CN107930903A - 用于抛光由增材制造系统形成的三维（3d）物体的表面的系统和方法 - Google Patents

用于抛光由增材制造系统形成的三维（3d）物体的表面的系统和方法 Download PDF

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CN107930903A
CN107930903A CN201710888687.0A CN201710888687A CN107930903A CN 107930903 A CN107930903 A CN 107930903A CN 201710888687 A CN201710888687 A CN 201710888687A CN 107930903 A CN107930903 A CN 107930903A
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CN107930903B (zh
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R·E·都佛特
L·C·胡佛
E·鲁伊斯
M·卡努恩格
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Xerox Corp
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Abstract

本发明涉及一种处理增材制造物体的粗糙表面以提高表面的透明度和光泽度的系统。该系统操作喷射器以将用于形成粗糙表面的流体材料施加至粗糙表面从而使表面变光滑，或者该系统操作致动器以将增材制造物体浸渍到与用于形成粗糙表面的材料相同的流体材料浴内从而使表面变光滑。加热器设置成干燥施加于粗糙表面的非UV可固化材料，UV辐射源设置成固化施加于粗糙表面的UV可固化材料。

Description

用于抛光由增材制造系统形成的三维(3D)物体的表面的系统 和方法
技术领域
本公开大致涉及由增材制造系统形成的物体，更具体地涉及用于抛光这些物体的表面的系统。
背景技术
由增材制造系统形成的零件的一些表面通常是不光滑的，表面粗糙度影响零件的视觉特性，比如其半透明性、颜色、光泽等。例如，粗糙表面可以使透明零件看上去不透明，颜色可以没那么鲜明，以及表面抛光可以是平的或粗糙的。典型的三维物体(3D)打印过程产生单个物体的广泛变化的表面粗糙度。例如，在材料喷射器的运动与物体形成其上的压板之间缺乏配准可以引起每个层的开始与终止之间的小的错位。由于各层的端部未彼此对准，因此打印过程产生垂直表面比物体的水平表面明显粗糙的零件。由此，利用来自喷射器的透明材料液滴制造的零件具有看上去不透明的垂直表面，而水平表面看上去是透明的。同一物体的其他表面处于透明与不透明之间的半透明范围内。由于熔融材料符合模具的光滑抛光表面，比如为注射模塑的非增材制造过程能够生产具有高度光泽的透明零件。因此，零件的垂直壁形成为与零件的水平表面一样光滑。
当前，增材制造零件可被处理以给予其更加一致或增强的外观。通常采用比如为砂磨、抛光和磨光的常规减材加工技术，然而这些方法是耗时的，难以在复杂物体几何形状上执行，可能破坏小的特征以及去除薄的颜色层。还采用比如为甘油浸渍或涂青漆的涂层，以增强表面光泽度和颜色活力，但其通常需要比如为磨光或抛光的减材加工技术，以准备用于涂层的表面，可能具有冗长处理或干燥时间，以及可能使零件在触摸时滑腻。另外，涂层可以随后与表面分离或从表面剥落，或者其在表面处或附近不匹配图像的颜色。因此，将需要一种在没有由减材加工技术或涂层引起的问题的情况下修复增材制造物体的粗糙表面的系统。
发明内容
