KR102155186B1 - Metal 3D Printing Manufacturing Method and Apparatus Using Junction Method Between Different Materials - Google Patents

Abstract

The present invention provides a 3D printing method, comprising: checking whether a 3D printing command is provided from the outside; And a powder material supply cartridge that receives the metal powder when the 3D printing command is provided, a laser beam light source that generates and irradiates a laser beam, a gas/pressure control device that supplies gas, and a metal 3D printing base plate made of the first material. The motion control bed on which the lower layer of is mounted, the metal powder from the powder material supply cartridge, the laser beam from the laser beam light source, and the gas/gas from the pressure control device are delivered to the metal 3D printing base plate. A method of manufacturing a 3D printing base plate comprising the step of forming an upper layer of the metal 3D printing base plate by melting a metal powder made of a second material by controlling the system in a lower layer of the metal 3D printing base plate 3D printing base plate is provided.

Description

Bonding structure of heterogeneous materials of 3D printing device or base plate of bonded structure, and its manufacturing method {Metal 3D Printing Manufacturing Method and Apparatus Using Junction Method Between Different Materials}

The present invention relates to a 3D printing device, and more particularly, a base in the form of a light-weight structure or a combined structure with a combination of heterogeneous materials that can effectively support and heat dissipation of a 3D printing model while responding to repeated polishing operations in a 3D printing device. It relates to a plate and a method of manufacturing the same.

In general, 3D printing devices were developed to make prototypes before launching products. The 3D printing device has the advantage of being able to produce a prototype that is exactly the same as a real product, and is able to find out the problems of the real product while saving cost and time.

With the development of such 3D printing device technology, more sophisticated products can be produced and applied to various products. These 3D printing devices manufacture products in various ways. Various methods such as photopolymerization, powder bed fusion (PBF), material jetting, and material extrusion (ME) are used as product production methods for these 3D printing devices. have.

For example, in the powder bed fusion (PBF) process, various powder materials such as metals, ceramics, and polymers are coated in a thin layer of powder and selectively irradiated with thermal energy to cause the powder to be sintered or melted. It is a method of manufacturing a desired product while re-stacking a new layer, and is attracting much attention in the expensive equipment market for its advantage that the precision of the product is excellent and various materials can be used.

On the other hand, as another 3D printing method, it is a Directed Energy Deposition (DED) type, in which finely pulverized metal powder is thinly sprayed together with thermal energy onto a base plate (a space to be shaped) and then melted and laminated. Unlike the method, it is possible to bond dissimilar metal materials such as laser welding and welding, so it has the advantage of being able to repair and remodel metal forms.

During the 3D printing manufacturing process, polymers fail to withstand their own loads during material lamination, and collapse occurs, and in metals, stress causes the lamination area to float upwards, resulting in heat dissipation and support as a supporter shape. The base plate is essentially used for fixing the parts and supporters that are manufactured while molding.

At this time, the commonly used 3D printing base plate has a size of around 250x250x 20mm (XYZ), and recently, a base plate of 800φ or more has been released for the manufacture of large parts, and it is formed of a single material that is the same as the part material to be manufactured. And it is fixed to the inner surface of the powder receiving portion, there is a locking bolt for this.

However, as the 3D printing base plate is formed of the same single material as the part manufacturing material, the cost is very high when using an expensive metal material, and there is a limit to reuse due to repeated polishing operations.

In addition, there is a problem in that a special device must be used due to a very high weight when moving to perform post processing upon completion of the product.

Accordingly, there is a need for fabrication of a 3D printing base plate having a light weight structure that can effectively support and heat dissipate a 3D model while responding to repeated polishing operations, which is cheaper and has a light weight structure.

This can be applied to all domestic and foreign metal 3D printer related industries as a breakthrough technology improvement plan in an industrial situation where it is difficult to improve quality and production speed through the development of new manufacturing methods.

Korean Patent Publication No. 10-2018-0006822 Korean Patent Publication No. 10-2018-0103334 Korean Patent Publication No. 10-2016-0121771 Korean Patent Publication No. 10-2018-0002305

The present invention was conceived to solve the above-described problems, in the form of a heterogeneous material bonding structure or a bonding structure capable of effectively performing support and heat dissipation of a 3D printing model while being able to cope with repetitive polishing operations in a 3D printing apparatus. It is an object of the present invention to provide a base plate and a method of manufacturing the same.

