METHOD AND DEVICE FOR 3D PRINTING

Abstract

The invention relates to a method for 3D printing of food, pharmaceutical products, cosmetics, and plastic or ceramic composite products, and to an apparatus for executing a method for 3D printing of these articles and products manufactured according to the method, and a control or regulating system for the apparatus for executing the method, and the use of the product bodies manufactured according to the method.

Claims

1-25. (canceled)

26. A method for simultaneous 3D printing of large product parts by means of synchronized printing processes, such as food, pharmaceutical products, cosmetics, and composite products made of, plastic, ceramic, or metal and natural substances, as non-symmetrical product bodies (16b, 17, 18) and/or non-symmetrically arranged compounds at different product size scales such as macro (in the centimeter range), meso (in the millimeter range), or micro (in the micrometer range), from flowable compounds, wherein the respective product bodies (16b, 17, 18) or product body parts that have been generated, are printed in each case with an average product size of 5 cm in terms of the width, height and length, with a precision of 1,000 micrometers, or <600 micrometers, or <100 micrometers, and the printed product body or printed product body parts are produced in a time interval of <60 seconds or <10 seconds, in each case with an average size of 5 cm in terms of the width, height, and length, a mass of >10 g and a density of 0.1 to 1.5 g/cm3.

27. The method according to claim 26, characterized in that the generated product bodies (16b, 17, 18) are produced with a shape retention (FH) of >95%, wherein this is obtained as a standard for a deviation in the product body dimensions or product body part dimensions and/or the cross section dimensions of the printed product body (16b, 17, 18) or product body part from a target value of <5%.

28. The method according to claim 26, characterized in that extrusion and/or jet printing methods are used for the production, wherein the compounds that are discharged are bonded to previously discharged, hardened and/or partially hardened compounds/compound portions by sintering, gluing, or welding.

29. The method according to claim 28, characterized in that the extent of the adhesion, sintering or welding is controlled or regulated by the compound-specific processing parameters, e.g. temperature and/or filament contact pressure, as well as the material-specific parameters for flow behavior, e.g. more fluid or more solid—more crystalline or more amorphic, or temperature-dependent solidifying, or ion type/ion concentration dependent more gel-binding—phase fractions in the compounds.

30. The method according to claim 26, characterized in that for each of the product bodies/product body parts (16b, 17, 18) that are to be printed, a printer (11a, 11b, 11c) is used that has been adjusted to the respective product size scale, composed of a print head (1a, 1b, 1c) with an appropriate print head characteristic, dosing unit (3a, 3b, 3c), temperature control unit (4a, 4b, 4c) and a robotic apparatus (2a, 2b, 2c), which form a production unit, wherein the printer (11a, 11b, 11c) can be coupled to or replaced by another printer (11a, 11b, 11c) on the robotic apparatus (2a, 2b, 2c) via a bayonet mount, wherein the components of the printer (11a, 11b, 11c) and the robotic apparatus (2a, 2b, 2c) can be controlled or regulated in a programmable manner, coordinated to one another temporally and spatially, and two or more of these production units, functioning partially to entirely simultaneously, print the product bodies (16b, 17, 18) or product body parts of different product size scales at controlled speeds, and place these parts during the printing such that a previously determined spatial arrangement and bonding are obtained.

31. An apparatus for executing the method for simultaneous 3D printing of large product parts by means of synchronized printing processes, such as food, pharmaceutical products, cosmetics, and composite products made of, plastic, ceramic, or metal and natural substances, as non-symmetrical product bodies and/or non-symmetrically arranged compounds according to claim 26, characterized in that for each of the product bodies/product body parts that are to be printed, there is a printer (11a, 11b, 11c) adjusted to the respective, characteristic product size scale, composed of a print head (1a, 1b, 1c) with an appropriate print head characteristic, dosing unit (3a, 3b, 3c), temperature control unit (4a, 4b, 4c) and a robotic apparatus (2a, 2b, 2c), which form a production unit, wherein the printer (11a, 11b, 11c) can be coupled to or replaced by another corresponding printer (11a, 11b, 11c) on the robotic apparatus (2a, 2b, 2c) via a bayonet mount, wherein the components of the printer (11a, 11b, 11c) and the robotic apparatus (2a, 2b, 2c) can be controlled or regulated in a programmable manner, coordinated to one another temporally and spatially, and two or more of these production units, functioning partially to entirely simultaneously, print the product bodies (16b, 17, 18) or product body parts of different product size scales at controlled speeds, and place these parts during the printing such that a previously determined spatial arrangement and bonding are obtained.

