insulating mat (56) does not provide sufficient stability, the support plate (52) and spacer plate (53) are connected by spacers (57) to the support profiles (39) of the vertical positioning system. For mounting countersunk screws (58) are used to improve the heat conduction to the pressure bed (14) by a flat contact surface between the support plate (52) and spring steel plate (48).
A removable print bed (14) has the advantage that it can be removed from the installation space (2) after printing together with the print object (12) without having to detach the print object (12) beforehand. The use of the spring steel plate (48) also facilitates the detachment, since the pressure bed (14) can be easily bent backwards at the sides. Alternatively, the print bed (14) can be placed in a solvent together with the print object (12) to remove the soluble support structures (13) and thus detach the print object (12) from the print bed (14). In addition, since the printing surface (49) may wear over time, the removable printing bed (14) can be replaced very easily.
Automatic Print Bed Calibration (Figs. 10 and 11) For reliable printing, it is important that the distance between the print surface (49) and the nozzle of the print head (8, 9) be set very accurately, as too small a distance can lead to a blockage and too great a distance to a detachment of the printing object (12) or the support structures (13) of the pressure surface (49). Due to manufacturing and assembly-related inaccuracies, it is therefore advantageous to calibrate the distance accurately before commissioning the 3D printer. To get the best print results, this should be done before each new print job.
In contrast to a manual calibration, which is very time-consuming and demanding especially with multiple print heads (8, 9), the automatic calibration helps to save time and avoid errors. For this purpose, the printing bed (14) is divided like a checkerboard into at least three calibration points, which are approached in sequence with the print head (8). At each calibration point, the print bed (14) is moved upwards until it touches the print head (8) and stores the corresponding position. Then it is driven down again and the procedure is repeated at the next calibration point.
After all calibration points have been approached, the alignment and the surface contour (at more than 3 calibration points) of the print bed (14) are determined by regression from the collected data. During later printing, the vertical position of the print bed (14) can be dynamically adjusted as a function of the horizontal position of the print head (8), so that the nozzle always has the same distance to the print surface (49) or to the print object (12). An inclination of the printed object (12) as a result of an inclined pressure bed (14) can also be compensated by a corresponding horizontal displacement of the individual layers.
By approaching any calibration point with the second print head (9) can also be determined, the vertical distance between the nozzles of both printheads, which can also be compensated for later printing. With a two-nozzle printhead or mechanical calibration, it would not be possible to compensate for the vertical distance between two nozzles. Another advantage of dynamic compensation with more than three calibration points is the possibility to compensate for unevenness of the printing surface (49).
The exact point of contact is determined, for example, by means of an acceleration sensor (not shown) which registers the vibrations occurring in the collision of the print head (8, 9) and print bed (14). Another way to determine the touch point is the monitoring of the motor signal ("back-EMF") to drive the vertical positioning system, which changes as soon as the upwardly moving print bed (14) encounters a resistance.
Since the calibration is preferably based on the direct contact between nozzle tip and pressure surface (49), unlike other methods (with separate surface scanning), no relative errors occur. Thus, when using an extendable microswitch ("z-probe") to scan the pressure surface (49) between the nozzle tip and the microswitch switching point, there is always an errored distance that adversely affects the accuracy of the calibration.
In the present case, for example, forty-nine checkerboard-distributed calibration points are used, each approached three times to improve the accuracy of the measurements by averaging. If the deviation of a measurement from the mean value is too large, the three measurements are repeated in order to avoid false readings due to external influences. It has been found that the cold nozzle calibration works most reliably, otherwise the measurement results of the acceleration sensor may be corrupted by the vibrations of the hot-nozzle fan or by the pressure exiting the hot nozzle. During printing, an optionally provided acceleration sensor can also be used to measure the movement frequency. Once this reaches a critical frequency range, the print speed can be temporarily adjusted to avoid otherwise occurring resonances.
11 shows in particular a schematic representation of the mathematical mapping of a reference plane 140, a surface (of the base body) 141, a first pressure layer 142 and a second pressure layer 143.
Printhead (Figs. 12, 13)
The printhead (8, 9) consists, inter alia, of an injection-molded front and middle part (59, 60) and of a rear cover plate (61). The front part (59) is attached to the connecting plate (34) and has on the front side a recess (62) for the two toothed belts (17) and the docking magnet (35). Also attached to the front (59) are a material-extruding stepper motor (63) and a power supply and signal transmission ribbon cable (64).
In the recess at the bottom of the print head (8, 9) is the melting unit (65), in which the solid printing material is liquefied before it is applied to the printing bed (14). This is cooled by an axial fan (66) fixed to the cover plate (61). The cooling of the applied printing material is effected by a between the central part (60) and cover plate (61) fixed radial fan (67) in conjunction with an inside running air duct (68).
The supply hose (6, 7), via which the printing material laterally enters the print head (8, 9), is held by a self-tapping hose coupling (69). It is guided downwards by a guide groove (70), where it is pressed by a horizontally movable carriage (71) with a spring on one side and an idler roller on the other side against the drive roller (72). This is driven by the stepper motor (63) and conveys the printing material in the underlying melting unit (65) which is fixed at its upper end between the front and middle part (59, 60).
In order to accelerate the solidification of the extruded material on the printing bed (14) and thus to improve the printing quality, it can be cooled in all embodiments. For this purpose, the radial fan (67) generates an air flow, which is passed through openings in the middle part (60) forward and through air channels (68) between the front and middle part (59/60) on both sides of the melting unit (65) down. Outlets at the bottom end eventually direct the airflow inward where the liquid material exits the nozzle. Compared to one-sided cooling, the two-sided cooling achieves a significant improvement in print quality.
Melting unit (FIG. 14)
The nozzle assembly or melting unit (65) comprises a heating unit (73) and a nozzle unit (74) in which the printing material is guided. The heating unit (73) comprises a cooling body (75), to which a ring-shaped heating element (77) is fastened via a spiral-shaped temperature barrier (76). The nozzle unit (74) comprises a guide tube (78) which is fixed to the nozzle (80) via a conical connection sleeve (79) and is screwed from below into the heat sink (75) so as to connect the nozzle unit (74) to the heating unit (73) to connect.