一种修复增材制造物体的粗糙表面的系统，包括壳体；喷射器和致动器中的至少一者，喷射器连接至流体材料源并且构造成朝向增材制造物体的表面引导流体材料的液滴，致动器构造成将增材制造物体降下到包含流体材料的储液器内并且从储液器提升增材制造物体，流体材料源或储液器中的流体材料是与增材制造制品的表面为相同材料的流体材料；以及控制器，其操作地连接至喷射器和致动器中的至少一者，控制器构造成将致动器操作为将增材制造制品降下到储液器中的流体内并且从储液器中的流体提升增材制造物体，或者将喷射器操作为将流体材料的液滴引导到增材制造物体的表面上，以将流体材料施加至增材制造物体的表面并且提高增材制造物体的透明度或光泽度。
一种处理增材制造物体的表面的方法，包括：将增材制造物体定位在壳体内；利用控制器操作致动器以将增材制造制品降下到储液器中的流体材料内并且从储液器中的流体材料提升增材制造物体，或者利用控制器操作操作地连接至流体材料源的喷射器，以将流体材料的液滴引导到增材制造物体的表面上，从而将流体材料施加至增材制造物体的表面并且提高增材制造物体的透明度或光泽度，流体材料源或储液器中的流体材料是与形成增材制造制品的表面相同材料的流体材料。
附图说明
在结合附图的以下说明书中说明了处理增材制造物体的表面以改善所需视觉特性的系统和方法的上述方面和其他特征。
图1是处理增材制造物体的表面以改善表面的视觉特性的系统的框图。
图2描绘了已结合到增材制造物体的粗糙表面以改善表面的视觉特性的材料。
图3描绘了处理增材制造物体的表面以改善表面的视觉特性的过程。
图4示出现有技术的增材制造物体的层的不规则配准，当从由不规则配准层形成的一侧的视角来看时其降低了物体的视觉特性。
具体实施方式
为了对当前实施例的大概了解，对附图做出参照。在附图中，相同的附图标记在全文中被用于指代相同的元件。
图4描绘了现有技术的增材制造物体404比如为管的侧视图。物体由层408形成。当叠层随时间竖直地增长时，磨板器使当前最上层变平，由此随后形成的层是水平的。尽管在图中放大，但是层408的端部412的配准是不精确的。由端部412形成的该粗糙表面散射冲击表面的光，该散射使得物体在通过粗糙表面观察时是不透明或至少半透明的。来自端部应该位于的位置的端部的实际变化可以以数十微米测量。因此，表面的整体不均匀度大概小于100μm。用于处理该效果的之前已知方法包括砂磨、抛光和磨光。然而，这些技术是时间密集的，并且难以应用于具有复杂几何形状的特征。对于由挤出ABS材料等形成的物体，物体可被放置在具有丙酮气氛的腔室中，因此丙酮蒸汽可以熔融暴露表面并且使表面变光滑。然而，由于丙酮不与固化的UV材料化学反应，因此该技术不能用于利用紫外线(UV)可固化材料制成的物体。
图1中示出使物体的表面有光泽或透明的新系统。系统100包括壳体104、比如为喷射器112或储液器116的流体材料源、壳体104内的旋转支承件108、加热器124、致动器128和控制器140。系统100描绘为具有喷射器112和储液器116两者，以简化用于使增材制造物体恢复光泽度或透明度的系统的附图和说明，尽管一些实施例可被构造成仅具有一者或另一者。控制器140操作地连接至致动器128、喷射器112和用户接口144。操作人员通过用户接口144输入数据以标识物体是要被喷射还是浸渍以及物体是被加热还是承受UV辐射，以将UV可固化材料结合至物体。
为了修复增材制造物体的粗糙表面，物体被放置在旋转支承件108上或从自致动器128之一延伸的构件130悬下，操作人员将标识处理过程和要使用的材料结合类型的数据输入用户接口144内。如果标识为喷射，则当控制器操作喷射器112以朝向物体的粗糙表面引导流体材料的液滴时，控制器140操作连接至支承件108的致动器128以使支承件和物体旋转。由喷射器112喷射的流体材料可以是形成被处理的粗糙表面的相同材料或与表面材料相容的另一种材料。液滴填充粗糙表面中的裂缝。如果流体材料未被标识为UV可固化，则控制器140操作加热器124以干燥物体上的流体材料，从而将填充裂缝的材料结合至粗糙表面。图2中示出填充有已经结合至物体404的侧面416的裂缝内的流体材料的物体的粗糙表面。侧面416比图4中由层408的端部412形成的侧面更加光滑。该光滑度使得侧面416比图4中示出的物体404的侧面更加透明和有光泽。