32. An apparatus according to claim 31, characterized in that each of printers (11a, 11b, 11c) has a print head (1a, 1b, 1c) with one or more adjustable dosing units (3a, 3b, 3c), each of which is connected to one or more replaceable compound storage/supply units.

33. The apparatus according to claim 31, characterized in that the print heads (1a, 1b, 1c) generate individual droplets (13), sprays (15), or filaments (14) with one or more dosing units (3a, 3b, 3c), each of which is adapted to the rheological properties of the compounds that are to be printed.

34. The apparatus according to claim 31, characterized in that the respective dosing units (3a, 3b, 3c) are adapted to the rheological properties of the compounds that are to be printed and to the dosing kinetics of a dedicated actuator and printing nozzle geometry.

35. The apparatus according to claim 31, characterized in that the print head (1a, 1b, 1c) is adapted to the rheological properties of the compounds in the range in which they are to be printed taking irreversible structure-changing tensions in the compounds into account via the temperature control thereof with a temperature adjustment precision of ±1° C., preferably ±0.5° C., more preferably ±0.1° C.

36. A product printed by the method according to claim 26, characterized in that the product is some type of food, i.e. a chocolate product, sugar confectionery product, pasta, pastry/baked good, spread, cheese, snack composite, plant-based meat equivalent, milk product, fat product, cold cuts/pâté, dessert, or ice cream.

37. The product manufactured by the method according to claim 26, characterized in that the product (16b, 17, 18) is a cosmetic/care product, i.e. a lipstick or soap.

38. The product manufactured by the method according to claim 26, characterized in that the product (16b, 17, 18) is a pharmaceutical product, i.e. a bandage, suppository, prosthesis, corset, artificial joint, support structure, or a surgical aid for setting bones.

39. The product manufactured by the method according to claim 26, characterized in that the product is a composite product comprised of two or more materials contained in the following group: plastics, ceramics, metals and natural materials, forming a supporting element, wooden component, prosthesis, corset, or artificial joint.

40. The product manufactured by the method according to claim 26, characterized in that the product is composed of two or more compounds of the same or different composition, wherein the product bodies (16b, 17, 18) or product body parts (16b, 17, 18) produced from the compounds are of different sizes, and these product body parts are permanently secured or moveably connected to one another.

41. The product manufactured by the method according to claim 26, characterized in that the product functionality is determined with regard to feel, texture, appearance, or smell by the application-specific composition of the compounds used in the printing process with regard to the concentrations of the components that give the product its aroma, flavor, or texture, or by the respective arrangement of these compounds in the product body (16b, 17, 18) or product body parts, or by the shape of the product body (16b, 17, 18) or the product body parts, or by the details of the surface structure of the product body (16b, 17, 18) or product body parts in question.

42. The product manufactured by the method according to claim 26, characterized in that the formulas for one or more compounds are obtained from a nutritional perspective.

43. The product manufactured by the method according to claim 26, characterized in that the formulation of the compounds with regard to sugar and/or salt and/or fat content, and/or the content of other additives, and/or functionalizing components, is coordinated to the arrangement in the product body (16b, 17, 18) or product body parts in order to reduce the amounts of these components in the overall product without resulting in functional or sensory losses.

44. The product manufactured by the method according to claim 26, characterized in that an application-specific composition or the respective arrangement of the compounds in the product body (16b, 17, 18), or the dimensions of the product body (16b, 17, 18) or product body parts, or the shape of the product, or the detailed surface structure result in an intensity curve of the perception of sugar, salt, fat, or aroma that is a function of how long it takes to consume the product.