In order to achieve the above object, the present invention provides a 3D printing method, comprising: checking whether a 3D printing command is provided from the outside; And a powder material supply cartridge that receives the metal powder when the 3D printing command is provided, a laser beam light source that generates and irradiates a laser beam, a gas/pressure control device that supplies gas, and a metal 3D printing base plate made of the first material. The motion control bed on which the lower layer of is mounted, the metal powder from the powder material supply cartridge, the laser beam from the laser beam light source, and the gas/gas from the pressure control device are delivered to the metal 3D printing base plate. A method of manufacturing a 3D printing base plate comprising the step of forming an upper layer of the metal 3D printing base plate by melting a metal powder made of a second material by controlling the system in a lower layer of the metal 3D printing base plate 3D printing base plate is provided.

The present invention has the advantage of being able to easily manufacture a metal 3D printing base plate that can effectively support and heat dissipation of a 3D model while responding to repeated polishing operations in a 3D printing apparatus.

In addition, the present invention can reduce the cost of a base plate made of the same 3D printing material, which is formed at a very high price by laminating and bonding different materials on the top of the base plate used in the PBF method, as well as preventing heat shrinkage and expansion. It is possible to control the deformation characteristics by using different materials, and maximize the effect of dissipating heat generated during metal 3D printing.

In addition, another object of the present invention is to melt (Melting) metal powder pulverized to a very small size of about 60 to 80 microns on a base plate together with heat energy in a 3D printing device of a Directed Energy Deposition (DED) type. There is an advantage in that the base plate can be repaired, reused, or remodeled by laminating to produce a base plate having a junction structure of different materials.

1 is a structural diagram of a PBF type 3D printing apparatus according to an embodiment of the present invention;
FIG. 2 is a diagram illustrating a metal 3D printing base plate combined with a heterogeneous material in the 3D printing apparatus of FIG. 1.
3 is a structural diagram of a DED type 3D printing apparatus according to another embodiment of the present invention.
FIG. 4 is a diagram illustrating a metal 3D printing base plate bonded to different materials in the 3D printing apparatus of FIG. 3.
5 is a flowchart of a method of manufacturing a metal 3D printing base plate bonded to a different material of FIGS. 3 and 4.

Hereinafter, a 3D printing apparatus and a 3D printing method using a metal 3D printing base plate of a heterogeneous material bonding structure or bonding structure according to a preferred embodiment of the present invention will be described in detail with reference to the drawings.

1 is a schematic diagram of the structure of a PBF type 3D printing apparatus 100 according to a first embodiment of the present invention.

Referring to FIG. 1, the PBF type 3D printing apparatus 100 according to the present invention includes a laser 101, a beam focusing optical unit 102, a galvanometer and an F-theta assembly 104, and a morten It is composed of a unit 108, a wiper and powder receiving unit 110, a 3D printing base plate 112, and a build platform 120 supporting the 3D printing base plate.

At this time, the 3D printing apparatus 100 irradiates a laser beam of 200W output generated by the laser 101 to the metal powder 114 accommodated in the wiper and the powder receiving unit 110 to melt the metal powder 114 A 3D model 116 is formed.

In addition, the beam focusing optical unit 102, the galvanometer, and the F-theta assembly 104 concentrate the laser beam irradiated through the laser 100 and then change the irradiation angle corresponding to the 3D model 116 Irradiation with powder 114.

In addition, a 3D printing base plate 112 is located at the lower end of the wiper and powder receiving part 110, and the 3D printing base plate 112 is a 3D model 116 formed by melting the metal powder 114 While supporting the lower surface of the metal powder 114, it performs a function of dissipating heat generated when the metal powder 114 is melted.

FIG. 2 is a view showing a metal 3D printing base plate 112 having a heterogeneous material bonding structure in the 3D printing apparatus of FIG. 1.

