The present invention relates to a method for manufacturing pieces by additive manufacturing also called stereolithography and to a manufacturing machine for implementing the method.
These parts are especially green pieces made of ceramic material, which are intended to be subjected to cleaning, debinding and sintering operations so as to obtain finished ceramic pieces.
The technique of additive manufacturing for obtaining such green pieces generally comprises the following steps:
The irradiation of the layers is performed by a laser scanning of the free surface of the spread photocurable composition or by a diode (LED) projection system or by any other light sources especially of the UV-type.
The present invention relates to additive manufacturing methods in which the photocurable composition takes the form of a paste the composition of which is photocurable, such as the one indicated above, and the viscosity of which may vary especially from 1 Pa·s to infinity for a zero shear rate.
In a manufacturing by pasty process, the working tray supports the different layers of the piece being manufactured as well as the amount of paste to be spread each time a layer is formed. Each of the layers is formed by lowering the working tray and spreading a large bead of paste for obtaining a layer with a predefined paste thickness which is formed on the working tray for the first layer or on the previous layer for the other layers of the stack. To that end, a supply of paste is stored in a tank which is automatically emptied of the predefined amount of paste at each layer by means of a piston, the piston raising this amount of paste through a slot so as to form the bead in the vicinity of an edge of the working surface. The paste bead is then spread by scraping by means of a scraping blade which, urged to be placed behind it, causes it to move forward while sweeping the working surface to its opposite edge so as to spread the bead with a pass motion perpendicular to the edge of the scraping blade.
Such a paste supply onto the working tray has several drawbacks:
To conclude, the current paste supply system does not always ensure the homogeneity of each spread layer, leads to important scraping efforts which may damage and even destroy the pieces being built, limits the working surface in both length and width, limits the height of the pieces to be built and only allows to print one ceramic at a time.
The Applicant Company has searched for a new paste supply system allowing to remove at least one of these drawbacks.
To that end, it is provided, according to the invention, that the paste is no more supplied from a paste bead brought along an edge of the working surface, but that the paste is supplied on the working surface from above the working surface, particularly from at least one nozzle arranged above the working surface and moveable to ensure an even supplying thereonto.
For example, by providing for a nozzle for dispensing a paste strand, which nozzle moves both back and forth on the width of the working surface (according to the axis Y) and straightly on the length of the working surface (according to the axis X) so that the paste strand is always located in front of the scraping blade in operation, an even serpentine of paste is formed on the working surface, which serpentine ensures an even and continuous spread of paste and does not require an important scraping effort because, each time, the scraping blade only pushes the useful amount of paste.
Thus, shear stresses related to a paste being spread onto a great length are minimized, even removed, and the formation of menisci is greatly reduced.
Furthermore, such a dispensing of the paste can be performed in the transversal direction on a width of the working tray much larger than that of the working trays which have been existing so far. The invention will therefore allow to make working trays much wider than currently (300 mm maximum) and theoretically with widths without limit.
Likewise, since the amount of paste for one layer is not fully supplied at the beginning but as and when the scraping blade moves forward by being supplied in front thereof whatever its progressing position, it is possible to well adjust the useful amount so as to avoid the formation of menisci and to minimize, even remove, stresses on the already cured lower layers; as a result, the scraping blade can work on a much greater length and more quickly due to little or no stress.
Besides, the fact that, each time a layer is formed, only the necessary amount of paste is supplied, allows the layers to be formed with materials which can be different from one layer to the other. It is therefore possible to form multi-material pieces, for example, ceramic pieces.
It is clearly provided, within the scope of the present invention, that several nozzles should be activated in a same pass, simultaneously or not, through programming of the nozzles, in the way of an inkjet printer, in order to have several materials on a same layer. It is therefore possible to deposit different materials at different widths on a same layer.
Furthermore, it is possible to provide layers of a photocurable composition without the ceramic material, in other words, of a composition comprising at least one photocurable monomer and/or oligomer, at least one photoinitiator and, if necessary, at least one additive, such as a plasticizer or a dispersant. Such layers can be supporting layers which will be destroyed when the piece is debinded or can be layers creating cavities necessary when the pieces are built, which layers will be destroyed during the debinding process.
