CN105765137A - 制作物体的方法 - Google Patents
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Abstract
本发明涉及一种根据从物体的计算机模型得到的计算机指令使用计算机控制的设备制作物体的方法。该方法包括:制作多个材料条,其中两个条的至少一部分毗连并且布置成彼此呈1?179°之间的角度。两个条可制作在相互交叉的各自的抽象平面内。替代地,两个条可制作为形成各自的非平面层。进一步替代地,两个条可以制作成三维条。两个条也可以弯曲并且形成各自的平面层。
Description
技术领域
本发明涉及一种使用计算机控制的设备制作物体的方法。特别是,本发明涉及一种通过该设备制造的多个材料条制作物体的方法。
背景技术
在一段时间以来,已经可以利用通常被称为“3D打印”的各种“增材制造”技术制作物体。通常,增材制造包括创建物体的三维计算机模型,从模型得到用以引导计算机控制的设备来制作物体的计算机指令,并且根据计算机指令操作计算机控制的设备,从而连续地以平面层的方式有选择地制作材料,从而制作物体,使得物体的几何结构与计算机模型相对应。
虽然已知的增材制造技术可以可靠地制作物体,但它们也具有很多缺点。例如,当从平面层制作物体时,所述层在相邻的层之间通常具有较弱的机械连接和/或缺少显著的化学键合。久而久之,由于层之间的较弱连接,或者如果经受特定的载荷或环境条件,层经常彼此分离,被称为“分层”。这不仅不美观而且破坏了物体的结构完整性,可能导致物体被丢弃或者需要修补。
并且,很多已知的增材制造技术利用许多平行的、直的材料条制作物体。因此也很常见的是,在承受一定的载荷时,相邻的条之间的键合将断裂,更增加了物体分层的风险。
因此,提供一种用于制造在材料层和/或材料条之间具有牢固粘结的物体(与现有技术的方法相比,其不易于分层)的方法或设备是很有用的。提供一种避免或者改善现有技术中任何缺点或者提供替代现有技术方法的方案也是有益的。
发明内容
根据本发明的一个方面,提供了一使用计算机控制的设备制作物体的方法,该方法包括以下步骤:使设备移动并且在第一抽象平面(notionalplane,理论平面)上制作第一条;以及使设备移动并且在与所述第一抽象平面交叉的第二抽象平面上制作第二条,所述第二条的至少一部分与所述第一条的至少一部分毗连并且布置成1-179°之间的角度。
关于本发明的另一个方面,提供了一种使用计算机控制的设备制作物体的方法,该方法包括以下步骤:使设备移动并且制作至少一个第一条以形成第一非平面层;以及使设备移动并且制作至少一个第二条以形成第二非平面层,所述至少一个第二条的至少一部分与所述至少一个第一条的至少一部分毗连并且布置成1-179°之间的角度。
在本发明的一个可选择的方面中,提供了一种使用计算机控制的设备制作物体的方法,该方法包括以下步骤:使设备移动并且制作第一三维弯曲条;以及使设备移动并且制作第二三维弯曲条,所述第二三维弯曲条的至少一部分与所述第一三维弯曲条的至少一部分毗连并且布置成1-179°之间的角度。
在本发明的又一个方面中,提供了一种使用计算机控制的设备制作物体的方法,该方法包括以下步骤:使设备移动并且制作至少一个第一弯曲条以形成第一平面层,以及使设备移动并且制作至少一个第二弯曲条以形成第二平面层,所述至少一个第二弯曲条的至少一部分与所述至少一个第一弯曲条的至少一部分毗连并且布置成1-179°之间的角度。
附图说明
将参照附图仅通过示例的方式描述本发明的优选实施方式,附图中:
图1为大致平面的物体的立体图;
图2为自由形状的、柱状物体的立体图;
图3是图2所示的物体的截面细节图;
图4是可供选择的自由形状的、柱状物体的立体图;
图5是进一步的可供选择的物体的主视图;
图6是图5所示的物体的细节截面图;
图7是可供选择的物体的细节图;
图8是另一个可供选择的、自由形状的物体的主视图;以及
图9是又一个可供选择的、自由形状的物体的细节图。
具体实施方式