利用形成物体的层的喷射器而非形成侧面416的喷射器112并非最佳，因为喷射器设计成喷射具有1至6mm直径的材料液滴。喷射器不能像喷射器112那样准确地在长距离上引导材料液滴。在一些实施例中提供加热器124，因此控制器140可以将加热器操作为加热所施加的流体材料并且减少用于材料的干燥时间。对于更大物体或者具有利用喷射难以到达的复杂几何形状的特征的物体，当物体从自致动器128延伸的构件130悬下时，操作人员利用用户接口144以将浸渍标识为物体处理。控制器140操作致动器以将物体降下到储液器116内，从而将物体浸入与形成物体的表面的流体材料相同的流体材料浴或与物体的表面相容的材料内，然后从储液器提升物体。一旦物体提升，控制器140操作加热器124以减少流体材料的干燥时间。为了改善一些流体材料进入粗糙表面的裂缝的能力，由喷射器112喷射的材料(其从流体材料源132接收)与来自变稀流体源136的恰当地相容的溶剂混合以降低材料的粘度。控制器140操作泵和阀148以将预定量的材料和溶剂从其各自的源拉出，从而实现上述混合。
如上所述的过程可以通过下载关于被处理的零件的几何形状的数据增强，因此控制器140可以利用该数据以定制抛光过程。具体地，控制器140利用该数据以标识零件上的建造定向在此产生更大表面粗糙度的区域，然后控制器操作喷射器112以在这些区域中施加附加涂层。通过操作喷射器以仅向这些选择区域施加材料，节省了材料并且保护了零件特征。另一个抛光方案组合浸渍和喷射零件两者。在该方案中，控制器140利用零件几何形状数据以通过以下定制抛光过程：浸渍零件以施加大致外涂层，然后喷射零件的控制器参照零件几何形状数据标识为具有更大表面粗糙度的选择区域。
如上所述，储液器116中的流体材料或通过喷射器112喷射的流体材料可以是用于形成粗糙表面的相同材料。向零件施加相同材料具有比不相似材料更好地粘附至粗糙表面的优势。另外，施加用于形成层的相同材料指的是两种材料的比如颜色、折射率、弹性和硬度的特性相匹配。这些优势对于利用UV可固化建造材料形成的物体是特别重要的。通过向粗糙表面施加相同UV可固化流体材料并且然后固化流体材料，所施加的材料结合至粗糙表面的裂缝内的UV可固化材料。对于用于使物体的利用UV可固化材料形成的表面透明或有光泽的实施例，系统100还包括UV辐射源120。UV源120可以在喷射器112已被操作或物体已浸没在储液器116中之后被操作，以固化施加于物体的UV流体材料。当喷射器被用于施加流体材料时，UV源120可被操作以固化所施加的材料层，然后可以通过喷射器施加另一层以及随后通过UV源固化。在固化每一层之后，物体的透明度或光泽度可被评估以确定是否需要另一层流体材料。对于大部分物体来说，增材制造物体的粗糙表面的光泽度或透明度在施加一至四个喷射层之后是显著提高的。
图3中示出用于使增材制造物体的粗糙表面变平滑以提高表面的透明度和光泽度的方法。该方法300以放置增材制造物体开始，支承材料已经在壳体内从增材制造物体去除(框304)。流体材料施加器操作为将材料施加到物体的粗糙表面上(框308)。施加器是如上所述的喷射器或将物体降下到储液器116内。根据施加于物体的材料的类型，所施加的流体材料然后被加热或固化(框312)，以将所施加的材料粘附至粗糙表面。评估表面的抛光(框316)，如果不满足或不超过预定水平的透明度或光泽度，另一个流体材料层被施加至粗糙表面(308)并且被干燥或固化(框312)。该方法继续，直到满足或超过预定水平的透明度或光泽度为止(框316)。此时，从壳体去除物体(框320)。
在如上所述的系统和方法的大部分实施例中，用于处理粗糙表面的流体材料是清澈的。通过利用清澈材料，不必匹配粗糙表面的颜色。对于一些着色表面，所施加的材料是用于形成物体的表面的相同材料，因此颜色匹配在该情况下不应为问题。

