Process for Producing an Object Having at Least Two Moving Parts

Abstract

A process for producing an object having at least two component parts ( 3, 4 ) which can move relative to one another is proposed. This involves preparing geometrical data of the entire object for a rapid prototyping process, with a predetermined minimum spacing between the moving parts being taken into consideration. According to the predetermined geometrical data, a first material as support material and a second material as material for the component parts are applied in layers, the support material filling gaps including those constituting the minimum spacing between the respective material for the component parts. Following completion of the layered construction, the support material is removed.

1 . A method for manufacturing an object with at least two components which are movable relative to one another, wherein geometry data is set up from the whole object for a rapid prototyping method, wherein a predefined minimal distance between the moving components is taken into account, wherein a first material as a support material and a second material as a component material are deposited in a layered manner according to the predefined geometry data, wherein the support material fills out gaps including those with the minimal distance between the respective component material, and wherein the support material is removed after the completion of the layered construction. 
   
   
       2 . A method according to  claim 1 , wherein the minimal distance between the components is determined such that while taking account of the characteristics of the support material, this may be led away between the components, on its removal out of the respective region. 
   
   
       3 . A method according to  claim 1  wherein at least one molecular layer of the support material is provided as a minimal distance, depending in the characteristics of the support material 
   
   
       4 . A method according to  claim 1  wherein a minimal distance between the moving parts of larger than 0.1 mm is provided. 
   
   
       5 . A method according to  claim 1  wherein the support material is selected such that it may be separated on account of at least one of its physical and chemical properties which are different with respect to the component material. 
   
   
       6 . A method according to  claim 1  wherein the support material has a lower melting point than the component material, and wherein the support material is led away by way of increasing the temperature beyond its melting point. 
   
   
       7 . A method according to  claim 1  wherein the support material is wax which has a melting point in the range of 60 to 70°. 
   
   
       8 . A method according to  claim 1  wherein the component material and the support material are deposited by way of one of printing, dispensing, and screen printing. 
   
   
       9 . A method according to  claim 1  wherein the component material and support material are deposited in a layered manner onto a platform by way of at least one application apparatus which is controlled depending on the geometry data, and are subsequently cured. 
   
   
       10 . A method according to  claim 1  wherein additional geometric measures are made at at least one of on the components, in the components, and between the components, which simplify at least one of a release and flowing away of the support material. 
   
   
       11 . A method according to  claim 10 , wherein the additional geometric measures are openings, channels or grooves. 
   
   
       12 . A method according to  claim 11 , wherein the opening is dimensioned such that it has a diameter of at least 1 mm. 
   
   
       13 . A method according to  claim 1  wherein a structure enclosing a cavity is selected as one of the at least two movable components, and a component accommodated in the cavity in a movable manner is selected as the other component, wherein at least one opening is provided in the outer structure for the flowing away of the support material. 
   
   
       14 . A method according to  claim 1  for manufacturing a gear with at least two cogs. 
   
   
       15 . A gear manufactured according to  claim 1  wherein the components are cogs and shafts.