45. The product manufactured by the method according to claim 26, characterized in that the composition of the compounds forming the product body (16b, 17, 18) results in a reduction of the overall content of functionalizing components by means of a physiologically determined arrangement of the functionalized compounds, or the dimensions of the product body parts generated by these compounds, or the shape thereof, or the compound properties that affect the release of the components that determine the functions, without impairing the intended physiological effects thereof.

46. A control or regulating system for an apparatus according to claim 31 for simultaneous printing of relatively large product parts by means of synchronized printing processes in the flexible 3D printing of non-symmetrical product bodies (16b, 17, 18) or product body parts, or non-symmetrically arranged compounds in these product bodies (16b, 17, 18) from two product bodies or product body parts printed partially to fully simultaneously in different product size scales, in the centimeter range, millimeter range, or micrometer range, by printers (11a, 11b, 11c) assigned to these product size scales, in the centimeter range, millimeter range, or micrometer range, with one or more multi-axle robots, with one or more computers, which control or regulate the printers (11a, 11b, 11c) with regard to the product bodies (16b, 17, 18) or product body parts that are to be printed according to product-specific data stored in a memory in the computer in question.

47. The control or regulating system for an apparatus according to claim 46, characterized in that the printers (11a, 11b, 11c) and the coupled robotic apparatuses can be controlled or regulated according to the data stored in the memory of the computer (10a, 10b, 10c) in question with regard to their movement sequences and printing speeds, taking the rheology of the product bodies (16b, 17, 18) or product body parts into account, wherein the adjustments of the printing compound temperatures via the respective temperature control units is used as an additional correcting variable for the fine tuning of the rheological compound properties.

48. The control or regulating system according to claim 46, characterized in that the computers (10a, 10b, 10c) and the dedicated printers (11a, 11b, 11c) are incorporated in an independent daisy chain in a superordinate control or regulating algorithm.

49. The control or regulating system according to claim 46, characterized in that the central control or regulating unit (10d) controls or regulates conveyors that run continuously or intermittently to remove printed product bodies.

50. Use of a product body (16b, 17, 18) printed according to claim 26 as a chocolate product, sugar confectionery product, pasta, pastry/baked good, spread, cheese, snack composite, plant-based meat equivalent, milk product, fat product, cold cuts/pâté, dessert, or ice cream.

Description

Achieving the Object Relating to the Use

[0086] The object is achieved according to claim 25 with a chocolate product, sugar confectionery product, pasta, pastry/baked good, spread, cheese, snack composite, plant-based meat equivalent, milk product, fat product, cold cuts/pâté, dessert, or ice cream, etc.

[0087] The substantial advantages are in the customized functionalization capabilities of such products with regard to (a) the sensory aroma, flavor, and textural properties, and (b) the functionalizing substance components that support the nutritional aspects and the health aspects and also result in savings potentials because of the possible physiologically preferential placement according to the invention, and the local concentration of these substance components coordinated to sensitivity thresholds.

[0088] The invention is illustrated, in part schematically, and in part as an exemplary embodiment, in the drawings. Therein:

[0089] FIG. 1 shows a production facility in the form of a layout diagram;

[0090] FIG. 2 shows a model of a synchronized multi-scaled 3D printed chocolate confectionery snack product; and

[0091] FIG. 3 shows, schematically, a (partially) synchronized multi-scaled 3D printed product body with macro, meso, and microscale product parts.

[0092] In FIG. 1, the components in which an “a” is added to the reference numeral belong to a printer 11a, which prints product parts on a macroscopic size scale. Accordingly, those with a “b” are components belonging to a printer 11b that prints product parts on a mesoscopic size scale, while those with a “c” are components belonging to a printer 11c that prints product parts on a microscopic size scale.