Claims (10)

1.一种用于处理增材制造物体的表面的系统，包括：
壳体；
喷射器和致动器中的至少一者，所述喷射器连接至流体材料源并且构造成朝向增材制造物体的表面引导所述流体材料的液滴，所述致动器构造成将所述增材制造物体降下到包含流体材料的储液器内并且从所述储液器提升所述增材制造物体，所述流体材料源或所述储液器中的所述流体材料是与所述增材制造制品的表面为相同材料的流体材料；以及
控制器，所述控制器操作地连接至所述喷射器和所述致动器中的至少一者，所述控制器构造成将所述致动器操作为将所述增材制造制品降下到所述储液器中的流体内并且从所述储液器中的所述流体提升所述增材制造物体，或者将所述喷射器操作为将所述流体材料的液滴引导到所述增材制造物体的表面上，以将所述流体材料施加至所述增材制造物体的表面并且提高所述增材制造物体的透明度或光泽度。
2.根据权利要求1所述的表面处理系统，还包括：
加热器，所述加热器定位在所述壳体内；
所述控制器操作地连接至所述加热器，所述控制器还构造成操作加热器以干燥施加于所述增材制造物体的表面的所述流体材料。
3.根据权利要求1所述的表面处理系统，还包括：
紫外线(UV)辐射源；
所述流体源或所述储液器中的所述流体材料是UV可固化流体材料，所述UV可固化流体材料是用于形成所述增材制造物体的表面的相同UV可固化流体材料；以及
所述控制器操作地连接至所述UV辐射源，所述控制器进一步构造成操作所述UV辐射源以固化施加于所述增材制造物体的表面的所述UV可固化流体材料的UV可固化流体材料。
4.根据权利要求1所述的表面处理系统，还包括：
支承件，所述支承件定位成与所述喷射器相对地放置所述增材制造物体；
致动器，所述致动器操作地连接至所述支承件；以及
所述控制器操作地连接至与所述支承件操作地连接的所述致动器，所述控制器构造成当所述控制器操作所述喷射器以向所述增材制造物体施加所述流体材料时操作所述致动器以使所述支承件旋转。
5.根据权利要求1所述的表面处理系统，其中，所述系统包括所述喷射器和致动器两者，所述喷射器连接至所述流体材料源并且构造成朝向所述增材制造物体的表面引导所述流体材料的液滴，所述致动器构造成将所述增材制造物体降下到包含流体材料的储液器内并且从所述储液器提升所述增材制造物体；所述系统还包括：
用户接口，所述用户接口操作地连接至所述控制器，所述用户接口构造成标识用于处理增材制造物体的表面的浸渍或喷射操作以及标识用于所述喷射器的所述流体材料源中的所述流体材料或者所述储液器中的所述流体材料是否为UV可固化流体材料；
加热器，所述加热器操作地连接至所述控制器；
UV辐射源，所述UV辐射源连接至所述控制器；以及
所述控制器还操作地连接至所述喷射器和所述致动器两者，所述控制器进一步构造成操作所述致动器以将所述增材制造制品降下到所述储液器中的流体内以及从所述储液器中的所述流体提升所述增材制造物体，以及操作所述喷射器以将所述流体材料的液滴引导到所述增材制造物体的表面上从而向所述增材制造物体的表面施加所述流体材料并且提高所述增材制造物体的透明度或光泽度，并且操作所述加热器以干燥施加于所述增材制造物体的表面的并非UV可固化流体材料的流体材料，以及操作所述UV辐射源以固化施加于所述增材制造物体的表面的UV可固化流体材料。
6.一种用于处理增材制造物体的表面的方法，包括：
将增材制造物体定位在壳体内；
利用控制器操作致动器以将所述增材制造制品降下到储液器中的流体材料内并且从所述储液器中的所述流体材料提升所述增材制造物体；或者
利用所述控制器操作操作地连接至流体材料源的喷射器，以将所述流体材料的液滴引导到所述增材制造物体的表面上，从而将所述流体材料施加至所述增材制造物体的表面并且提高所述增材制造物体的透明度或光泽度，所述流体材料源或所述储液器中的所述流体材料是为形成所述增材制造制品的表面的相同材料的流体材料。
7.根据权利要求6所述的表面处理方法，还包括：
定位在所述壳体内的加热器；
利用所述控制器操作定位在所述壳体内的加热器以干燥施加于所述增材制造物体的表面的所述流体材料。
8.根据权利要求6所述的表面处理方法，还包括：
利用所述控制器操作UV辐射源以固化施加于所述增材制造物体的表面的UV可固化材料的UV可固化材料，所述流体源或所述储液器中的所述流体材料是为用于形成所述增材制造物体的表面的相同UV可固化材料的UV可固化流体材料。
9.根据权利要求6所述的表面处理方法，还包括：
定位成与所述喷射器相对地放置所述增材制造物体的支承件；
操作地连接至所述支承件的致动器；以及
利用所述控制器操作操作地连接至支承件的致动器，所述支承件定位成与所述喷射器相对地放置所述增材制造物体，以当所述控制器操作所述喷射器以向所述增材制造物体施加所述流体材料时使所述支承件旋转。
10.根据权利要求6所述的表面处理方法，其中，所述方法包括所述控制器操作所述喷射器和操作所述致动器两者，所述喷射器连接至所述流体材料源并且构造成朝向所述增材制造物体的表面引导所述流体材料的液滴，所述致动器构造成将所述增材制造物体降下到包含流体材料的储液器内并且从所述储液器提升所述增材制造物体，所述方法还包括：
通过操作地连接至所述控制器的用户接口接收所述增材制造物体的表面要利用浸渍或喷射操作处理的标识，以及关于用于所述喷射器的所述流体材料源中的所述流体材料或所述储液器中的所述流体材料是否是UV可固化流体材料的标识；以及
利用所述控制器操作所述喷射器、所述致动器、加热器和UV辐射源，所述控制器参照从所述用户接口接收的所述流体材料的所述标识操作所述加热器，以干燥施加于所述增材制造物体的表面的并非UV可固化材料的材料，并且所述控制器参照从所述用户接口接收的所述流体材料的所述标识操作所述UV辐射源以操作所述UV辐射源从而固化施加于所述增材制造物体的表面的UV可固化材料。
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