Abstract
A method for additively manufacturing a textile sheet product and a three-dimensionally printed textile sheet product (1) are disclosed. The method includes the steps of creating a three-dimensional model of the pre-product and additively manufacturing the pre-product according to the three-dimensional model of the pre-product. In additive manufacturing, a production material is applied layer by layer in this case. At at least one predetermined crossover position of at least two fibrous structures (2a, 2b) and a separation layer material is applied which can be removed from the pre-product and/or inactivated.
Claims
1. A method for additively manufacturing a textile sheet product having a plurality of fibrous structures, comprising the steps of: creating a three-dimensional model of a pre-product; additive manufacturing of the pre-product according to the three-dimensional model of the pre-product; applying, during additive manufacturing, a production material layer by layer and a separation layer material at at least one predetermined crossover position of at least two fibrous structures, wherein the separation layer material is removable and/or inactivatable from the pre-product.
2. The method of claim 1, wherein the separation layer material is removed from the pre-product in a subsequent step.
3. The method of claim 1, wherein the separation layer material is deposited between two layers of the production material during additive manufacturing.
4. The method of claim 1, wherein the separation layer material comprises a soluble polymer, preferably a photopolymer, a powder or a gel.
5. The method according to claim 1, wherein the separation layer material is removed from the pre-product by washing with an alkaline solution.
6. The method according to claim 1, wherein the textile sheet product comprises a woven fabric, knitted fabric and/or warp knitted fabric.
7. The method according to claim 1 further comprising the following steps during the step of creating the three-dimensional model of the pre-product: defining connection points of the pre-product, wherein the connection points remain free of separation layer material during subsequent additive manufacturing; and/or defining crossover positions, wherein the crossover positions are coated with separation layer material during the subsequent additive manufacturing.
8. The method according to claim 1, wherein the separation layer material is applied in a thickness of 0.01 to 0.3 mm, preferably 0.05 to 1.5 mm.
9. The method according to claim 1, wherein the additive manufacturing is performed with a layer thickness of 0.01 to 0.1 mm, preferably 0.01 to 0.04 mm.
10. The method of claim 1, wherein the additive manufacturing is performed by selective laser sintering (SLS), laser-based stereolithography (SLA), polyjet, or fusion deposition (FDM).
11. A three-dimensionally printed textile sheet product (1), the sheet product (1) containing fibrous structures (2a, 2b) which are connected to one another by crossovers (3), and wherein the fibrous structures (2a, 2b) are arranged such that they can move relative to one another.
12. The three-dimensionally printed textile sheet product (1) according to claim 11, wherein the crossovers (3) comprise knots, interlaces, weavings, and/or loops.
13. The three-dimensionally printed textile sheet product (1) according to claim 11, wherein the individual fibrous structures (2a, 2b) have in themselves a variable thickness, variable diameter, variable height and/or width and/or a variable cross-sectional shape.
14. The three-dimensionally printed textile sheet product (1) according to claim 11, wherein the fibrous structures (2a, 2b) are not material bonded to one another at the crossovers (3).
15. The three-dimensionally printed textile sheet product (1) according to claim 11, wherein the sheet product (1) comprises a fabric having a first and a second fiber system, wherein the fibrous structures of the first and the second fiber system cross each other transversely.
16. The three-dimensionally printed textile sheet product (1) of claim 15, wherein the fabric comprises a third fiber system, wherein the fibrous structures of the third fiber system intersect with the fibrous structures of the first and second fiber systems.
17. A garment comprising a three-dimensionally printed textile sheet product (1) according to claim 11.
18. Use of a three-dimensionally printed textile sheet product according to claim 11 for the manufacture of a garment.
Description
BRIEF DESCRIPTION OF SEVERAL VIEWS OF THE DRAWINGS
[0054] Aspects of the invention are explained in more detail with reference to the embodiments shown in the following figures and the accompanying description.
[0055] FIG. 1 shows a section of a three-dimensionally printed textile sheet product according to one embodiment of the invention;
[0056] FIG. 2 shows a schematic view of a three-dimensionally printed textile sheet product according to a further embodiment of the invention;
[0057] FIG. 3 shows a schematic view of a three-dimensionally printed textile sheet product according to a further embodiment of the invention;
[0058] FIG. 4 shows a schematic view of a three-dimensionally printed textile sheet product according to a further embodiment of the invention;
[0059] FIG. 5 shows a section of a three-dimensionally printed textile sheet product according to a further embodiment of the invention;
[0060] FIG. 6 shows a detail enlargement of a three-dimensionally printed textile sheet product according to a further embodiment of the invention;
[0061] FIG. 7a schematically shows an additively manufactured pre-product in cross-section according to one embodiment of the invention; and
[0062] FIG. 7b shows a schematic cross-section of the three-dimensionally printed textile sheet product of FIG. 1.
DETAILED DESCRIPTION OF THE INVENTION
[0063] FIG. 1 shows a three-dimensionally printed textile sheet product 1 according to the invention, which was manufactured additively according to a method according to the invention. The textile sheet product 1 extends in the horizontal plane of the x and y direction, as shown by the coordinate system. Additive manufacturing is performed layer by layer in the vertical direction, i.e., along the z-axis in the coordinate system shown. The three-dimensionally printed textile sheet product 1 contains fibrous structures 2a and 2b, which are interconnected by crossovers 3. In the embodiment shown, the crossovers are formed as interweavings. The fibrous structures 2a and 2b have a substantially rectangular cross-section. As shown in the figures below, the fibrous structures are arranged to be movable relative to each other.