Finally, it is possible to provide that the dispensing of paste in front of the blade should be programmable, that is to say activated and stopped on demand, which allows to provide the formation of several pieces in parallel on the width and/or the length of a working tray, the dispensing of paste by the nozzle(s) being activated only around the location of each piece to be formed on the working tray.
The subject-matter of the present invention is a method for manufacturing a piece, especially a green piece made of ceramic material, by the technique of additive manufacturing according to which layers of a photocurable paste are successively allowed to cure according to a pattern defined for each layer, the first layer being formed on a working surface on a working tray, each layer, before curing according to a defined pattern, being spread by scraping by one scraping blade or parallel scraping blades from an amount of paste supplied onto said working tray, which is lowered upon each formation of a layer, characterised in that, upon each formation of a layer, the amount of paste necessary to form said layer is dispensed onto the working surface, from at least one nozzle which is moved in front of the scraping blade, or in the case of parallel scraping blades, in front of the front scraping blade.
The nozzle or each nozzle can be moved transversally back and forth parallel to the scraping blade or to the scraping blades and longitudinally according to the advance movement of the one or more scraping blades from an edge of the working surface to the opposite edge thereof.
At least one parameter selected among the flow rate of the nozzle or of each nozzle and the transversal and longitudinal advance speeds of the nozzle or of each nozzle can be adjusted depending on at least one parameter selected especially among the viscosity of the paste and the thickness of the layer.
The dispensing of paste by one nozzle or each nozzle can be controlled depending on the layer to be formed.
The nozzle or each nozzle can be supplied with paste by means of a pipe for supplying paste from a paste tank or the nozzle or each nozzle can be supplied with paste by means of a paste cartridge which forms the upper part of the nozzle or of each nozzle and which contains a stock of paste advantageously sufficient to form at least one layer.
The paste can be dispensed from at least two nozzles aligned according to an axis parallel to the one or more scraping blades or according to an axis perpendicular to the one or more scraping blades.
When spreading at least one of the paste layers, at least one scraping blade in working position, in addition to its scraping advance movement, is allowed to go back and forth in its plane according to a so-called vibration motion.
The paste deposit can be controlled in a continuous way, thus forming a paste strand on the working surface, and/or in a discontinuous way, thus forming deposits by points on the working surface.
The invention relates also to a machine for manufacturing pieces, especially green pieces made of ceramic material, by the technique of additive manufacturing according to which layers of photocurable paste are successively allowed to cure by irradiation according a pattern defined for each layer, said machine comprising:
The or at least one of the nozzles of the machine can be supplied with paste by a flexible pipe connected to a paste tank, particularly a piston-type supply tank, or the or at least one of the nozzles can be supplied with paste by a paste cartridge which forms the upper part of the nozzle or of each nozzle, which contains a stock of paste advantageously sufficient to form at least one layer, and which can be refilled from a supply tank mounted or not to the machine or which can be replaced when it is empty with a full cartridge, it being possible that this replacement be performed by a robotic arm.
The or at least one of the nozzles can be moveably mounted by means of a robotic arm or to a holder which allows a movement in front of the scraping.
The or each nozzle can be mounted to a portal frame adapted to move on the frame over the working tray according to the length thereof, said portal frame being the portal frame equipped with the one or more scraping blades or being another portal frame, moveable independently thereof, the or each nozzle being further moveably mounted to a transversal rail of the portal frame which carries it.
In a particular embodiment, the portal frame is a portal frame equipped with scraping blades, especially comprising two scraping blades, one being operational when the portal frame moves in one direction, and the other, when the portal frame moves in the other direction, the or each nozzle being moveably mounted to a transversal rail of said portal frame, the or each nozzle being arranged between both blades.
In a particular embodiment, the machine according to the present invention can comprise at least two nozzles arranged according to the advance axis of the portal frame or according to a transversal axis.
The amplitude of one or of each nozzle in the portal frame can be greater than the width of the working tray, so that each nozzle is adapted to dispense paste at each point of the working tray.
The machine according to the present invention can comprise adjusting means of at least one parameter selected among the flow rate of the nozzle or of each nozzle and the transversal and longitudinal advance speeds of the or each nozzle, depending on at least one parameter selected especially among the viscosity of the paste and the thickness of the layer.
The machine according to the present invention can comprise controlling means of the paste deposit in a continuous way, thus forming a paste strand on the working surface, and/or in a discontinuous way, thus forming deposits by points on the working surface.