本说明书涉及一种通过计算机控制的设备采用多个材料条制作物体的方法,其中两个条的至少一部分毗连并且布置成彼此呈1-179°的角度,两个条可以在彼此相交的各自的抽象平面上制作。替代地,可以将两个条制作得形成各自的非平面层,进一步可供选择地,两个条可以制作成三维条。两个条也可以被弯曲并形成各自的平面层。
通过与物体的几何结构相关的计算机指令控制计算机控制的设备。计算机指令通常从采用计算机辅助设计(CAD)软件或其它类似软件生成的物体三维(3D)计算机模型中生成。通过用户运行CAD软件或者通过应用程序执行算法以自动生成3D模型、或者通过这些方法的组合而生成3D模型。通常通过将3D模型分成多个路径得到计算机指令,其中沿着所述路径制作材料,且通常是一个或多个路径形成物体的一层。路径(以及层)可以通过CAD软件或者其它应用程序自动估算,或者可通过手工完成。替代地,路径也可以根据预先定义的功能参数进行的自动输入和人工输入的组合而得到,例如用户输入典型的将要作用在物体上的力,使得基于这些力的分析通过软件来优化层的几何结构。
在图1中,示出了物体1。物体1通过计算机控制的设备(未示出)用三个大致平面的层2-4制成,该计算机控制的设备适用于由与物体1的几何结构相关的计算机指令引导,在指定位置制作材料。物体1具有底部层2,中间层4以及上层4,其中每个后续的层被设置在先前制作的层的上面。优选地,设备通过选择性地将材料沉积在指定位置而制作材料,如典型的熔融沉积成型工艺中那样。通常,本说明书涉及通过沉积制作材料,然而应当理解的是,其它制作方法(例如大致上液体的材料的选择性凝固/固化,通常称为光固化立体造型术)也是适合的。
设备可以适用于通过相对于固定的基底移动制作装置(例如材料挤压喷嘴)、或者相对于制作装置移动平台、或者这些方法的组合而在指定位置制作材料。其可以包括通过六轴线机械臂相对于基础表面移动制作装置,因而在指定位置沉积材料。替代地,其可以包括相对于材料的液池的上表面移动制作装置以选择性地使材料的部分固化,这些部分通过构建的平台支撑和移动(包括围绕一个或多个轴线旋转),因此允许所制作的材料相对于上表面和制作装置移动和重定向。
物体1的每层2-4包括材料的多个条5-7。条5-7通过设备沿着多个路径(未示出)沉积材料而形成,每个路径与每个条的纵向轴线共线。每个条由大致液态或者熔融的材料挤压而形成,这些材料冷却和/或固化以形成固体条。
底部层2由大致平行的条5的规则阵列形成。相邻的层3、4由弯曲的条6、7的不规则阵列形成,条6、7中的至少一些被布置成与相邻的条6、7不平行和/或不同心,并且一些条也与相邻的条6、7间隔开。
具有沿彼此不同方向布置的材料条5-7的物体1的层2-4的构造允许物体1的几何结构最优化,以用于不同的功能性要求或美学要求,例如抵抗施加在部件1上的特定的载荷。例如,中间层3和上层4的条6、7的纵向轴线相互交叉,使得至少一个条6、7的至少一部分彼此毗连,并且被布置成彼此呈1-179°间的角度。类似的,底部层2的条5的轴线延伸穿过中间层的条6的轴线。
在这样的布置中,相邻层2-4中的相邻的条5-7之间的结合(是物体1的最弱化的区域)被布置成彼此呈一定角度,对较弱结合的区域提供额外的支撑并且因此增加了物体1的刚度。例如,如果在物体1的角落A上施加载荷,则条5-7的布置确保上层4的条7之间的较弱结合区域通过布置成与之交叉且成角度的中间层3的条6支撑。类似地,底部层2的条5延伸穿过中间层3的条6的结合区域,给这些条6提供进一步的支撑。这种“交叉-层压”或者交织结构因而降低了任何层2-4的条5-7之间由于施加在角落A上的载荷而断裂的可能性。
由于各种参数的输入(例如在使用过程中将要施加在物体1上的力),可以计算出物体1的中间层3和上层4的条6、7在弯曲方面的布置。例如,在物体1的可以施加重大的载荷的区域,将条6、7的弯曲布置成提供较大角度的交叉-层压,也就是说,相邻层3、4中的至少一些相邻的条6、7的角度在90°左右。类似地,为了特定穿过层3、4或者在层3、4之间传输力,可以计算条6、7的各种弯曲度以及相同的层3、4中的条6、7相对于彼此的布置。