[0064] FIG. 2 shows a schematic representation of a three-dimensionally printed textile sheet product 1 according to an embodiment of the invention. The textile sheet product 1 contains fibrous structures which are interconnected by weaving. The woven fabric thereby comprises a first fiber system which extends in the y-direction. As shown, the first fiber system comprises a plurality of parallel fiber-like structures extending in the y-direction. The woven fabric further comprises a second fiber system extending in the x-direction of the coordinate system shown. The second fiber system thereby comprises a plurality of fibrous structures being parallel to each other and extending in the x-direction. As indicated by the arrows, such a three-dimensionally printed textile sheet product 1 has the advantage that it is not flexible in either the x or y direction, but is flexible in each case at an angle of 45° to the x or y direction. Thus, the textile fabric 1 cannot be stretched in the direction of the crossed-out arrows, but it can be stretched in the direction of the four diagonal arrows shown. This can be advantageous, for example, in the case of garments which are stretched in certain directions but are to be as rigid as possible in other directions in order, for example, to support and thus facilitate and/or guide a movement of the wearer. If this is desired, during the manufacture of a three-dimensional surface product, instead of some crossover positions, connection points can be determined at which no separation layer material is applied. In the subsequent additive manufacturing process, these connection points become materially bonded joints of the respective intersecting fibrous structures. Thus, the achieved flexibility can be interrupted at predetermined areas. For example, in this or further embodiments described herein, a flexibility separation line can be provided, which is predetermined by corresponding arrangement of connection points in the three-dimensional model during manufacture.
[0065] FIG. 3 shows a schematic representation of a three-dimensionally printed textile sheet product 1 according to a further embodiment of the invention. The textile sheet product 1 also comprises a woven fabric with a first and a second fiber system (see FIG. 2). In addition, the three-dimensionally printed textile sheet product 1 shown has a further, third fiber system. The third fiber system comprises a plurality of fibrous structures arranged parallel to each other, which are each arranged at an angle of substantially 45° to the fiber-shaped structures of the first and second fiber systems. The fiber-shaped structures of the three fiber systems are thereby connected to each other in each case by crossovers. As indicated by the shown crossed-out arrows, the third fiber system has the consequence that the textile sheet product 1 is neither flexible in x direction, nor in y direction, and additionally not flexible in a further third direction arranged at substantially 45° to the x and y direction. However, the textile sheet product 1 is arranged to be flexible, respectively stretchable and/or extensible, in one direction, namely as represented by the two diagonal arrows. In the present coordinate system, this direction is described by a straight line of the function y=−x.
[0066] FIG. 4 schematically shows a further embodiment of a three-dimensionally printed textile sheet product 1 according to the invention. The textile sheet product 1 comprises a woven fabric with a first, second and third fiber system, as already shown in FIG. 3. In addition, the textile sheet product further comprises a fourth fiber system with mutually parallel fibrous structures arranged 90° to the third fiber system and 45° to the first and second fiber systems. Compared with the textile fabric of FIG. 3, such a woven fabric is essentially inflexible in all directions, since the fourth fiber system prevents stretching and/or elongation in the direction y=−x. Such an area product can also be achieved by superimposing two three-dimensionally printed textile area products rotated by 45° relative to each other, as shown in FIG. 2.
[0067] FIG. 5 shows a three-dimensionally printed textile sheet product 1 according to the invention, which can be manufactured additively by a method according to the invention. The textile sheet product 1 extends in the horizontal plane of the x- and y-directions, as shown by the coordinate system. Additive manufacturing is performed layer by layer in the vertical direction, i.e., along the z-axis in the coordinate system shown. The three-dimensionally printed textile sheet product 1 contains fibrous structures 2a and 2b, which are interconnected by crossovers 3. In the embodiment shown, the crossovers are formed as interlaces, so that the three-dimensionally printed textile sheet product 1 comprises a knitted fabric, or a warp-knitted fabric.
[0068] FIG. 6 shows a photograph of a knitted fabric after removal of the separation layer material. It can be seen that the fibrous structures are not bonded to each other, particularly at the crossovers.
[0069] FIG. 7a shows a cross-section of an additively manufactured pre-product 1′ comprising fibrous structures 2a and 2b, wherein a separation layer material 4 is arranged between the structures at the three crossover positions of the fibrous structures 2a and 2b shown. The separation layer material 4 thereby prevents the fibrous structures 2a and 2b of the pre-product 1′ from contacting each other at the crossover positions.
[0070] In FIG. 7b, the three-dimensionally printed textile sheet product 1 of FIG. 1 is shown in cross-section along the y-z plane. The textile sheet product can be produced by removing the separation layer material 4 shown in FIG. 7a from the pre-product 1′. The fibrous structures 2a and 2b of the three-dimensionally printed textile sheet product 1 are arranged so as to be movable relative to one another and are not bonded to one another, at least at the crossovers.