Since the nozzle (80) can become clogged over time, ease of maintenance is crucial. By the use of a nozzle unit (74) which can be replaced as a whole, the nozzle change is greatly facilitated, since the nozzle (80) in contrast to the conventional construction, in which the nozzle (74) is directly connected to the heating element (77) , neither heated nor separated from this before.
When the nozzle unit (74) is screwed into the heating unit (73), the conical connecting sleeve (79) is pressed against the likewise conical inner side at the lower end of the cooling body (75), so that the heat from the heating element (73) via this and the connecting sleeve (79) can be transferred to the nozzle (80). The helical temperature barrier (76) thereby reduces the heat flow upwards and at the same time serves as a spring to improve the contact between the heating unit (73) and the nozzle unit (74) and thus the heat transfer to the nozzle (80). For the print quality, it is crucial to heat the print material quickly and to keep the transition region between solid and liquid state by a high temperature gradient in the printing material as short as possible. For this reason, the heat transfer to the nozzle (80) as high as possible, but must be as low as possible, with upwardly occurring heat losses must be dissipated quickly by active cooling in the upper region.
For better dissipation of heat losses occurring upwards and for better heat transfer to the nozzle (80), the heat sink (75) should be made of a thermally highly conductive material such as aluminum. The same applies to the connecting sleeve (79) and the nozzle (80). In contrast, the guide tube (78) should be made of a thermally poorly conductive material such as stainless steel or titanium to allow a high temperature gradient along the printed material.
In order to increase the life of the nozzle unit (74), the inside of the guide tube (78) can have as little friction as possible against the partially viscous printing material, which can be achieved by surface finishing processes such as polishing, curing, electroplating or coating. In particular, polishing and nitriding as well as a galvanic PTFE coating on the inside are possible.
Automatic material flow monitoring (Fig. 15)
By measuring the back-EMF, engine load in the printhead can be determined to anticipate and resolve potential extrusion problems (such as clogging). While the measured value ("stall value") in a normal extrusion is relatively constant (t = 50-60), it first drops (t = 60-75) when extrusion problems occur and fluctuates strongly when the motor steps because of the high load omits (t = 75 - 90). Extrusion problems are detected as soon as the moving sigma exceeds a certain value.
For example, in the event of extrusion problems, the printing process is automatically interrupted and a cleaning procedure is carried out, in which the printing material in the print head is moved back and forth several times to rinse possible deposits from the nozzle before the printing is continued in the same place. If further extrusion problems are found, the cleaning procedure is repeated until the user is prompted to change the nozzle after the third unsuccessful attempt.
The measurement of the retro-motor voltage (back EMF) also supports the automatic material introduction (see "Material cassette and supply unit"). As the engine load increases, the print material conveyed from the feed unit to the print head has reached the engine and is pushed by it into the still cold nozzle. Thus, the printing material is completely inserted and does not need to be introduced further by the feed unit.
Supply unit and material cassette (Fig. 16)
The two supply units (4, 5) for model and support material are attached to both sides of the partition to the left of the installation space (2). They comprise an insertion slot (81), two pairs of guide rails (82), an ejection unit (83), a locking unit (84), a contactless transmission device such as an RFID or NFC unit (85), a feed unit (86) and a Adapter unit (87).
The printing material (89) is located on a spool (90) inside the material cassette (88) and leaves it via a guide channel between the two injection-molded outer shells (91) at the rear upper end. Shortly before the outlet opening is a recess for the feed unit (86) and a spring plate made of plastic (92), which presses the printing material (89) against the opposite wall of the guide channel and thus prevents it falls inside the material cassette (88) , Mounted on the rear wall of the material cassette (88) is a non-contact transfer device such as an RFID or NFC chip (93) mounted on the rear wall of the insertion slot (81) by the non-contact transfer device such as the RFID or NFC unit (85) ) can be read out and described.
The RFID technology, for example, allows the automatic and non-contact identification of objects with radio waves. An RFID chip consists of a microchip with a memory unit and an antenna. The RFID module is simultaneously transmitter and receiver and can read or manipulate the data stored on a nearby RFID chip. Although other technologies can be used for the communication between the material cassette and the printer, RFID technology is used as an example. As an alternative to an RFID chip, however, any suitable non-contact transmission devices can be used in all embodiments.
When a material cassette (88) is inserted into a supply unit (4/5), the guide rails (82) on the upper and lower inner sides of the insertion slot (81) engage corresponding grooves in the material cassette (88) and those on the rear wall of the insertion slot (81) mounted ejection unit (83) is tensioned. Once the correct position is reached, the locking unit (84) snaps into a corresponding recess on the top of the material cartridge (88) and thus fixes it in the correct position.
At the same time, the printing material (89) is pressed by the feed unit (86) against the spring plate (92) in the material cassette (88) so that it detaches from the wall of the guide channel and can be moved by the feed unit (86) (see FIG 17). Since the life of the spring plate (92) only needs to reach the life of the material cartridge (88), the wear by friction is not a problem.
As soon as the material cassette (88) has been completely inserted, the non-contact transmission device, in particular the RFID unit (85), reads the contactless transmission device thereon, in particular the RFID chip (93), on which any information about the contained printing material (89 ), such as serial number, material type, expiration date, security code, and remaining amount of material that will be updated after every use. It is automatically detected when a material cassette (88) is inserted, which type of material it is, whether it is still usable and whether it is sufficient for the upcoming printing. In addition, the material-dependent parameters such as the pressure temperature can be automatically adapted to the inserted material cassette (88).
Before the printing is started, the printing material (89) is first pushed out of the material cassette (88) by the feed unit (86), introduced into the supply tube (6, 7) via an adapter unit (87) and then transferred to the print head (8, FIG. 9) forwarded. As soon as the print material (89) has reached the motor in the print head (63), which is detected by measuring the back-EMF (see above), the nozzle (77) can be heated up and the pressure started. During the printing process, the two motors in the feed unit (86) and in the print head (63) are synchronized to ensure an even supply of material.
Before the material cassette (88) can be removed again, the printing material (89) first from the supply hose (6, 7) in the
Material cassette (88) are returned by being withdrawn from the feed unit (86). As soon as the sensor in the adapter unit (87) recognizes that the printing material (89) has completely left the supply hose (6, 7), the locking unit (84) is opened so that the material cassette (88) from the ejection unit (83) is light pushed forward and can be removed from the supply unit (4/5).