图2示出了替代的物体10。物体10也是通过计算机控制的设备制作成层11-13,以形成芯层11,中间层12以及外层13。与图1中示出的物体类似,物体10的每个层11-13包括沿着各自的多个路径(未示出)通过设备沉积的多个材料条14-16。
芯层11包括一堆大致环形的条14,通过设备在各自的多个抽象的第一平面上挤压材料而制作条14。每个抽象的第一平面被布置成与相邻的抽象的第一平面平行或者间隔开,同时也与底板表面17平行。
中间层12包括多个类似柱状的条15,条15远离底板表面17延伸,与芯层11毗连并且围绕该芯层的外周,通过设备沿着各自的多个抽象的第二平面(未示出)挤压材料而制作每个类似柱状的条15,每个抽象的第二平面与第一抽象平面交叉并且与第一抽象平面大致垂直布置。
外层13包括又一堆环形条16,该环形条与中间层12毗连并且围绕该中间层的外周,通过设备在各自的多个抽象的第三平面(未示出)挤压材料而制作外层13,抽象的第三平面被布置成大致彼此平行并且彼此之间相互间隔,并且与抽象的第一平面大致平行。
为了强度/刚度的要求而特别优化了物体10的层11-13的布置。由于芯层11、中间层12和外层13的条14-16的定向与相邻层的条14-16大致垂直,物体的结构形成了条14-16的三维格构,该三维格构对条14-16之间的结合区域提供支撑,并且特别能抵抗施加在物体10上的径向的或者弯曲的力。
同时,芯层11和外层13中,每个条14、16的开始/结束的位置可以相对于相邻的条14、16的开始/结束的位置交错。例如,第一条14可以在0°开始和结束,与第一条14相邻且在第一条顶部的第二条14可以在30°开始和结束,并且与第二条相邻且在第二条顶部的第三条可以在60°开始和结束,以此类推。这导致在单个环形条14、16中的结合(是弱化的区域)偏移相邻的环形条的结合,进一步增加物体10的刚度。
虽然在物体10的制作过程中使用的第一抽象平面、第二抽象平面以及第三抽象平面是抽象的平面表面,但应当理解的是这些抽象平面中的一个或多个可以被配置成单弯曲或双弯曲平面。例如,抽象平面中的一个或多个可以通过挤压弯曲而形成,因此在二维空间内弯曲。替代地,一个或多个抽象平面可以由三维表面形成,因此在所有三维空间内弯曲。在抽象平面为单弯曲或者双弯曲的情况下,因而允许在其上挤出的条也遵循平面的弯曲度,从而形成弯曲的条。
优选地,采用在由设备沉积后能够立即支撑自身重量的材料制作物体10,因此允许远离底板表面17竖直地挤出条。这可能由于以下原因而实现:材料具有高粘度并且在沉积后快速固化;设备适用于通过调节材料的温度、或者通过设备向材料中加入化学制品或化学催化剂、或者通过这些或其它方法的组合而快速固化材料。例如,设备可以适用于同时沉积一种以上的材料。在这样的实施方式中,允许设备同时沉积材料,这些材料在彼此接触时引起化学反应,例如环氧树脂的成分,以加速材料的固化从而形成固态的条。替代地,其可以包括将固化剂与所配置的材料同时沉积以快速地加快材料的固化。
在沉积过程期间,还可以调整通过设备沉积以形成物体10的层11-13的材料的性能,因而允许每层表现出一些不同于其它层的性能。例如,每层的抗拉强度、弹性、孔隙度、密度、耐火性是可以调整的。这可以通过改变沉积的材料的量、改变喷嘴形状或者直径、在构建材料容器中混合多种原料、或者通过从两个或者更多个相邻的沉积喷嘴沉积不同的材料的沉积情况下实现。替代地,通过设备更替材料供给,在制作过程中,一种材料可以替换成另一种。在沉积过程中通过两种或更多种材料的混合,也可以根据梯度改变沉积的材料。例如,这允许将要制作的物体在部件一侧沉积的材料比在另一侧沉积的材料更致密。类似地,在沉积过程中材料可以替换材料以改变物体相对于作用在结构上的力的性能,增加部件的将承受增加载荷的部分的刚度。