As shown in FIG. 2, the metal 3D printing base plate 112 having a heterogeneous material bonding structure has an upper end 112a and a lower end 112b separated from each other. At this time, in the base plate 112, since the top (112a) and the bottom (112b) are separated from each other, in order to combine the separated top (112a) and the bottom (112b), at each edge of the base plate 112 It can be combined in a fixed form using four fixing nuts and upper/lower fixing bolts 113. For example, by setting the length of the fixing bolt to 10 mm, interference with the built-in platform 120 fixing the base plate of the 3D printing apparatus can be minimized.

In addition, since the 3D printing base plate 112 having a heterogeneous material bonding structure is implemented in a heterogeneous material bonding (Bolting) form, the upper end is made of the same metal material as the material to be produced through 3D printing. For example, the PBF type 3D printing device in FIGS. 1 and 2 is widely used for manufacturing customized medical devices, and the upper part of the 3D printing base plate 112 is a biocompatible material, such as titanium alloy, nickel-titanium alloy, and cobalt. Alloy, stainless steel, etc. may be used.

On the other hand, it is preferable to use an aluminum alloy or copper alloy material as a combination type as a metal material that is inexpensive and has a good heat dissipation effect at the lower end.

In addition, the tolerance between the upper part and the lower part can be optimized and applied in the range of 0.1mm to compensate for the difference in the coefficient of thermal expansion of the dissimilar metal material.

In addition, it is preferable to apply a chamfer (radius) of 0.5mm so as not to be disturbed when the lower edge is coupled.

Accordingly, stable 3D printing is possible by applying the same material as the 3D printing structure to be produced in the upper part, and the lower part allows selection of inexpensive materials, and the lower part can be separated when moving in a combined form, thereby significantly reducing the weight. have.

In addition, it is desirable to set the thickness of the metal 3D printing base plate in a 1:1 ratio between the upper and lower parts, which has the best heat dissipation effect, and the cost reduction effect is realized because the ratio of adding expensive materials is small even when the thickness is high. I can.

In this way, the base plate 112 used in the PBF method according to the first embodiment of the present invention can reduce the cost of a base plate made of the same material for 3D printing, which is formed at a very high price by laminating and bonding different materials on the top. Of course, it is possible to control deformation characteristics due to thermal contraction and expansion by using different materials, and to maximize the effect of dissipating heat generated during metal 3D printing.

3 is a schematic diagram showing the structure of a DED type 3D printing device according to a second embodiment of the present invention, and FIGS. 4A and 4B are a metal 3D printing base plate of a heterogeneous material bonding structure in the 3D printing device of FIG. 212) is a perspective view and a side cross-sectional view.

3, the DED type 3D printing device is largely composed of a mechanism device 200 and a control device 300, and implements 3D printing using a metal 3D printing base plate 212 of a heterogeneous material bonding structure. do.

The device 200 is a device for 3D printing of a Directed Energy Deposition (DED) method, and includes an outer housing 230, a powder material supply cartridge 202, a 5-axis drive system 204, and a laser beam light source 206 ), a base material 214, and a gas/pressure control device 216.

The housing 230 surrounds the outside of the 3D printing device and melts gas and powder materials to form a space for manufacturing a 3D printing structure.

The powder material supply cartridge 202 receives the metal powder and then delivers it to the melt pool 210 under the control of the control device 300. The metal powder is formed by pulverizing very small, about 60 to 80 microns (Micron).

The laser beam light source 206 generates the laser beam and irradiates it to the melt pool 210, and the melt pool 210 includes powder from the powder material supply cartridge 202 and the gas/pressure control device 216. Materials and gases 208 are supplied to perform 3D printing.

The motion control bed 220 performs 3D printing while moving the upper surface of the metal 3D printing base plate 212 under the control of the control device 300.

The control device 300 includes a control unit 302, a memory unit 304, and an external device interface unit 306. In this case, the memory unit 304 stores information necessary for the control unit 302 to execute a program. The external device interface unit 306 is responsible for an interface between the external device and the control unit 302.

In this case, a metal 3D printing process through the control device 300 will be described as follows.

In addition, the control unit 302 performs 3D printing according to a preferred embodiment of the present invention by controlling each part of the mechanical device 200 according to a user's request through an external device, and the metal 3D printing base plate 212 Can be produced.