权利要求:
Claims (54)
[1]
claims
Device for forming a dimensionally stable, three-dimensional object (12) by consecutive or continuous application and curing of a moldable printing material (89), in particular FFF-3D printer, comprising: - a base body acting as a basis for the construction of the object (12) (14), - at least one print head (8, 9) for applying the print material, - a movement device (94) for changing the relative position of the print head (8, 9) relative to the base body (14), and - at least one print material reservoir (88 ) for receiving the printing material (12) and for outputting the printing material (12) to the print head (8, 9), - wherein the moving device (94) at least one, along an x-axis (10) extending, elongate first support member (97 ), wherein a driving carriage (98) which is connected or connectable to the print head (8, 9) is linearly guided along the x-axis (10) on the first carrier element (97) and is in particular guided in parallel, characterized in that - two printing heads (8, 9) are provided, - that the drive carriage (98) has a coupling device (99), - and that the drive carriage (98) via the coupling device (99) with the print heads (8, 9 ) and the print heads (8, 9) is releasable, - wherein the drive carriage (98) via the coupling device (99) either with one of the print heads (8, 9), or with none of the print heads (8, 9), or with both printheads (8, 9) is coupled.
[2]
2. Device according to the claim 1, characterized in that the by the coupling device (99) made connection of the drive carriage (98) to the print head (8, 9) is a magnetic or non-positive connection, in particular when overcoming the holding force of the coupling device (99) is separable by moving the drive carriage (98) along the x-axis (10).
[3]
3. Device according to one of claims 1 or 2, characterized in that the coupling device (99) comprises a magnetic or magnetizable body (35) which is coupled or coupled via magnetic forces with an element of the print head (8, 9).
[4]
4. Device according to one of claims 1 to 3, characterized in that the print heads (8, 9) in each case via a print head carriage (100) along the x-axis (10) on the first support member (97) are linearly guided.
[5]
5. Device according to one of claims 1 to 4, characterized in that the drive carriage (98) along the path of the first support member (97) between the two printhead carriage (100) of the two print heads (8, 9) is arranged.
[6]
6. Device according to one of claims 1 to 5, characterized in that the first carrier element (97) has a rail portion (101) in which the print heads (8, 9) along the x-axis (10) are movable and positionable, and that in each of the two end regions (102) of the rail section (101) or the first support element (97) there is provided a holding device (104) for the temporary fixing of a respective print head (8, 9) and in particular one parking position (105).
[7]
7. Device according to one of claims 1 to 6, characterized in that the first carrier element (97) has a rail portion (101) in which the print heads (8, 9) along the x-axis (10) are movable and positionable, and that in the two end regions (102) of the rail portion (101) or the first support member (97) each have a holding device (104) for temporary fixing each of a print head (8, 9) is provided, that the holding devices (104) each have a holding element (106), such as in particular comprise a movable latch (107), and that the holding elements (106) of the two holding devices (104) simultaneously, synchronized or mechanically coupled to each other are actuated or that the holding elements (106) of the two holding devices (104) independently can be actuated from each other.
[8]
8. Device according to one of claims 1 to 7, characterized in that the apparatus for forming a dimensionally stable, three-dimensional object (12) by consecutive or continuous melting, targeted, multi-layered dot-shaped or strip-shaped applications and curing a fusible, wirelike or filamentary printing material ( 89) is set up.
[9]
9. Apparatus according to claim 1 to 8, characterized in that a machine frame (108) is provided, which is optionally surrounded or formed by a housing (1), and that by the machine frame (108) or by the housing (1) a Building space (2) for forming the object (12) is formed.
[10]
10. Device according to one of claims 1 to 9, characterized in that - the movement device (94) at least one along the x-axis (10) extending, elongated first support member (97), - that the movement device (94) at least a (11), elongated second carrier element (103) extending along the y-axis, comprising - the first carrier element (97) linearly guided along the y-axis (11) on the second carrier element (97) and in particular parallel, in that the second carrier element (103) is in particular fixed or rigidly connected to the machine frame (108), and that a drive carriage (98) connected or connectable to the print head (8, 9) along the x-axis (10) on the first carrier element (97) is linearly guided and in particular guided in parallel so that an xy kinematics (109) for moving the print head (8, 9) in an xy plane (110) is formed.
[11]
11. The device according to one of claims 1 to 10, characterized in that - the movement device (94) connected to the drive carriage (98) first drive belt (111) for moving the print head (8, 9), at least a first belt drive (112 ) with a Riemenantriebsrad (113) for driving the drive belt (111) and a plurality of deflection rollers (26) for deflecting the drive belt (111), - that the first belt drive (112) in particular stationary on the machine frame (108) is mounted, - that at least a deflection roller (26) on the first carrier element (97) and at least one deflection roller (26) on the machine frame (108) is mounted, - and that the first drive belt (111) substantially in a first drive plane (114) extends parallel to the xy Level (110) runs.
[12]