[0093] Print heads have the reference symbols 1a, 1b, and 1c, each of which are dedicated to multi-axle robot 2a, 2b, and 2c, respectively, the motors and power lines for which are not shown in detail for purposes of simplification. Each print head 1a, 1b, and 1c has a dedicated dosing unit 3a, 3b, and 3c, as well as a temperature control unit 4a, 4b, and 4c. The supply lines 6a, 6b, 6c are each connected to a material tank 5a, 5b, and 5c for conducting materials, via which the individual material flows can be fed to the respective print heads 1a, 1b, and 1c in a controlled or regulated manner, specific to a formula.

[0094] The reference symbols 10a, 10b, and 10c each indicate computers dedicated to the respective printers 11a, 11b, and 11c. The computers 10a, 10b, and 10c each have dedicated memories, not shown in detail, in which data for the respective formulas of the compounds that are to be printed and the product bodies that are to be printed, as well as the tolerance data and algorithms (including AI/machine learning based) for the temporal sequencing, are stored. The computers 10a, 10b, and 10c each have a control or regulating unit 7a, 7b, 7c for dosing the print materials supplied to the print head 1a, 1b, and 1c, respectively, and its dosing units 3a, 3b, and 3c.

[0095] Each control or regulating unit 8a, 8b, and 8c controls or regulates its respective temperature control unit 4a, 4b, and 4c.

[0096] Furthermore, 9a, 9b, and 9c indicate control or regulating units for controlling or regulating the movement of the multi-axle robots 2a, 2b, and 2c and their print heads 1a, 1b and 1c, and potentially other parts thereof.

[0097] The respective control and regulating units 7a, 7b, and 7c are each connected for signal transfer to their dedicated dosing units 3a, 3b, and 3c via a respective line 20a, 20b or 20c, while the control and regulating units 8a, 8b, and 8c for temperature control are each connected to the temperature control units 4a, 4b, and 4c via a respective line 21a, 21b, and 21c.

[0098] The control and regulating units 9a, 9b, and 9c are each connected to their respective robots 2a, 2b, and 2c via a line 22a, 22b, 22c for data transfer, to control the movements of the robots 2a, 2b, and 2c, respectively.

[0099] In the embodiment shown here, the relevant print head 1a, 1b or 1c can spray a spray jet 15 onto a substrate or a suitable base 19, or discharge a filament 14 onto the substrate or base 19, or print the print material in the form of droplets onto the substrate or base 19, depending on the design. Instead of a substrate 19, a conveyor 23 can be placed here, which transports the product bodies or product body parts printed by the printer 11a, 11b, or 11c with the print head 1a, 1b, or 1c, respectively, into the printing zone of another printer, e.g. 11b, 11c, which has another robot, e.g. 2b or 2c, which then prints the product body part printed by the printer 11a with other product body parts, and bonds them thereto, to form a completed product body. In the embodiment preferred according to the invention, the working areas of the printers 11a, 11b and 11c overlap spatially in order to obtain the partially to fully synchronized printing processes in the various size scales. The conveyor 23 supplements the movement sequences of the robots 2a, 2b and 2c in this case in a program-controlled manner, to minimize or optimize the travel paths.

[0100] FIG. 1 also shows a central control or regulating unit 10d for a production facility 12 composed of numerous printers 11a, 11b, 11c, in which formula-specific data and algorithms (including AI/machine learning based algorithms) are stored in a central memory for regulating the temporal sequence for the product body parts or product bodies that are to be printed in conjunction with the various printers 11a, 11b, 11c, in which the printers 11a, 11b, 11c are composed in turn of the respective print heads 1a, 1b, and 1c, the dosing units 3a, 3b, and 3c, the temperature control units 4a, 4b and 4c, and the respective dedicated robots 2a, 2b, and 2c.

[0101] The central control and regulating unit 10d is connected for data transfer to the three computers 10a, 10b, and 10c for the printers 11a, 11b, and 11c via lines 24, 25, 26, as shown by way of example in FIG. 1. This connection can also be wireless.

[0102] The computers 10a, 10b and 10c each have a dedicated multi-axle robot 2a, 2b, and 2c.