对于一些应用,通过将增强纤维18-20合并到条14-16的至少一些中而进一步地增强物体10的强度。这些增强纤维18-20可由有机材料或者无机材料制成,诸如由钢、聚合物、玻璃、碳、芳族聚酰胺、高强度聚芳酯纤维(vectran)、椰壳纤维、亚麻纤维、大麻纤维、蕉麻制成,或者条可以包括由不同材料形成的纤维的组合。纤维18-20通常用刚性比沉积材料更高的材料制成从而增加条14-16的刚度或抵抗力,或者所述纤维可以调整条14-16的其它性能,诸如传导性、弹性或感知能力。优选地,纤维18-20被布置成与每个条14-16的纵向轴线共线,以增强条14-16的抗弯曲性和/或抗断裂性。优选地,纤维连续贯穿条14-16,以进一步优化条14-16的强度。可选地,为了将物体的不同层制作成具有不同的性能,在制作过程中可以调整纤维18-20的数量、结构和材料。纤维也可以包括切断的不连续的束或者纤维,其在沉积点处改变以具有其它性能(例如波纹的或者弯曲的外形),从而增加材料基质内的附着。
优选地,设备适用于在材料沉积以形成条14-16之前或者期间,自动地将纤维18-20结合在材料中。在连续的纤维18-20结合到条14-16中的情况中,纤维18-20从进料部(例如鼓形件)展开,该纤维结合有液体或者熔融构件材料供应,并且在设备完成沉积条14-16时该纤维由设备自动切断。
图3是图2示出的物体10的截面细节图,更清楚地示出了每层11-13中的增强纤维18-20的定向。芯层11的纤维18被布置成围绕环状条14的曲线。中间层12的纤维19沿着每个类似柱状的条15的长度布置并且用多个点表示,这些点示出了每个纤维19的截面。
图4示出了替代的物体30。物体30也通过计算机控制的设备制作成层31-33,以形成芯层31、中间层32以及外层33。
层31-33与物体10的层11-13类似地布置,其中芯层31包括一堆环状条34,并且中间层32和外层33包括多个类似柱状的条35、36,条35、36远离底板表面37延伸并且与先前制作的层31、32毗连且围绕先前制作的层。每个层31-33为非平面的并且至少一部分为单弯曲或双弯曲的,从而在整个三维空间延伸。例如,通过设备远离底板表面37挤出条35以形成在第一旋转方向环绕芯层31的大致螺旋形形状。然后通过设备远离底板表面37挤出条36以形成在第二旋转方向环绕中间层32的类似的大致螺旋形形状。因此这种布置确保至少一些条34-36的至少一部分彼此毗连并且被布置成彼此呈1-179°之间的角度。可以通过相对于底板表面37移动设备的制作装置和/或相对于制作装置移动并旋转底板表面37而执行螺旋形条35、36的挤压。
图5示出了替代的物体40的主视图。与图2-4中示出的物体10和30类似,物体40通过计算机控制的设备制作为层41-43,以形成芯层41、中间层42和外层43。每个层41-43由通过设备沉积的多个条44-46形成。
如图5所示,在从主视图看时,条44-46被布置成彼此成一定角度。例如,中间层42和外层43的条45、46与芯层41的条44形成角α。中间层42的条45还与外层43的条46形成角β。
通常,随着角α和角β在1-179°之间变化,物体40的特征被调节,因为不同层41-43的条44-46之间的角度关系影响了同一层41-43中相邻的条44-46之间的结合强度,并且有利于物体40的刚度和耐久度。
图6是图5所示的物体40的细节截面图,示出了条44-46的弯曲布置。
在某些情况下,物体40可以具有较大的尺寸,大于1m3,并且在某些情况下大于20m3,以在建筑物或类似的结构中提供功能。在这种情况下,构建材料可以是水泥质的材料,例如混凝土或地聚物(geopolymer)。设备也可以适用于沉积和/或固化这样的材料,例如在沉积前或沉积期间,调整材料的温度,或添加化学催化剂或其它固化剂。
图7示出了又一替代的物体50,其具有多个相互连接分支部分51和空隙52。物体50通过计算机控制的设备制作为层53-55,以形成内层53、中间层54以及外层55。每个层53-55由通过设备沉积的至少一个条形成。
层53-55是三维的非平面层,其可以制作在结构(例如泡沫板)上或者在原位制作,以便修复结构,或者作为组装结构中独立的自支撑部件。每层53-55的条均在与先前制作的层的条53-55大致垂直的方向上制作以优化物体50的强度。示出了中间层54和外层55为部分制作的以说明每层54、55的条的方向。然而,部分制作的层54、55也可以用于增强物体50的特定部分并且改变这些部分的强度或重量,或者提供特别的、装饰性的外观,例如形成材料的稀松组织。