12. Device according to one of claims 1 to 11, characterized in that - the movement device (94) connected to the drive carriage (98) second drive belt for moving the print head, at least one second belt drive (115) with a Riemenantriebsrad (112) for Drive of the drive belt (111) and a plurality of deflection rollers (26) for deflecting the drive belt (111), - that the second belt drive (115) in particular stationary on the machine frame (108) is mounted, - that at least one deflection roller (26) on the first support element (97) and at least one deflection roller (26) is mounted on the machine frame (108), - and that the second drive belt (116) extends substantially along a second drive plane (117) which is parallel and spaced from the first drive plane (114) and / or parallel to the xy plane (110).
[13]
13. Device according to one of claims 1 to 12, characterized in that the movement device (94) per drive belt (111, 116) comprises two driven deflection rollers (71) for driving the drive belt (111, 116) - or that the movement device ( 94) per drive belt (111, 116) comprises two belt drives (112, 115) for driving the drive belt (111, 116), - wherein the two driven deflection rollers (71) or the two belt drives (112, 115) of a drive belt (111, 116) in the course of the drive belt (111, 116) before and after the connection point (118) with the drive carriage (98) are arranged, and that the two drives (112, 115) are in particular synchronized.
[14]
14. Device according to one of claims 1 to 13, characterized in that the movement device (94) per drive belt (111, 116) has two belt drives (112, 115) or two driven pulleys (71) for driving the drive belt (111, 116). wherein the two belt drives (112, 115) or the two driven deflection rollers (71) of a drive belt (111, 116) in the course of the drive belt (111, 116) in each corner position (119) immediately before and after the connection point (118 ) are mounted to the drive carriage (98) on the machine frame (108).
[15]
15. Device according to one of claims 1 to 14, characterized in that the movement device (94) comprises a base drive device (120) for movement and in particular for parallel movement of the base body (14) along the z-axis (15), wherein the base drive device ( 120) comprises a base drive (121) and at least one guide element (122), wherein the base drive (121) as a linear drive (123) and in particular as a stepping motor (46) with a spindle (44) and one with the ball screw (44) in operative contact standing spindle nut (43) is formed, and wherein the guide element (122) as a linear guide (124) and in particular as along a rail (42) guided bushing (125) is formed.
[16]
16. Device according to one of claims 1 to 15, characterized in that the movement device comprises a base drive device (120) for movement and in particular for parallel movement of the base body (14) along the z-axis (15), wherein the base drive device (120) has a Basic drive (121) and at least one guide element (122), wherein the base drive (121) as a linear drive (123) and in particular as a stepping motor (46) with a ball screw (44) and with the ball screw (44) in operative contact spindle nut ( 43) is formed, wherein the guide element (122) as a linear guide (124) and in particular as along a rail (42) guided bushing (125) is formed, and that designed as a cantilever pressure platform (126) for supporting the base body (14) is provided, which runs essentially normal to the direction of movement of the base body (14), in particular in a plane parallel to the xy plane (110), and which is slidable and drivable via the base drive device (120) along the z-axis (15).
[17]
17. The device according to one of claims 1 to 16, characterized in that the base body (14) as a removable pressure bed (14) and releasably connected to the pressure platform (126) or is connectable, and that the releasable connection is in particular a magnetic connection.
[18]
18. Device according to one of claims 1 to 17, characterized in that a heating device (127) for heating the base body (14) is provided.
[19]
19. Device according to one of claims 1 to 18, characterized in that the print head (8, 9) a printhead main body (128) and at a connection point (144) connected to the printhead main body (128) nozzle assembly (129) for melting and projecting the Printing material (89), wherein the nozzle assembly (128) starting from the connection point (144) successively a heat sink (73), a decoupling point (130) and a heated or heated nozzle (77).
[20]
20. Device according to one of claims 1 to 19, characterized in that the print head (8, 9) a printhead main body (128) and at a connection point (144) with the printhead main body (128) connected nozzle assembly (129) for melting and projecting the Printing material (89), wherein the nozzle arrangement (129) starting from the connection point (144) successively a heat sink (73), a decoupling point (130) and a heated or heated nozzle (77), and that the decoupling point (130) a Tube (80) for passage of the printing material (89), wherein the tube (80) is at least partially formed from a solid, heat-resistant material with low thermal conductivity, so that through the tube (80) a thermal separation between the heated nozzle (77) and the heat sink (73) is formed.
[21]
21. Device according to one of claims 1 to 20, characterized in that the print head (8, 9) a printhead main body (128) and at a connection point (144) with the printhead main body (128) connected nozzle assembly (129) for melting and projecting the Printing material (89), wherein the nozzle arrangement (129) starting from the connection point (144) successively a heat sink (73), a decoupling point (130) and a heated or heated nozzle (77), and that the decoupling point (130) a Tube (80) for the passage of the printing material (89), wherein the tube (80) at least on the inside (131) opposite the molten printing material (89) friction or substantially non-adhesive is formed.
[22]
22. Device according to one of claims 1 to 21, characterized in that the print head (8, 9) a printhead main body (128) and at a connection point (144) with the printhead main body (128) connected to the nozzle assembly (129) for melting and projecting the Printing material (89), wherein the nozzle arrangement (129) starting from the connection point (144) successively a heat sink (73), a decoupling point (130) and a heated or heated nozzle (77), and that the decoupling point (130) a Pipe (80) of a metal alloy, a titanium alloy or a stainless steel alloy, and / or that the inside (131) of the tube (80) is polished, hardened, galvanized and / or coated, wherein the inside (131) in particular polished and nitrided or provided with a PTFE coating.