That is, the five-axis drive system 204 is the delivery path of the metal powder from the powder material supply cartridge 202, the laser beam irradiation position of the laser beam light source 206, and the gas delivery from the gas/pressure control device 216 The path is changed according to the control of the control device 300 to change the position of the melt pool 210 to form a metal layer of the same material as the metal material for 3D printing on the upper surface of the metal 3D printing base plate 212.

Accordingly, the metal 3D printing base plate 212, as shown in FIGS. 4A and 4B, may be implemented in a form of bonding of heterogeneous materials composed of an upper layer 212a and a lower layer 212b. do.

For example, the lower layer 212b was originally a single substrate formed of a metal having high thermal conductivity, such as an aluminum alloy or a copper alloy, but a metal powder was melted above the lower layer 212b by the 3D printing apparatus of the present invention. It is bonded to form an upper layer 212a. Accordingly, the metal 3D printing base plate 212 has a structure in which heterogeneous materials are bonded to each other including an upper layer and a lower layer. That is, the lower layer is an aluminum alloy or copper alloy material substrate, and the upper layer is the same metal material substrate as the 3D printing structure of FIG. 3, and the upper layer is stacked on top of the lower layer through 3D printing, and the lower layer and the upper layer are bonded together to form one base. The plate 212 is formed.

Here, in the metal 3D printing base plate 212 having a bonding structure of different materials, the lower layer is formed of an alloy having high thermal conductivity as described above, and a plurality of lower holes 215 are formed at predetermined intervals. In addition, an upper layer is formed thereon.

In this way, the lower hole formed in the lower end 212b of the base plate 212 is effective in heat dissipation and has a lightweight structure, so that the weight of the entire base plate 212 can be reduced. In addition, a plurality of bottom holes are formed at predetermined intervals and can form a multistage structure as a whole, and at this time, the bottom holes form a multistage shape of a parallel structure or a multistage shape of a lattice structure on the entire bottom surface. , It is possible to reduce the weight of the entire base plate 212 by forming a plurality of holes.

In addition, the metal 3D printing base plate 212 having a bonding structure of dissimilar materials has a locking bolt formed at the edge for fixing to the base material 214 of the mechanism device 200, and has a minimum thickness of 20 mm for support. The range is the optimum range, and a radius of 0.5 mm is applied to the edge so that the edge does not interfere with the coupling when it is combined with the base material 214 or the outer housing 230 of the mechanical device 200. .

Accordingly, the metal 3D printing base plate 212 having a junction structure of heterogeneous materials according to the present invention can be applied with the same material as the 3D printing structure to be manufactured at the upper end, enabling stable 3D printing, and maximizing thermal conductivity at the lower end. Because of this, it is possible to solve the heat dissipation problem from the base plate, which is an anxiety factor in metal 3D printing.

Through this, conventionally, since the base plate is a single material, there is a limit to reuse due to the polishing operation in the repeated 3D printing process, but in the present invention, since the structure of bonding of heterogeneous materials, the part lost when polishing the base plate is registered through 3D printing. There is an advantage that it can be used continuously as a layer.

Next, a process of manufacturing a metal 3D printing base plate having a bonding structure of different materials in the metal 3D printing apparatus described in FIGS. 3 and 4 will be described in detail with reference to the flowchart of FIG. 5.

First, the manufacturer prepares the lower layer 212b of the metal 3D printing base place 212 in advance or by separating the upper layer 212a for reuse and seating it on the motion control bed 220 of the 3D printing device. In addition, the lower layer 212b is formed of a metal having high thermal conductivity, such as an aluminum alloy or a copper alloy.

In this way, after placing the lower layer 212b of the metal 3D printing base place 212 on the motion control bed 220 of the 3D printing apparatus, the manufacturer will form the upper layer 212a of the metal 3D printing base place 212. After determining the thickness and size of the metal material and the metal layer, 3D printing information is generated through an external device such as a computer terminal and provided to the control device 300.