图8示出了进一步替代的物体60。物体60通过计算机控制的设备制作为层61-63,以形成内层61、中间层62和外层63。每个层61-63由通过设备沉积的至少一个条形成。每个条为三维弯曲的,允许形成“自由形状”的分支结构(例如柱状节点)。
图9是进一步替代的物体70的细节图。物体70通过计算机控制的设备制作以形成三层71-73。通过多个三维弯曲的条74-76将两个内层71、72与外层73间隔开,在内层与外层之间形成有空隙77。三维弯曲条74-76被设置成形成三维非平面的层的组,其中每个层中的条74-76的仅一部分彼此毗连。第一组条74与内层72毗连并且通常沿第一方向延伸,第二组条75在第一节点78处与第一组毗连并且通常沿垂直于第一方向的第二方向延伸,并且第三组条76在第二节点79处与第二组条75毗连以及与外层73毗连且通常沿第一方向布置。三维弯曲条74-76的在节点78、79处相邻的部分被布置成彼此成一定角度,因而在每个节点78、79处形成交叉-压层连接。
三维弯曲条74-76可以由弹性材料形成,因而允许层72、73相对于彼此移位。空隙77也可以用特定的气体或其它材料填充以影响物体70的隔热和/或隔音性能。
将明白的是,依照本发明的思想可以对本发明作出明显的改变或者改进,这些也是本发明的一部分。尽管上面参考特定实施方式对本发明进行了描述,应当理解的是这不是对那些实施方式的限制并且能够以其它形式具体实施。
Claims (20)
1.一种使用计算机控制的设备制作物体的方法,该方法包括以下步骤:
使所述设备移动并且在第一抽象平面上制作第一条;以及
使所述设备移动并且在与所述第一抽象平面交叉的第二抽象平面上制作第二条,所述第二条的至少一部分与所述第一条的至少一部分毗连并且布置成1-179°之间的角度。
2.根据权利要求1所述的制作物体的方法,其中,制作第二条的步骤还包括在定向成与所述第一抽象平面大致垂直的所述第二抽象平面上制作所述第二条。
3.根据权利要求1所述的制作物体的方法,其中,制作所述第一条和所述第二条中至少一种的步骤还包括:使相应的抽象平面为弯曲的,并且在相应的弯曲的抽象平面上制作相应的条。
4.根据权利要求1所述的制作物体的方法,其中,制作所述第一条和所述第二条中至少一种的步骤还包括:使相应的抽象平面为三维表面,并且在相应的三维表面上制作相应的条。
5.根据权利要求1所述的制作物体的方法,其中,制作所述第一条的步骤和制作所述第二条的步骤还包括:选择性地沉积材料,从而形成相应的条。
6.根据权利要求5所述的制作物体的方法,其中,选择性地沉积材料的步骤还包括:向所述材料中选择性地加入增强纤维。
7.一种使用计算机控制的设备制作物体的方法,该方法包括以下步骤:
使所述设备移动并且制作至少一个第一条以形成第一非平面层;以及
使所述设备移动并且制作至少一个第二条以形成第二非平面层,所述至少一个第二条的至少一部分与所述至少一个第一条的至少一部分毗连并且布置成1-179°之间的角度。
8.根据权利要求6所述的制作物体的方法,其中,制作至少一个第一条以及至少一个第二条中的至少一种的步骤还包括由自支撑材料制作至少一个相应的条,从而所述至少一个相应的条保持三维结构。
9.根据权利要求6所述的制作物体的方法,其中,制作至少一个第一条的步骤还包括:制作多个第一条。
10.根据权利要求9所述的制作物体的方法,其中,制作多个第一条的步骤还包括:将所述第一条中的至少一些制作成与相邻的第一条大致平行。
11.根据权利要求10所述的制作物体的方法,其中,制作多个第一条的步骤还包括:将所述第一条中的至少一些制作成与相邻的第一条毗连。
12.根据权利要求6所述的制作物体的方法,其中,制作至少一个第一条的步骤还包括:将所述至少一个条制作成形成具有双曲面的第一层的至少一部分。
13.根据权利要求6所述的制作物体的方法,其中,制作至少一个第一条的步骤还包括:将所述至少一个第一条制作成形成有刻面的第一层的至少一部分。