[23]
23. Device according to one of claims 1 to 22, characterized in that the print head (8, 9) a printhead main body (128) and at a connection point (144) with the printhead main body (128) connected nozzle assembly (129) for melting and projecting the Printing material (89), wherein the nozzle assembly (129) starting from the connection point (144) successively a heat sink (73), a decoupling point (130) and a heated or heated nozzle (77), and that the nozzle assembly (129) separable connected to the printhead body (128) or connectable.
[24]
24. Device according to one of claims 1 to 23, characterized in that the printing material reservoir (88) is designed as a removable printing material reservoir (88) which is connected in a modular manner with the machine frame (108) or connectable, wherein the connection in particular via a fastening device and / or a slot is made.
[25]
25. Device according to one of claims 1 to 24, characterized in that the printing material reservoir (88) comprises a clamping device (132) that the clamping device (132) has a clamping position (133) in which a portion of the printing material (89) between a resiliently biased spring element (92) and a clamping jaw (135) is clamped, and that the clamping device (132) has a conveying position (136) in which the clamping of the clamping device (132) is lifted so far, so that a promotion of the printing material ( 89) can take place.
[26]
26. Device according to one of claims 1 to 25, characterized in that the printing material reservoir (88) comprises a clamping device (132) that the clamping device (132) has a clamping position (133) in which a portion of the printing material (89) between a resiliently biased spring element (92) and a clamping jaw (135) is clamped, that the clamping device (132) has a conveying position (136) in which the clamping of the clamping device (132) is lifted so far, so that a promotion of the printing material (89 ), and that the clamping device (132) automatically changes from the clamping position (133) into the conveying position (136) when the printing material reservoir (88) is or is connected to the device.
[27]
27. Device according to one of claims 1 to 26, characterized in that stationary on the machine frame (108) a printing material drive (137) with a drive wheel (138) for conveying the printing material (89) from the printing material reservoir (88) to the print head (8, 9 ), and when the print material reservoir (88) is connected to the apparatus, the drive wheel (138) is in operative contact with a portion of the print material (89) or abuts directly on a portion of the print material (89) so as to be actuated the drive (137) is or is a promotion of the printing material (89) causes.
[28]
28. Device according to one of claims 1 to 27, characterized in that stationary on the machine frame (108) a printing material drive (137) with a drive wheel (138) for conveying the printing material (89) from the printing material reservoir (88) to the print head (8, 9 ), and when the print material reservoir (88) is connected to the apparatus, the drive wheel (138) is in operative contact with a portion of the print material (89) or abuts directly on a portion of the print material (89) so as to be actuated the drive (137) is or is caused to convey the printing material (89), and in that the portion of the printing material (89) is clamped between the drive wheel (138) and the resiliently biased spring element (92) so that the friction between the drive wheel (89) 138) and printing material (89) is increased to improve the promotion.
[29]
29. Device according to one of claims 1 to 26, characterized in that stationary on the machine frame (108) a printing material drive (137) with a drive wheel (138) for conveying the printing material (89) from the printing material reservoir (88) to the print head (8, 9 ), and when the print material reservoir (88) is connected to the apparatus, the drive wheel (138) is in operative contact with a portion of the print material (89) or abuts directly on a portion of the print material (89) so as to be actuated the drive (137) is or is caused to convey the print material (89) and that the print material drive (137) and the drive wheel (138) remain in the machine frame (108) when the print material reservoir (88) is removed.
[30]
30. Device according to one of claims 1 to 29, characterized in that the printing material reservoir (88) with a fastening device (139), in particular as the machine frame (108) provided insertion slot (134) is formed, with the machine frame (108) connectable or is detachably connected.
[31]
31. Device according to one of claims 1 to 30, characterized in that the printing material reservoir (88) comprises a non-contact transmission device, in particular an RFID chip (93) in the inserted position of the printing material reservoir of a contactless transmission device, in particular an RFID unit (85) is readable and / or writable, wherein a non-contact transmission device, in particular the RFID unit (85), with the data processing device (96) is connected, and wherein a non-contact transmission device, in particular the RFID unit (85) on the Fastening device (139), on the insertion shaft (134) or on the machine frame (108) is mounted.
[32]
32. Device according to one of claims 1 to 31, characterized in that the printing material reservoir (88) comprises a non-contact transmission device, in particular an RFID chip (93) readable by a non-contact transmission device, in particular an RFID unit (85) and and / or writable, and that data of the printing material reservoir (88) such as serial number, type of material, date of flippability, security code, remaining amount of material that is updated in particular after each use, and / or material-dependent parameters such as the optimum printing temperature or the optimum printing speed.
[33]
