METHOD FOR PRODUCING A THREE-DIMENSIONAL OBJECT
A method for producing a three-dimensional object by successive solidification of layers of a powder-type construction material that can be solidified using radiation. The method includes providing a laser system with a housing, a construction chamber, a coating device for applying construction material in layers, a radiation device for applying the applied layers of construction material with radiation, and a group structure on which the object and/or a support structure for the object is additively constructed; forming the support structure for supporting the three-dimensional object, by successive solidification of layers of the construction material; forming individual sub-objects that form a determined section of the three-dimensional object, by successive solidification of layers of the construction material, wherein one sub-object is formed on the support structure; forming joining regions between the sub-objects for joining the sub-objects by forming the three-dimensional object; removing the three-dimensional object from the support structure.
1 . A method for producing a three-dimensional object ( 1 ) by successive solidification of layers of a powder-type construction material that can be solidified using radiation, said method comprising the following steps:
providing a laser sintering system or a laser melting system with a housing, a construction chamber arranged therein, a coating device for applying construction material in layers, a radiation device for radiating the applied layers of construction material, and a group structure on which the object and/or a support structure for the object is additively constructed;
characterized by the following steps
forming the support structure ( 2 ) for at least partially supporting the three-dimensional object ( 1 ) to be produced, by successive solidification of layers of the construction material;
forming a number of individual sub-objects ( 6 ) that form a determined section of the three dimensional object ( 1 ) to be produced, by successive solidification of layers of the construction material, wherein at least one sub-object ( 6 ) is formed at least partially on the support structure ( 2 );
forming joining regions ( 7 ) between the sub-objects ( 6 ) for at least partially joining the sub-objects ( 6 ) by forming the three-dimensional object;
removing the three-dimensional object ( 1 ) from the support structure ( 2 ).
2 . A method according to claim 1 , characterized in that at least a part of the support structure ( 2 ) and at least a part of at least one sub-object ( 6 ) are formed simultaneously.
3 . A method according to claim 1 , characterized in that forming the joining regions ( 7 ) is performed outside or within the SLS or SLM system.
4 . A method according to claim 1 ,
characterized in that the joining regions ( 7 ) are formed such that they join together sub-objects ( 6 ) that are, at least partially, arranged or to be arranged next to each other and/or on top of each other.
5 . A method according to claim 1 ,
characterized in that the joining regions ( 7 ) are designed geometrically different depending on the position of the sub-objects ( 6 ) to be joined using these joining regions related to the three-dimensional object ( 1 ) to be produced.
6 . A method according to claim 1 ,
characterized in that at first at least a part of the sub-objects ( 6 ) is joined using joining regions ( 7 ) of a first, especially point-type, geometric design, in order to convert the sub-objects ( 6 ) joined in this manner into a manageable state, and successively joining regions ( 7 ) of a second, especially linear, geometric design are formed and/or joining regions ( 7 ) of the first geometric design already formed are successively completed by forming, especially linear, joining regions ( 7 ) of the second geometric design.
7 . A method according to claim 1 ,
characterized in that at least a part of the joining regions ( 7 ) is at least partially formed elastically such that deformation-related mechanical stresses of the sub-objects ( 6 ) and/or of the object ( 1 ) are reduced.
8 . A method according to claim 1 ,
characterized in that sub-objects ( 6 ) arranged next to each other and/or on top of each other are joined such that a slot-type gap space ( 8 ) is formed between them.
9 . A method according to claim 1 ,
characterized in that forming appropriate joining regions ( 7 ) is performed by solidification of powder-type construction material and/or by melting on already solidified sub-object portions of already produced sub-objects ( 6 ).
10 . A method according to claim 1 ,
characterized in that appropriate sub-objects ( 6 ) to be joined are joined together by forming appropriate joining regions ( 7 ) by substance bonding.
11 . A method according to claim 10 , characterized in that the appropriate sub-objects ( 6 ) to be joined are welded together.
12 . A method according to claim 1 ,
characterized in that forming the support structure ( 2 ) and/or forming the sub-objects ( 6 ) is interrupted temporarily, to perform at least one measure affecting the properties of the support structure ( 2 ) formed by then and/or the properties of the sub-objects ( 6 ) formed by then, for example, heat treatment.
13 . A method according to claim 1 ,
characterized in that at least two of the appropriate sub-objects ( 6 ) are formed with equal or different geometric design.
14 . A method according to claim 1 ,
characterized in that at least one sub-object ( 6 ) is formed with at least one reception room limiting the, especially closed, reception volume for reception of at least one third item.
15 . A three-dimensional object ( 1 ) produced according to a method of claim 1 .