To better illustrate the subject-matter of the present invention, several particular embodiments of the scraping device of the machine according to the invention will be described hereinafter, by way of example and not limitation, with reference to the accompanying drawing. On each of the Figures, the arrow indicates the advance direction of the scraping device.
In this drawing:
In reference to
The scraping device 1 comprises, slidably mounted on the frame 3 of the machine, a portal frame 4 with a motor which drives it with a ball screw or a rack. A blade holder 5, in which is arranged a scraping blade 6, is integrally formed with the portal frame 4.
The frame 3 comprises two elongated blocks 3a located on either side of the working tray 2, each of these blocks 3a bearing a rib 3b which extends horizontally over its entire outer lateral face and the function of which is indicated below.
The portal frame 4 consists in a block comprising an upper part 4a in the form of an elongated rectangular parallelepiped which is arranged over the working tray 2 and the frame 3, transversally to the blocks 3a, and which extends by two lower lateral parts 4b.
The rear face of the upper part 4a comprises two vertical protrusions 4c, each having a U-shaped section a wing of which is contiguous to said rear face. The grooves 4d of these U-shaped sections are arranged opposite to each other. The function of these grooves 4d is indicated below.
In the vicinity of its base, each lateral part 4b comprises, inwardly facing, a groove 4e into which the block 3a associated to the frame 3 is adapted to slide by its corresponding rib 3b.
The blade holder 5 consists in a plate adapted to vertically slide by its two lateral edges into the grooves 4d of the associated vertical protrusions 4c of the portal frame 4. The scraping blade 6 is carried by the lower part of the blade holder 5. This scraping blade 6 can be seen on
According to the invention, and as it can be seen on
The functioning of the scraping device 11 of
In reference to
In the position of
When the portal frame 4 reaches the end of its stroke, in other words when the paste layer is completely deposited, the supply of the nozzle 8 is stopped, the scraping blade 6 is raised by raising the blade holder 5 and the portal frame 4 is returned to its starting position (
In reference to
The functioning of the scraping device 12 in
On
Starting from the position shown on
The simultaneous advance movements of the portal frame 4 and back-and-forth movements of the nozzle 8 into the rail 7 (see
Once the layer of paste is deposited, the blade holder 5 is raised and the portal frame 4 is returned to the position in
In reference to
The faces of the upper parts of both portal frames making up the double portal frame 4′ comprise each two protrusions with a U-shaped section facing each other (respectively two protrusions 4′c and two protrusions 4″c), in which are slidably mounted, in the same way as in the previous embodiments, the blade holders 5 and 5′ respectively with their associated scraping blades (see blade 6′ on
In the example shown, only the portal frame of the double portal frame 4′ comprising the blade holder 5′, has, on its inner face—the one which is turned towards the other portal frame, the rail 7 on which is transversally slidably mounted the nozzle 8 topped by its refill 11. Thus, the nozzle 8 is adapted to move between both portal frames of the double portal frame 4′.
Thus, the double portal frame 4′ will move from an end of the working tray 2 to the other on an forward stroke where only one scraping blade associated to a blade holder will be active, the opposite blade holder being raised so that its associated blade, raised, should not be operational, the double portal frame 4′ then moving on a return stroke for which the blades will be successively raised and lowered.
On
The functioning of the scraping device 13 can be described with reference to
The blade associated to the blade holder 5 is lowered and the one associated to the blade holder 5′ is raised. The blade associated to the blade holder 5 is therefore operational, the portal frame 4 moving according to the arrow indicated with paste being deposited by the nozzle 8 which transversally moves back and forth along the rail 7.
After forming the layer, the refilling takes place as in the previous embodiment. The blade associated to the blade holder 5′ is lowered and the one associated to the blade holder 5 is raised. The blade associated to the blade holder 5′ will therefore be operational to form the following layer, the portal frame 4′ being ready to move in the opposite direction.
The portal frame 4′ moves according to the arrow indicated (
In reference to
The functioning is the same as for the devices 11 and 12.
It can be seen, when comparing
In reference to
In reference to
In reference to
The devices 15, 16 and 17 can be useful if a large amount of paste to be deposited is desired or if the type of paste is desired to be changed between layers, in which case, only one nozzle is operated to apply one layer.
Number | Date | Country | Kind |
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1751685 | Mar 2017 | FR | national |