33. Device according to one of claims 1 to 32, characterized in that two printing material reservoirs (88) are provided which are each connected via a printing material line (95) with a print head (8, 9).
[34]
34. A method of forming a dimensionally stable three-dimensional object by consecutive or continuous application and curing of a moldable printing material, in particular to form a dimensionally stable, three-dimensional object by consecutive or continuous application and curing of two moldable printing materials, and more particularly to printhead change methods comprising the steps of Moving the drive carriage and the first print head coupled to the drive carriage via a coupling device, moving the drive carriage to a second print head which is located in a parking position arranged in the end area of the first carrier element and temporarily arrested there by a holding device, coupling the second one Printhead with the drive carriage via the coupling device, - releasing the holding device of the second printhead, so that the second printhead can be moved from its parking position, - wherein before d he clutch of the second print head with the drive carriage or after the coupling of the second print head with the drive carriage of the drive carriage and coupled to the drive carriage via a coupling device first print head is transported to the parking position of the first print head, where the holding device of the first print head is closed and the first print head is released from the drive carriage, so that the first print head is locked in its parked position, wherein after the printhead change, only the second print head is connected to the drive carriage; or comprising the following steps: moving the drive carriage and the first print head coupled to the drive carriage via a coupling device to the parking position of the first print head at the end region of the first support element, closing the holding device of the first print head and releasing the first print head from the drive carriage by releasing the coupling device so that the first printhead is locked in its parking position, - moving the drive carriage to a second printhead which is in a parked in the opposite end of the first support member parking position and is temporarily locked there by a holding device, - coupling the second printhead to the drive carriage via the coupling device, - releasing the holding device of the second printhead so that the second printhead can be moved out of its parking position, - and moving the drive carriage and the drive carriage over the coupling device coupled second printhead.
[35]
35. The method of claim 34, comprising the following steps: - Moving the drive carriage and coupled to the drive carriage via a coupling device first printhead to a second print head, which is located in a arranged in the end of the first support member parking position and there temporarily locked by a holding device - coupling the second printhead to the drive carriage via the coupling device so that the drive carriage is connected to both printheads, - releasing the second printhead support so that the second printhead can be moved out of its parked position, - moving the drive carriage and the two printheads coupled to the drive carriage via the coupling device to the parking position of the first printhead at the opposite end region of the first carrier element, closing the holding device of the first printhead and releasing the first printhead from the drive carriage n by releasing the coupling device so that the first print head is locked in its parked position, - moving the drive carriage and coupled to the drive carriage via the coupling device second print head.
[36]
36. The method of claim 34 or 35, characterized in that the holding device of the first printhead and the holding device of the second printhead are simultaneously released, synchronized or coupled with each other or closed.
[37]
37. The method of claim 34 to 36, characterized in that for locking a printhead in the parking position of the printhead is moved into the corresponding end portion of the first support member, then the corresponding holding device is closed, and then the coupling device by moving away the drive carriage and by overcoming the holding force is disconnected.
[38]
38. The method according to any one of claims 34 to 37, in particular method for calibrating a device, wherein the device is adapted to form a dimensionally stable, three-dimensional object, wherein the object is formed in particular by konsekutives or continuous jobs and curing a moldable printing material, and wherein the apparatus has a base body acting as a base for building the object, at least one print head for applying the print material, and a moving device for changing the relative position of the print head relative to the base body, comprising the steps of: positioning a print head along the xy plane a first calibration point, reducing the distance between the base body and the printhead until the base body contacts a calibration reference element of the printhead, and detecting the contact between the base body and the calibration reference element.
[39]
39. The method according to any one of claims 34 to 38, characterized in that following the detection of the contact between the base body and the calibration reference at the first calibration point, a distance between the base body and the calibration reference is made.
[40]
40. The method according to any one of claims 34 to 39, characterized in that after re-establishing a distance between the base body and the Kalibrierreferenzelement the print head is moved to a second calibration point, wherein the second calibration point in the xy plane a distance from the first calibration point in that subsequently the distance between the base body and the printhead is reduced until the base body contacts the calibration reference element of the printhead and a detection of the contact between the base body and the calibration reference element takes place, and that following the detection of the contact between the base body and the printhead Calibration reference element at the second calibration point in turn, a distance between the base body and the calibration reference is made.
[41]