[0103] The printer 11a has a dedicated robot 2a with a print head 1a, a dosing unit 3a, and a temperature control unit 4a, with which relatively large printed product bodies 16 are generated, while the printer 11b has a dedicated robot 2b with a print head 1b, dosing unit 3b and temperature control unit 4b. The printer 11b prints product bodies 17 of medium size. The printer 11c with its robot 2c, print head 1c, dosing unit 3c and temperature control unit 4c prints small product bodies 18, which are placed on a product body 17, for example, which was printed in turn on a larger product body 16, printed by the print head 1a.

[0104] The conveyor 23 is driven in the direction X or Y, e.g. by an electric motor that can be regulated or controlled. The conveyor can be driven continuously or intermittently, controlled by the central control or regulating unit 10d in coordination with the robots 2a, 2b, or 2c, which have multiple axles, e.g. six axles.

[0105] Numerous production facilities can be arranged in parallel or successively and controlled or regulated by the central control or regulating unit 10d, such that different product bodies or product body parts can be printed simultaneously or successively, in parallel and/or in a series.

[0106] A production facility can generate a macroscopic 3D macro housing profile for a chocolate bar with different 3D cavities, insert a mesoscale filler body in parts of these cavities, and print microscale aroma capsule droplets in other cavities or on parts of the product surface (see FIG. 2 by way of example) in the field of chocolate confectionery technology with the associated printers 11a, 11b, and 11c (as shown by way of example in FIG. 1), for the partial to fully simultaneous printing of product parts on a macro (cm), meso (mm) and micro size scale 100 micrometers).

[0107] A relatively complicated product body structure, with the reference symbol 27, is shown schematically in FIG. 2, which is somewhat reminiscent of broccoli or cauliflower and is composed of two macro-product body parts 16a, 16b, eight meso-product body parts 17, and numerous micro-product body parts 18, the materials of which are integrally bonded to one another to form the overall product body 27 in the manner shown therein.

[0108] The various macro, meso, and microscale printed body parts are provided with the reference symbols 16a (macro), 17 (meso), and 18 (micro) in FIG. 3.

[0109] Aside from functionalized food and cosmetic products, body parts for automobiles, e.g. rocker panels, bumpers, struts with reinforcement fins and shock absorbing subsections can be printed in the manner according to the invention, in particular from composite construction materials. These product bodies are joined to the body with adhesive such that it is possible to produce weight-saving, multi-functional lightweight structures which satisfy the current endeavors to reduce fuel consumption and protect the environment.

LIST OF REFERENCE SYMBOLS

[0110] 1 print head [0111] 2 robot [0112] 2a dosing unit [0113] 3 dosing unit [0114] 4 dosing unit [0115] 5 temperature control unit [0116] 6 computer [0117] 7 control or regulating unit for the a dosing unit [0118] 8 control or regulating unit for the a dosing unit [0119] 9 control or regulating unit for the a dosing unit [0120] 10 line [0121] 11 line [0122] 12 line [0123] 13 line [0124] 14 line [0125] 15 line [0126] 16 material tank [0127] 17 material tank [0128] 18 material tank [0129] 19 spray jet [0130] 19a substrate [0131] 20 filament [0132] 21 droplet [0133] 22 control or regulating unit [0134] 23 line [0135] 24 line [0136] 25 line [0137] 26 control or regulating unit [0138] 27 control or regulating unit [0139] 28 control or regulating unit [0140] 29 robot [0141] 30 robot [0142] 31 robot [0143] 32 print heat [0144] 33 product body [0145] 33a print head [0146] 34 product body [0147] 35 print head [0148] 36 conveyor [0149] 37 product body [0150] 38 product body part [0151] X-Y direction of conveyance

LIST OF CITED DOCUMENTS

[0152] U.S. Pat. No. 6,280,784 B1 [0153] WO 2014/110590 A1 [0154] WO 2017/215641 A1 [0155] WO 2019/199505 A1 [0156] WO 2020/152689 A1