When the production of the metal 3D printing base plate is requested through the external device (step 400), the control device 300 is a powder material supply cartridge 202 to spray metal powder to form an upper layer of the metal 3D printing base plate. In addition to controlling the gas/pressure control device 216 to supply gas for melting the metal powder (steps 402 and 404). As a result, a metal layer of a different material (material) is formed on the upper surface of the metal 3D printing base place 212 by supplying a metal powder, a laser beam and a gas for melting it to the melt pool 210 (step 406).

A dissimilar metal layer is formed on the top layer 212a of the metal 3D printing base plate by repeatedly performing the above-described metal powder spraying, laser beam irradiation, and fusion bonding of the metal powder through gas supply to the entire upper surface of the metal 3D printing base plate. To form.

That is, the lower layer is an aluminum alloy or copper alloy material substrate, and the upper layer is the same metal material substrate as the 3D printing structure, and the upper layer is stacked on top of the lower layer through 3D printing, and the lower layer and the upper layer are bonded together to form one The base plate 212 is formed.

Accordingly, the metal 3D printing base plate 212 having a junction structure of heterogeneous materials according to the present invention can be applied with the same material as the 3D printing structure to be manufactured at the upper end, enabling stable 3D printing, and maximizing thermal conductivity at the lower end. Because of this, it is possible to solve the heat dissipation problem from the base plate, which is an anxiety factor in metal 3D printing.

Through such a Directed Energy Deposition (DED) type 3D printing device according to the present invention, metal powder pulverized to a very small size of about 60 to 80 microns is sprayed thinly with thermal energy on the base plate and then laminated by melting. Thus, by manufacturing the base plate, there is an advantage of enabling repair, reuse, and remodeling of the base plate.

200: mechanism device
202: powder material supply cartridge
204: 5-axis drive system
206: laser beam light source
208: powder material and gas
210: melt pool
212: 3D printing base plate
216: gas/pressure control device
220: motion control bed
300: control device
302: control unit
304: memory unit
306: external device interface unit

Claims (10)

In the 3D printing device,
A powder material supply cartridge containing metal powder;
A laser beam light source for generating and irradiating a laser beam;
A gas/pressure control device for supplying gas;
A metal 3D printing base plate made of a first material;
A motion control bed on which the lower layer of the metal 3D printing base plate is seated;
A five-axis drive system for delivering the metal powder from the powder material supply cartridge, the laser beam from the laser beam light source, and the gas from the gas/pressure control device to the metal 3D printing base plate; And
The powder material supply cartridge, laser beam light source, gas/pressure control device, motion control bed, and 5-axis drive system are controlled according to the 3D printing command from the outside to transfer the metal powder made of the second material to the metal 3D printing base plate. Including; a control device for forming an upper layer of the metal 3D printing base plate by melting it on the upper portion of the lower layer of,
The metal 3D printing base plate forms a heterogeneous material bonding structure consisting of a flat lower layer formed of an aluminum alloy or a copper alloy and an upper layer formed by melting the metal powder into the lower layer, and at the edge of the flat lower layer 3D printing apparatus, characterized in that the binding groove is formed, and the edge portion is formed with a chamfer of a predetermined diameter. The method of claim 1,
3D printing apparatus, characterized in that the first material is an aluminum alloy or a copper alloy. In the 3D printing method,
Checking whether a 3D printing command is provided from the outside;
When the 3D printing command is provided, a powder material supply cartridge that receives metal powder, a laser beam light source that generates and irradiates a laser beam, a gas/pressure control device that supplies gas, and a metal 3D printing base plate made of the first material. A motion control bed on which a lower layer is seated, and a 5-axis drive system that delivers metal powder from the powder material supply cartridge, a laser beam from the laser beam light source, and gas from the gas/pressure control device to the metal 3D printing base plate Forming an upper layer of the metal 3D printing base plate by controlling the metal powder made of a second material to melt in a lower layer of the metal 3D printing base plate; And
And forming a binding groove at an edge of a lower layer of the metal 3D printing base plate and forming a chamfer of a predetermined diameter at the edge portion. The method of claim 3,
The first material is a 3D printing base plate manufacturing method, characterized in that the aluminum or copper alloy. delete delete delete delete delete delete

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