41. The method according to any one of claims 34 to 40, characterized in that after re-establishing a distance between the base body and the calibration reference element of the print head is moved to a further, in particular third, calibration point, wherein the further calibration point in the xy plane a Distance to the already reached calibration points, that then the distance between the base body and the print head is reduced until the base body touches the Kalibrierreferenzelement of the print head and a detection of the contact between the base body and the Kalibrierreferenzelement takes place, and that following the detection of the Contact between the base body and the calibration reference at the further calibration point a distance between the base body and the calibration reference is made.
[42]
42. The method according to any one of claims 34 to 41, characterized in that successively at least three calibration points are approached until each contact between the base body and the calibration reference is detected, and that relative or absolute position data, in particular x-, y-, and z Values of the points of contact or of the height differences of the points of contact along the z-axis are transmitted to a data processing device.
[43]
43. The method according to any one of claims 34 to 42, characterized in that successively a plurality of planar, grid-like or checkerboard-like arranged along the base body calibration points are approached until each contact between the base body and the calibration reference is detected, and that relative or absolute position data, in particular x, y, and z values of the points of contact or the height differences of the points of contact along the z-axis are transmitted to a data processing device.
[44]
44. Method according to claim 34, characterized in that the x, y, and z values of the contact points or the height differences of the contact points along the z axis are transmitted to a data processing device, and in that the data processing device comprises a calibration matrix or determines a calibration surface, which essentially corresponds to a mathematical mapping or an approximate mathematical mapping of the surface of the base body.
[45]
45. Method according to claim 34, characterized in that each calibration point is approached more often, in particular three times, that the position data of a calibration point recorded thereby are compared with one another and that the calibration point is approached at least once more when the recorded one Position data, in particular the z-values of the position data, deviate from one another by a value which exceeds a predetermined maximum deviation value.
[46]
46. Method according to claim 34, characterized in that two printheads are provided so that after the calibration points are approached with the first printhead, a printhead change is performed, so that only the second printhead is coupled to the drive carriage, that subsequently an arbitrary, Already approached with the first printhead calibration point, in particular a single arbitrary already approached with the first printhead calibration point, is also approached with the second printhead, and that from the recorded position data of the second printhead a z-difference value is calculated to the corresponding value of the first printhead.
[47]
47. Method according to claim 34, characterized in that the calibration area or the calibration matrix of the second printhead is calculated by mathematical displacement of the calibration matrix of the first printhead by the z-difference value, wherein the displacement of the calibration matrix is calculated in particular by vector addition.
[48]
48. The method according to any one of claims 34 to 47, characterized in that is moved to form a three-dimensional object, the printhead in a movement in the xy plane along the calibration or parallel to the calibration, in order, in particular during the printing process, the distance between the base body and to keep the nozzle tip constant.
[49]
49. Method according to claim 34, characterized in that, during the formation of an object, the z-position of the base body is dynamically adjusted as a function of the xy position of the print head so that the nozzle of the print head is at the same distance from the print surface in each print position or to the print object.
[50]
50. The method according to any one of claims 34 to 49, characterized in that an inclination of the print object is compensated as a result of an inclined base body in the printing process by a horizontal displacement of the individual layers.
[51]
51. The method according to any one of claims 34 to 50, characterized in that the calibration is carried out automatically or automatically, wherein the automation is carried out in particular programmatically by a data processing device.
[52]
52. The method according to any one of claims 34 to 51, characterized in that the calibration reference element is the tip of the nozzle of the print head, an element provided at the tip of the nozzle or an element forming the tip of the nozzle.
[53]
53. The method according to any one of claims 34 to 52, characterized in that for relative movement between the base body and the print head, the base is moved along the z-axis, wherein the movement is effected by operating the base drive device.
[54]
54. A method for forming a dimensionally stable, three-dimensional object by consecutive or continuous application and curing of a formable printing material, in particular methods for monitoring the printing material conveying, comprising the following steps: - actuating a drive wheel of a printing material drive for conveying the printing material, - measuring the retroactive motor voltage of the printing material drive Comparing the retroactive motor voltage with a desired value or range, in particular comparing a sliding standard deviation of the retroactive motor voltage with a desired value or range, initiating an alternative operating mode or a cleaning mode when the value or the sliding standard deviation of the retroactive motor voltage is different from the nominal value or deviates from the target range.