14.根据权利要求6所述的制作物体的方法,其中,制作至少一个第二条的步骤还包括:将所述至少一个第二条制作成形成第二层,所述第二层至少部分围绕第一层。
15.一种使用计算机控制的设备制作物体的方法,该方法包括以下步骤:
使所述设备移动并且制作第一三维弯曲条;以及
使所述设备移动并且制作第二三维弯曲条,所述第二三维弯曲条的至少一部分与所述第一三维弯曲条的至少一部分毗连并且布置成1-179°之间的角度。
16.根据权利要求15所述的制作物体的方法,其中,制作所述第一三维弯曲条以及所述第二三维弯曲条中至少一种的步骤还包括由自支撑材料制作相应的条,从而所述相应的条保持三维结构。
17.一种使用计算机控制的设备制作物体的方法,该方法包括以下步骤:
使所述设备移动并且制作至少一个第一弯曲条以形成第一平面层;以及
使所述设备移动并且制作至少一个第二弯曲条以形成第二平面层,所述至少一个第二弯曲条的至少一部分与所述至少一个第一弯曲条的至少一部分毗连并且布置成1-179°之间的角度。
18.根据权利要求17所述的制作物体的方法,其中,制作所述至少一个第二弯曲条的步骤还包括:制作多个第二弯曲条。
19.根据权利要求18所述的制作物体的方法,其中,制作多个第二弯曲条的步骤还包括:将一个或多个第二弯曲条的至少一部分制作成与相邻的第二弯曲条不平行。
20.根据权利要求18所述的制作物体的方法,其中,制作多个第二弯曲条的步骤还包括:将一个或多个第二弯曲条的至少一部分制作成与相邻的第二弯曲条间隔开。
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AU2013904190A AU2013904190A0 (en) | 2013-10-30 | Method of Fabricating a Construction Element | |
AU2013904190 | 2013-10-30 | ||
PCT/AU2014/050324 WO2015061855A1 (en) | 2013-10-30 | 2014-10-30 | Method for fabricating an object |
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EP (1) | EP3063340B1 (zh) |
JP (1) | JP6588901B2 (zh) |
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CN (1) | CN105765137B (zh) |
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US10343320B2 (en) | 2019-07-09 |
KR20160078361A (ko) | 2016-07-04 |
EP3063340B1 (en) | 2020-04-15 |
AU2014344811B2 (en) | 2019-03-21 |
HK1223993A1 (zh) | 2017-08-11 |
SG11201603160VA (en) | 2016-05-30 |
AU2014344811A1 (en) | 2016-05-26 |
WO2015061855A1 (en) | 2015-05-07 |
CN105765137B (zh) | 2018-08-24 |
EP3063340A1 (en) | 2016-09-07 |
JP2016539823A (ja) | 2016-12-22 |
JP6588901B2 (ja) | 2019-10-09 |
EP3063340A4 (en) | 2017-06-21 |
US20160263806A1 (en) | 2016-09-15 |
CA2928481A1 (en) | 2015-05-07 |
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