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同族专利:

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公开号 | 公开日

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DE102016108353A1|2016-11-10|

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EP3291969B1|2020-04-22|

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DE102016108355A1|2016-11-10|

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DE102016108348A1|2016-11-10|

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AT516839B1|2016-09-15|

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US20190118467A1|2019-04-25|

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EP3291969A1|2018-03-14|

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DE102016108351A1|2016-11-10|

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WO2016177772A1|2016-11-10|

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EP3689580A1|2020-08-05|

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法律状态:
2020-11-15| PC| Change of the owner|Owner name: XIONEER SYSTEMS GMBH, AT Effective date: 20200922 |

优先权:

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申请号 | 申请日 | 专利标题

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ATA50366/2015A|AT516839B1|2015-05-06|2015-05-06|Apparatus and method for forming a three-dimensional object|ATA50366/2015A| AT516839B1|2015-05-06|2015-05-06|Apparatus and method for forming a three-dimensional object|

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US15/571,788| US20190118467A1|2015-05-06|2016-05-04|Apparatus and method for forming a three-dimensional object|

---

DE102016108353.4A| DE102016108353A1|2015-05-06|2016-05-04|Apparatus and method for forming a three-dimensional object|

---

EP20162947.4A| EP3689580A1|2015-05-06|2016-05-04|Method for forming a three-dimensional object|

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DE102016108351.8A| DE102016108351A1|2015-05-06|2016-05-04|Apparatus and method for forming a three-dimensional object|

---

EP16722123.3A| EP3291969B1|2015-05-06|2016-05-04|Apparatus and method for forming a three-dimensional object|

---

PCT/EP2016/059985| WO2016177772A1|2015-05-06|2016-05-04|Apparatus and method for forming a three-dimensional object|

---

DE102016108348.8A| DE102016108348A1|2015-05-06|2016-05-04|Apparatus and method for forming a three-dimensional object|

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DE102016108355.0A| DE102016108355A1|2015-05-06|2016-05-04|Apparatus and method for forming a three-dimensional object|